Mitsubishi Outlander XL. Manual — part 13

GROUP 3

WELDED PANEL REPLACEMENT

CONTENTS

ULTRA HIGH STRENGTH STEEL PLATE
. . . . . . . . .

3-2

FRONT END CROSSMEMBER. . .

3-3

FENDER SHIELD. . . . .

3-4

FRONT SIDEMEMBER (PARTIAL
REPLACEMENT). . . . . .

3-8

FRONT PILLAR. . . . ....

3-10

FRONT PILLAR (PARTIAL REPLACEMENT)
. . . . . . . ....

3-14

CENTER PILLAR. . . . ...

3-17

SIDE SILL. . . . . ...

3-20

QUARTER OUTER. . . . ...

3-23

ROOF (ALUMINUM ROOF). . ....

3-26

REAR END CROSSMEMBER. . ....

3-31

REAR FLOOR. . . . . ..

3-34

QUARTER INNER. . . . ...

3-36

QUARTER INNER (PARTIAL REPLACEMENT)
. . . . . . . .

3-40

FRONT DOOR OUTER PANEL (WELDED TYPE)
. . . . . . . .

3-43

FRONT DOOR OUTER PANEL (ADHESION
TYPE). . . . . . ...

3-45

REAR DOOR OUTER PANEL (WELDED TYPE)
. . . . . . . .

3-46

REAR DOOR OUTER PANEL (ADHESION
TYPE). . . . . . ...

3-48

ALUMINUM PANEL. . . . .

.3-49

ALUMINUM PANEL CHARACTERISTICS. .

3-49

ALUMINUM PANEL LOCATIONS. .

3-50

ALUMINUM PANEL REPAIR. . ...

3-50

ALUMINUM PANEL PAINT. . .

3-56

3-1

ULTRA HIGH STRENGTH STEEL PLATE

M40300000151USA0000010000

ULTRA HIGH STRENGTH STEEL PLATE APPLICATION

ZB600358

: High-tensile steel panel in 590Mpa-class

: Ultra-high-tensile steel panel in 980MPa-class

0000

ADVANTAGES OF ULTRA HIGH

STRENGTH STEEL PLATE

The ultra high strength steel plate has the following
advantages as compared with conventional high
strength steel plate.

｠

It has tensile strength approximately 1.7 times
higher than the conventional high strength steel
sheet.

｠

It has a higher yielding point and yielding ratio
(yielding point/tensile strength).

These advantages allow thinner and lighter plates and
better fuel efficiency than the high strength steel plate.

PRECAUTION UPON MAINTENANCE OF

ULTRA HIGH STRENGTH STEEL PLATE

｠

Use a spot cutter for ultra high strength steel plate
to ensure that the spot-welded area is cut off.

｠

For the part in which the ultra high strength steel
plate is used, do not repair it by cutting and bonding
to avoid the reduction in strength by heat. Instead,
replace the whole assembly including the part.

3-2

WELDED PANEL REPLACEMENT

ULTRA HIGH STRENGTH STEEL PLATE

｠

Be careful with rough extending work, because the
ultra high strength steel plate has higher tensile
strength and a higher yielding point than high
strength steel plate and general steel plate.
Careless work will cause symptom such as over-
pulling and springback. Do not extend it completely

at a time. Do it gradually while removing the
distortion by sheet metal processing with a hammer.

｠

Plug welding of Φ 8 mm (0.31 inches) diameter plug
for repair ensures the strength equivalent to spot
welding for 2 steel sheets. For 3 sheets, weld 2
sheets each time instead of welding from one side
to give sufficient welding strength.

FRONT END CROSSMEMBER

M40300000152USA0000010000

ZB6001650000

( )

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

3-3

FRONT END CROSSMEMBER

ZB600068

A

A

B

0000

B

REPAIR WELDS

FENDER SHIELD

M40300000040USA0000010000

AB501088

ZB6001440000

( )

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.)

3-4

WELDED PANEL REPLACEMENT

FENDER SHIELD