Mitsubishi Galant (2004+). Manual — part 34
BODY REPAIR
TSB Revision
BASE OF BODY REPAIR
9-15
NOTE: If a replacement panel is to be mounted by doing
plug welding from the side of the panel remaining on the
body, either a hole can be made in the panel on the body, or
a hole can be made right through both the panel which is to
remain on the body and the panel to be replaced.
CAUTION
When performing this operation, warping of the surround-
ing panels may occur if an excessive amount of heat is
applied; therefore, be careful to avoid doing this.
4. 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.
5. 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 (dustproof glasses).
6. 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.
AB200054
AB200055
AB200056
AB200057
BODY REPAIR
TSB Revision
BASE OF BODY REPAIR
9-16
7. Flange correction for spot weld traces
Correct any flanges that become bent or deformed when
spot welds are broken or during other work.
CAUTION
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.
8. 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.
9. 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.
CAUTION
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 weld-
ing before proceeding with the rest of the work.
AB200058
AB200059
AB200060
AB200061
AB
EDGE OF THE
NEW PART
EDGE OF THE
PANEL ON THE BODY
BODY REPAIR
TSB Revision
BASE OF BODY REPAIR
9-17
CAUTION
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 cut-
ting of the inner panel and that of the outer panel approxi-
mately 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 (dou-
ble-box construction), cut the outer panel and the reinforce-
ment at the same position, and don't forget to butt weld the
reinforcement. If the inner panel is an assembly replace-
ment part, cut it at two places in order to provide ample
working space for the butt welding of the reinforcement.
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.
AB200062AB
OUTER PANEL
APPROX. 50 mm
(2.0 in)
INNER PANEL
TWO-LAYER
CONSTRUCTION
AB200063AB
INNER PANEL
INNER PANEL
CUT LINE
INNER PANEL CUT LINE
OUTER PANEL
AND REINFORCE-
MENT CUT LINE
THREE-LAYER CONSTRUCTION
AB200064
BODY REPAIR
TSB Revision
BASE OF BODY REPAIR
9-18
CAUTION
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 nec-
essary that all work concerning these areas be done care-
fully 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.
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.
CAUTION
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.
AB200065
AB200066
AB200067
AB200068
Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.
Текст