Mitsubishi Outlander XL. Manual - part 46

FLOWCHART

ZB600277

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

0000

4. Adhesive application

14. Coating

BASE OF BODY REPAIR

9-43

REPAIR OF SYNTHETIC-RESIN PARTS

REPAIR JUDGMENT

REPAIRABLE AREA

｠

In case of a hole, the damaged area is reshaped to be a circle
or ellipse for easier filling of the repair agent. The diameter 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,  holding  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 painting,
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

ZB6002780000

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

9-44

BASE OF BODY REPAIR

REPAIR OF SYNTHETIC-RESIN PARTS

2. Reshaping of damaged area

ZB600279 0000

The grind surface area should be larger than the resin putty
application area.
Remove burrs on the rear surface reinforcement point, and grind
with  a  sandpaper  #60  to  #80,  as  a  surface  preparation  for
painting. When using a sander #80, grind at a low speed 6000
r/min. For PP, apply PP primer after grinding.

Primer : PP primer
Brand  :  3M™  Automix  Polyolefin  Adhesion  Promoter
5907 or equivalent

3. Fixing of glass cloth (Backing)

ZB600280 0000

｠

After applying the instant adhesive, fix the repair area.

｠

For PP, apply PP primer.

Apply the adhesive to the glass cloth fixing area of the repair part
in order to adhere the glass cloth.

｠

Tape: Glass cloth tape
Brand: 3M™ Glass Cloth Tape 6400 or equivalent

｠

Adhesive: Urethane adhesive
Brand: 3M™ Duramix Plastic Repair Semi-rigid 4040
or equivalent

4. Adhesive application

ZB600281 0000

Apply  a  resin  adhesive  to  cover  the  fixing  glass  cloth  and  its
surrounding area. Then smooth it, using a spatula, and dry.

 

BASE OF BODY REPAIR

9-45

REPAIR OF SYNTHETIC-RESIN PARTS

5. Base surface preparation (Surface grinding)

ZB6002820000

Background

Old paint layer

Remove burrs on the surface, and grind with a sandpaper #120
to make the repair area surface lower than the surrounding area.
When using a sander #120, grind at a low speed 6000 r/min.

6. Rough grinding

ZB600283 0000

Grind the base surface area with a sandpaper #80 as a surface
preparation for painting.

 

7. Filling (Putty application)

ZB600284 0000

ZB6002850000

When mixing the two kinds of liquid, be sure that the air is
not mixed in.

1.

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

2.

For scrape, apply putty to the repair area.

｠

Putty: Epoxy resin putty
Brand: 3M™ Automix EZ Sond Flexble Parts 5887 or
equivalent

｠

Putty: Epoxy resin putty
Brand: 3M™ Resin Putty No.1, 8120 or equivalent

NOTE:

｠

The amount to be applied at a time is approximately 1.5 mm
(0.06 inches). Therefore, recoat it as needed.

｠

For tear and scratch, apply putty after sanding the surface.

 

9-46

BASE OF BODY REPAIR

REPAIR OF SYNTHETIC-RESIN PARTS