Mitsubishi Outlander XL. Manual - part 39

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When performing this operation, warping of the
surrounding panels may occur if an excessive amount of
heat is applied; therefore, be careful to avoid doing this.

Breaking of brazing and arc welds
Heat only the brazed or arc welded portion (such as the upper
portion of pillars, etc.), and then separate by using a
screwdriver while melting occurs.

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Finishing work of spot welding
Grind and smooth any weld traces which might be left on the
body surface by using an air grinder or similar tool, being
careful not to damage any of the panels which is not to be
replaced. When performing this operation, be sure to wear
safety goggles (dust proof glasses).

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Making of holes in new parts for MIG plug welding
Make holes approximately 5 - 6 mm (0.2 inch) in diameter at
points where plug welding is to be performed because spot
welding is not possible.

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Flange correction for spot weld traces
Correct any flanges that become bent or deformed when spot
welds are broken or during other work.

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Do not use a flame for paint coat removal because doing so
might damage the paint coat of panels which are not to be
replaced, thus causing corrosion.

Removal of the paint coat from new parts and from the
vehicle body
In order to provide for the proper flow of electric current during
spot welding operations, remove the paint coat from both
sides of the new part and the body by using a polisher wheel
or similar tool.

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Rough cutting of new parts
Cut off the unnecessary portions of new parts. Allow an
overlap of approximately 30 - 50 mm (1.2 - 2.0 inches) when
performing overlap cutting of the pillars, side sills, or other
locations.

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Edge of the
new part

Edge of the
panel on the body

Carefully select the location for cutting, taking care not to
cut a reinforcement at the inner side of a pillar, etc. or a
panel that is not to be replaced.

10.

Overlap cutting of new parts
For locations in which butt welding is to be done, first
temporarily attach the new parts to the body, and then cut the
two panels simultaneously.

NOTE:

If a reinforcement or a panel which is not to be

replaced is cut accidentally, first repair the mistake
by welding before proceeding with the rest of the work.

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Outer panel

Approx. 50 mm

(2.0 in)

Inner panel

Two-layer
construction

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Inner panel

Inner panel
cut line

Inner panel cut line

Outer panel
and reinforcement
cut line

Three-layer construction

Perform the operations carefully so that the cut ends fit
together properly.

11.

Cutting of new parts by using a measurement marking
If overlap cutting is not possible in a place where butt welding
is to be done, make a measurement marking on the new part
at the exact same measurement which was used for the
cutting of the body panel, and then cut the new part by using
this measurement marking.

｠

Two-layer construction
When cutting a front pillar or center pillar which has a two-
layer construction but no reinforcement, make the cutting
of the inner panel and that of the outer panel approximately
50 mm (2.0 inches) apart in order to obtain maximum
strength.

｠

Three-layer construction
When cutting a front pillar or center pillar which has a three-
layer (including a reinforcement) construction (double-box
construction), cut the outer panel and the reinforcement at
the  same  position,  and  don't  forget  to  butt  weld  the
reinforcement.  If  the  inner  panel  is  an  assembly
replacement part, cut it at two places in order to provide
ample  working  space  for  the  butt  welding  of  the
reinforcement.

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12.

Application of spot sealer to spot-welded points
Apply an electro-conductive spot sealer to the connecting
surfaces of both the new parts and the vehicle body in order
to provide corrosion protection.

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During  temporary  mounting,  it  is  extremely  important  to
obtain  accurate  measurements  for  each  component.  The
mounting positions for the front and rear suspensions are
especially  crucial  with  regard  to  safety;  therefore,  it  is
necessary  that  all  work  concerning  these  areas  be  done
carefully and correctly.

13.

Temporary mounting of new parts

(1)

In order to bring the new parts into the proper mounting
position, measure each part carefully and make any
corrections necessary in order to obtain agreement with
the measurements.

(2)

In addition, make temporary welds, and then check to
confirm that the closing and fit of the doors, fenders, etc.,
are correct.

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For parts which should be symmetrical to the body center,
measure the distances from the body center point to both
the left part and the right part, and confirm that the
distances are the same.

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Weld completely so that there are no pinholes.

14.

Butt welding
For burr welding, make a 10 - 15 mm (0.4 - 0.6 inch) MIG spot
weld, and then, in order to prevent warping which might be
caused by the welding heat, complete the welding by making
welds of the specified width at alternate positions.

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15.

Spot welding
When doing spot welding, it is not only important to correctly
position the electrode tips, but also to hold the two panels
securely together with vise-grip pliers or some other type of
clamps, being sure that they are in perfect contact with each
other.

｠

Be sure that the force applied by the arm is sufficient.

｠

Use a test piece to check the secondary current and the
current application time of the spot welder, and adjust the
values as appropriate.

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