Mitsubishi Outlander XL. Manual - part 20

NOTE ON REPAIR WORK

REMOVAL

ZB600140

AB302193

0000

1.

Place supporting bars in the vehicle to prevent the side panels
from  expanding  or  tilting  when  removing  the  roof  panel
assembly.

ZB600129 0000

Foot

Belt sander

Self piereing rivet

Roof panel

2.

Grind the self piercing rivet foot with a belt sander [belt width
of 10 mm (0.39 inch)] or the like.

ZB600143

Punch

0000

Roof panel

Self piereing rivet

3.

Remove the self piercing rivet by striking it up at the bottom
with a punch or the like to disconnect it from the side structure.

INSTALLATION

1.

Temporarily  install  the  new  roof  panel  to  the  body  and  drill
holes  at  riveting  positions  with  a  drill  [5  mm  (0.19  inch)  in
diameter].

2.

Remove the roof, remove burrs at the drilled holes, and clean
the body.

3.

Apply structural adhesive to the body, and install the roof.

Adhesive: Epoxyayresin adhesive
Brand: 3M™ AAD Part No.8115 or equivalent

WELDED PANEL REPLACEMENT

3-29

ROOF (ALUMINUM ROOF)

ZB600154 0000

Recommended tool 

Rivet diameter 4.8 mm (0.18 in)

ZB600142

Recommended tool

Roof lid rivet

A

Flange 
surface

Recommended tool

1

2

3

4

0000

Roof panel

4.

Use the recommended tool to tighten the roof lid rivet by the
following procedure.

(1)

Insert the rivets into the roof.

(2)

Mount the recommended tool on the A-section of the rivet.

(3)

Operate the tool's handle while pushing the flange surface
of the rivet by the recommended tool.

(4)

Part A of the rivet is cut and the rivet is tightened.

ZB600141

AB302189

0000

A

A

Body sealing

Rivet

Roof panel

5.

After  the  adhesive  is  dried,  remove  the  excessive  residues
and apply body sealant to the whole rivets and the roof edge
in order to prevent water leakage.

3-30

WELDED PANEL REPLACEMENT

ROOF (ALUMINUM ROOF)

REAR END CROSSMEMBER

M40300000150USA0000010000

ZB6001520000

(                                                              )

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.)

WELDED PANEL REPLACEMENT

3-31

REAR END CROSSMEMBER

ZB6000870000

A

B

D

B

C

A

REPAIR WELDS

3-32

WELDED PANEL REPLACEMENT

REAR END CROSSMEMBER