Mitsubishi Outlander XL. Manual — part 25

Brand : 3M™ AAD Part No.8542 or
equivalent

｠

Adhesive 2: Epoxyayresin adhesive

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

NOTE ON REPAIR WORK

INSTALLATION

1.

When installing the rear door outer panel, grind and remove
the paint, etc. from the bonded surface of the outer panel to
ensure the bonding strength. After the removal, degrease it.

2.

Install the outer panel and hem it. Wipe off the excessive
adhesive and finish it.

ALUMINUM PANEL

ALUMINUM PANEL CHARACTERISTICS

M40300000005USA0000010000

Description of aluminum panel

A new aluminum panel with higher strength and better
workability has been developed by adding a small
amount of metallic elements, including magnesium
(Mg), copper (Cu) and silicon (Si), to aluminum. This
type of aluminum material has equivalent strength to
cold rolled steel sheets.

Advantage of aluminum panel

1.

Lighter: The specific gravity of aluminum is 2.7,
which is only one third of general steel panel (7.9).
However, it requires 1.4 times in thickness to obtain

the same rigidity as the steel panel, resulting in one
half in weight.

2.

More durable: Aluminum has the property of
creating oxide coating on its surface when it
contacts with the air. This coating prevents it from
being corroded.

3.

More heat-conductive: The heat conductivity of
aluminum is twice as high as that of iron. This
means that aluminum absorbs and disperses heat
more quickly, which results in prompt change of its
temperature.

4.

More electric-conductive

5.

Non-magnetic substance

WELDED PANEL REPLACEMENT

3-49

ALUMINUM PANEL

ALUMINUM PANEL LOCATIONS

M40300000006USA0000010000

ZB600163 0000

Roof panel

Application

Thickness

Roof panel

1.3 mm (0.05 inches)

ALUMINUM PANEL REPAIR

M40300000007USA0000010000

Precautions upon sheet metal processing

1.

Major difference in processing between sheet metal and steel
sheet (On the basis of general body shop)

Work
descript
ion

Aluminum alloy panel Steel sheet

Hammeri
ng

Mallet or plastic hammer Sheet

metal

hammer

Washer
welding

Not possible

Possible

Gas
welding

Not good workability but
possible

Possible

Spot
welding

Not possible

Possible

3-50

WELDED PANEL REPLACEMENT

ALUMINUM PANEL

Work
descript
ion

Aluminum alloy panel Steel sheet

MIG
welding

Possible by a welding
machine for aluminum
and argon gas

Possible by a
general
welding
machine and
CO2gas

2.

If strong impact is given under low temperature, its strength
becomes low and cracking occurs.

3.

The springback (returning force to the original condition) is
large due to high elastic modules.

4.

The thermal effect is large due to high heat conductivity.

5.

When excessively heated, its strength will be deteriorated.
When heated additionally, it will be melted without
discolouration. [The heating temperature is approximately
250°C (482°F)].

Material

Melting point

Aluminum

475 to 660 °C (887 to 1220 °F)
<varying with the alloy content>

Steel sheet

1500 to 2500 °C (2732 to 4532 °F)

Weld and repair it if the side sill reinforcement front is
damaged.

6.

Because the material is soft, choose an abrasive carefully.
Wear a dustproof mask and safety glasses, because ground
particle is light and tends to float in the air.

7.

If a disk sander is strongly pressed against the aluminum
plate, friction heat is generated, resulting in exfoliation of the
aluminum alloy and clogging of the disk sander with the
exfoliated particles.

8.

Because the clogged disk sander will damage the aluminum
alloy panel, replace it with a new one as soon as possible.

9.

General tools and sanding tools shall not be shared for both
aluminum alloy and steel panels. (Iron powder remaining on
the surface may cause electric corrosion with a different type
of metal).

10.

During MIG welding, protect the vicinity because the spatters
are hard to see and spread father than expected.

Correction of uneven surface

Basically, the same as the steel panel. However, give a
consideration to the aluminum alloy characteristics.

WELDED PANEL REPLACEMENT

3-51

ALUMINUM PANEL

ZB600117

0000

ZB600118

0000

1.

Repair of sheet metal

(1)

Heat with a burner.

｠

Heat-up the panel until you feel heat with a keplar
work glove on the reverse side of the panel.

｠

Keep moving the burner evenly to prevent heat from
concentrating in one point.

(2)

Because hammering may stretch the panel, use a mallet
or plastic hammer.

Minimize the stretch and hardening, and give no
hammer dent.

ZB6001110000

2.

Distortion check: Grind the surface with #80 to #120-grit
sandpaper and then check for distortion.

ZB6001140000

3.

Straightening: Remove distortion by the draw correction
procedure with a flattening hammer and a burner.

｠

The heating temperature should be approximately 250°
C (482°F).

｠

Pay particular attention to heating, because it is melted
without discolouration by heat.

｠

Cover the vicinity of the area to be heated with a wet rag
or the like to prevent temperature rise and influence of
heat (distortion).

｠

Do not use a draw hammer for steel sheets because it
may cause the panel crack.

3-52

WELDED PANEL REPLACEMENT

ALUMINUM PANEL