Mitsubishi Evolution X. Manual - part 11

 

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Mitsubishi Evolution X. Manual - part 11

 

 

CORROSION PROTECTION

TSB Revision

BASE OF BODY REPAIR

9-41

2. Use a brush to apply spot sealer to the contact surfaces of 

the panels (both the new panel and the panel remaining on 
the body) to be spot welded.

3. Do not spot welding.

NOTE: The spot welding can be done as the spot sealer is 
dry to the touch.
Dry to the touch: 30 minutes or less at 20

°

C (68

°

F)

BODY SEALING

Even if a car body is restored to the exact specified dimen-
sions, the body repair work cannot be considered to be com-
plete if an ample amount of sealant is not applied to each of the 
panel joints and seams. Insufficient sealant will result in water 
leakage, corrosion, etc.
NOTE: Use a piece of clean cloth dampened in lead-free gaso-
line or a similar material to clean parts and areas where sealant 
is applied.

• When applying sealant to areas at which the external 

appearance is important (areas which can be seen or where 
the condition of the paint coat is important), be sure to apply 
the sealant so that it is perfectly level with the surrounding 
panels.

• Apply the sealant at the fuel port so that it is perfectly level 

with the surrounding panel so that drops of fuel will not col-
lect.

AB200119

AB200120

AB301490AD

Clean away
any excess

AB301490

AB200122

CORROSION PROTECTION

TSB Revision

BASE OF BODY REPAIR

9-42

• After applying sealant to the door-stop, etc., clean away any 

excess so as to be sure that there is no interference with 
installed parts, etc.

UNDERCOATING

• Be sure to mask any parts installation holes, and 

the area around the place where undercoating is 
to be applied, before applying it.

• Be sure not to apply the undercoating to tires or 

to the drive shaft and other drive components.

If the undercoating application inside the wheel 
housing, on the under body, etc., is insufficient, it can 
result in corrosion. Be sure, therefore, to apply a 
good coating of undercoating to such parts after 
repairs are completed.

AB200123

AB301464

: Undercoating application locations

AD

AB301464

REPAIR OF SYNTHETIC-RESIN PARTS

TSB Revision

BASE OF BODY REPAIR

9-43

REPAIR OF SYNTHETIC-RESIN PARTS

SYNTHETIC-RESIN PARTS REPAIR PROCEDURES

M4090000300090

Bumper is taken as a repair work example for expla-
nation.

FLOWCHART

AB401319

Hole (diameter 50 mm 
(1.97 in) or smaller)

Crack, tear (length 
200 mm (7.8 in) or smaller)

Scratch (length 200 mm x 
width 120 mm (7.8 x 4.7 in) 
or smaller)

1. Cleaning

2. Reshaping of damaged area

3. Fixing of glass cloth (backing)

5. Base surface preparation (surface grinding)

6. Rough grinding

7. Filling (putty application)

8. Surface grinding

9. Surface preparation for primer-surfacer

12. Primer-surfacer coating

13. Primer-surfacer grinding

10. Cleaning and degreasing

11. Masking

AB

4. Adhesive application

14. Coating

AB401319

REPAIR OF SYNTHETIC-RESIN PARTS

TSB Revision

BASE OF BODY REPAIR

9-44

REPAIR JUDGMENT

.

REPAIRABLE AREA

• In case of a hole, the damaged area is reshaped to be a cir-

cle or ellipse for easier filling of the repair agent. The diame-
ter or major diameter should be 50 mm (1.97 inches) or 
smaller.

• In case of a crack or tear, if the both ends of the crack or 

tear are not separated from the body, the length of the area 
should be 200 mm (7.8 inches) or smaller. If one of the ends 
reaches the bumper edge, the length of the damaged area 
should be 200 mm (7.8 inches) or smaller, and also the 
width should be a half or less of the bumper width.

• In case of a scratch, the area should be 200 x 120 mm (7.8 

x 4.7 inches) or smaller.

.

UNREPAIRABLE COMPONENTS

Black-base area is raw urethane base and repairable, however, 
its color does not match in color of the repair agent (ash gray). 
In this case, the replacement of the bumper is preferable.

.

BUMPER REMOVAL AND CLEANING

• The damage of holes, cracks, and tears requires a repair 

work from the rear surface. Remove the bumper to clean 
the whole surface, degrease the front and rear surfaces of 
the repair area using SU Silicone Off, and then repair, hold-
ing the bumper to avoid twisting.

• In case of a scratch, a softener is applied to the bumper as 

repair paint. The repair area cannot be polished after paint-
ing, and surface/gloss matching is difficult. Therefore, do 
not apply gradated topcoat painting, and paint the whole 
surface as a rule.

REPAIR PROCEDURE

.

1. CLEANING

Using SU Silicone Off, degrease the repair area, and then 
remove the wax and oil completely.

.

AB401311AB

 

 

 

 

 

 

 

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