Mitsubishi Galant (2004+). Manual — part 35

BODY REPAIR

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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.

16.Plug welding

If spot welds cannot be made, make holes for plug welding
in the new parts, and then MIG weld. Because the quality of
the fusion varies according to the size of the holes, they
should be about 5

−

6 mm (0.2 inch) in diameter. In addition,

be sure the two surfaces are in complete contact with each
other by using vise-grip pliers to securely hold them.
NOTE: Depending on the working conditions, it might also
be necessary to make holes in the panel remaining on the
body

17.Hemming work

(1) If hemming work is to be done for the rear wheel cut line,

the door outer panels, or other parts, use a hammer and
a dolly or a hemming tool to do the work manually.

AB200070

AB200070

AB200071

AB200072 AB

HEMMING TOOL

BODY REPAIR

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(2) After completing the hemming work, make MIG spot

welds at 50

−

60 mm (2.0

−

2.4 inches) intervals on the

inside.

CAUTION

Be sure not to grind the panel down too much. Before
welding the outer panel, be sure to apply an anticorrosion
agent.
18.Finishing work for butt welding and plug welding

Do the finishing work to smooth the protruding weld traces.
However, the butt joints of reinforcements and other internal
parts will be stronger if the weld traces are not finished.

19.Application of body sealant

Apply a coating of sealant carefully, without breaks, as
described in the section (of the manual corresponding to
that model).
NOTE: After application has been made to any external sur-
faces, perform smooth-finishing work.

AB200073

AB200074

AB200076

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CAUTION

Wipe off any anticorrosion agent which oozes out onto
surfaces to be painted later; the presence of such anticor-
rosion agent would prevent correct adhesion of the paint
coat.
20.Application of an anticorrosion agent

Apply an ample amount of anticorrosion agent to any
welded areas and to all surfaces from which the paint coat
was removed.
The paint coat of welded areas will have been damaged by
the heat; be sure to apply an anticorrosion agent to surfaces
to be repaired.
Use an aerosol-type anticorrosion agent for application to
the side sills, the pillars, and other similar parts which have a
hollow construction, by utilizing the trim mounting holes, etc.

21.Application of undercoating

If the underbody is repaired or replaced, carefully apply a
coating of undercoating as described in the section (of the
manual corresponding to that model).

CAUTIONS REGARDING BODY REPAIR

Because each component part of a single-unit con-
struction body makes some contribution, more or
less, to the overall strength of that body, it is neces-
sary to sufficiently understand the actual function of
any part to be repaired before attempting any repair
or welding procedure.

.

STRENGTH AND RIGIDITY

1. The suspension installation part plays an impor-

tant role, determining the wheel alignment. Wheel
misalignment is of course potentially very danger-
ous because it can lead to driving instability,
one-sided braking, abnormal tire wear, abnormal
vibration, etc.

At the time of repair, it is particularly necessary to
take measurements at the components noted
below, and to make all welds and installations
with special care.

•

Front sidemember

•

Rear floor sidemember

•

Front wheelhouse (inner)

•

Rear wheelhouse (inner) (Independent rear
suspension type)

2. Because the places where the floor panel and

sidemember parts are joined have an important
effect upon the rigidity of the entire body, welds in
these places must be done with particular care.

3. After repairs have been completed, the wheel

alignment, wheel base, tread, etc., must be care-
fully checked to be sure that there is no deviation.

.

AB200077

AB200078

AB200079

BODY REPAIR

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SAFETY

1. Procedures related to the installation of any com-

ponent related to safety must be done with partic-
ular care in order to assure full maintenance of
safety.

•

Suspension installation parts

•

Fuel pipe

•

Brakes

•

Fuel tank installation parts, etc.

2. Because seat belts are directly related to driver

and passenger safety, any welds of seat belt
anchor points or reinforcements must be done
with particular care in order to maintain strength.

.

PREVENTION OF CORROSION AND OF WATER
OR DUST ENTRY

1. After any work is completed, it is important to

completely remove any welding residue, particles
or residue from cutting, and any other dirt, etc.

2. Corrosion-prevention material must without fail

be applied at the following places:

•

At any place where paint has flaked off or
peeled away.

•

At any surfaces that have been cut.

•

At the outer and inner side of every welded
place.

•

Within any semi-enclosed structure or compo-
nent (aerosol-type rust inhibitors are effective
for difficult-to-reach places).

•

At the outer and inner side of any place sub-
jected to heat.

3. Apply a coating of undercoating if the underbody

is repaired.

4. Use spot sealer if spot welds are made.
5. Repair any scratches to panels made by mold-

ings, sashes, etc.

6. Carefully apply body sealant to panel connection

joints and other fitting places.

7. Tape over any unused holes in the panel inner

side by using sealing tape.

.

VIBRATION AND NOISE

1. Prevent any decrease of tensional rigidity caused

by welding distortion.

2. Carefully apply body sealant to panel connection

joints and other fitting places.

3. Tape over any unused holes in the panel inner

side by using sealing tape.

.

CONTACT AND ALIGNMENT

1. In order to maintain the precision of openings,

make careful measurements as repairs are being
made.

2. Make contact/alignment adjustments of door

hinge, lid, and hood hinge installation parts.

THEFT PROTECTION

M4090007000045

In order to prevent theft, following Vehicle Identification Number
(VIN) has been engraved and attached, in the form of a label to
the engine, transaxle, and main of the outer body:

Engine cylinder block, Transaxle housing, Fender,
Doors, Quarter panel, Hood, Liftgate, Trunk lid,
Bumpers

Furthermore, supplementary parts for the main portions of the
outer body have theft protection labels attached and the sup-
plementary parts for the engine and the transaxle are engraved
with the same details.

AC211646

THEFT PROTECTION LABEL
FOR ORIGINAL PARTS

FOR REPLACEMENT PARTS

AB