Mitsubishi Outlander XL. Manual - part 16

ZB600128 0000

 : Body sealant

2.

When installing the front pillar outer, apply body sealant as
shown in the figure.

ZB600362 0000

Urethane
foam

3.

When installing the new front pillar outer, affix urethane foam
as shown in the figure as a temporary measure to fill the inside
of the front pillar.

ZB6001380000

4.

After installing the front pillar outer, seal the hole and flange
with bolt and aluminum tape, and then fill the hole with foam
materials as shown in the figure.

Foam: 3M™ AAD ULTRAPRO Panel foam-Yellow

WELDED PANEL REPLACEMENT

3-13

FRONT PILLAR

ZB6001120000

5.

Wait 2 hours after filling the foam materials to remove the bolt
and  aluminum  tape,  then  melt  the  foam  materials  with  a
soldering gun to ensure that a clip, etc. can be inserted in the
hole filled with foam materials.

FRONT PILLAR (PARTIAL REPLACEMENT)

M40300000158USA0000010000

0000

ZB600348

(                                                              )

Symbol

Operation description

Spot welding

MIG plug welding

indicates two panels to be welded

indicates three panels to be welded

MIG spot welding

MIG arc welding (continuous)

Braze welding

Anti-corrosion agent applications locations
(Use access holes to apply liberally to butt-welded joints.)

3-14

WELDED PANEL REPLACEMENT

FRONT PILLAR (PARTIAL REPLACEMENT)

ZB600293

D

E

B

REPAIR WELDS

200 mm

(7.9 in)

210 mm

(8.3 in)

0000

B

D

E

(With the side outer panel removed)

A

C

A

C

Acoustic foam

When repairing the area using foam materials do
not  use  firing  tools  since  the  foaming  materials
may burn.

WELDED PANEL REPLACEMENT

3-15

FRONT PILLAR (PARTIAL REPLACEMENT)

NOTE ON REPAIR WORK

REMOVAL

ZB600021

350 mm

(13.7 in)

0000

side outer panel

Side sill outer reinforcement front

Side sill inner
support front

Because partial replacement of the side sill outer reinforcement
front is impossible, remove the side sill outer reinforcement front
on the body side. Cut and remove the side outer panel at 350
mm (13.7 inches) behind the side sill cutting section.

INSTALLATION

ZB600459

120 mm
(4.7 in)

60 mm
(2.4 in)

0000

side outer
panel

Front pillar 

reinforcement lower

1.

To assure the strength of the front pillar cutting section, cut the
front  pillar  reinforcement  lower  60  mm  (2.4  inches)  upward
from the front pillar cutting section, and the side outer panel at
120 mm (4.7 inches) upward.

ZB6003490000

Side sill outer
reinforcement front

Front pillar
reinforcement lower

2.

When installing the side sill outer reinforcement front and front
pillar reinforcement lower, weld them in advance as shown in
the figure.

ZB600362 0000

Urethane
foam

3.

When installing the new front pillar outer, affix urethane foam
as shown in the figure as a temporary measure to fill the inside
of the front pillar.

3-16

WELDED PANEL REPLACEMENT

FRONT PILLAR (PARTIAL REPLACEMENT)