Mercedes-Benz Sprinter / Dodge Sprinter. Manual — part 477
(2) Apply 50 mm (2 in.) masking tape in 150 mm
(6 in.) lengths along weatherstrips, weld seams or
moldings. After each length is applied, drive the vehi-
cle. If noise goes away after a piece of tape is applied,
remove tape, locate, and repair defect.
POSSIBLE CAUSE OF WIND NOISE
• Moldings standing away from body surface can
catch wind and whistle.
• Gaps in sealed areas behind overhanging body
flanges can cause wind-rushing sounds.
• Misaligned movable components.
• Missing or improperly installed plugs in pillars.
• Weld burn through holes.
STANDARD PROCEDURE
STANDARD PROCEDURE - PLASTIC BODY
PANEL REPAIR
There are many different types of plastics used in
today’s automotive environment. We group plastics in
three different categories: Rigid, Semi-Rigid, and
Flexible. Any of these plastics may require the use of
an adhesion promoter for repair. These types of plas-
tic are used extensively on DaimlerChrysler Motors
vehicles. Always follow repair material manufactur-
er’s plastic identification and repair procedures.
Rigid Plastics:
Examples of rigid plastic use: Fascias, Hoods,
Doors, and other Body Panels, which include SMC,
ABS, and Polycarbonates.
Semi - Rigid Plastics:
Examples of semi-rigid plastic use: Interior Panels,
Under Hood Panels, and other Body Trim Panels.
Flexible Plastics:
Examples of flexible plastic use: Fascias, Body
Moldings, and upper and lower Fascia Covers.
Repair Procedure:
The repair procedure for all three categories of
plastics is basically the same. The one difference is
the material used for the repair. The materials must
be specific for each substrate, rigid repair material
for rigid plastic repair, semi-rigid repair material for
semi-rigid plastic repair and flexible repair material
for flexible plastic repair.
Adhesion Promoter / Surface Modifier:
Adhesion Promoters/Surface Modifiers are required
for certain plastics. All three categories may have
plastics that require the use of adhesion promoter/
surface modifiers. Always follow repair material man-
ufacturer’s
plastic
identification
and
repair
procedures.
SAFETY PRECAUTION AND WARNINGS
WARNING:
•
EYE PROTECTION SHOULD BE USED WHEN
SERVICING
COMPONENTS.
PERSONAL
INJURY
CAN RESULT.
•
USE AN OSHA APPROVED BREATHING MASK
WHEN MIXING EPOXY, GRINDING, AND SPRAYING
PAINT OR SOLVENTS IN A CONFINED AREA. PER-
SONAL INJURY CAN RESULT.
•
AVOID PROLONGED SKIN CONTACT WITH
RESIN, PETROLEUM, OR ALCOHOL BASED SOL-
VENTS. PERSONAL INJURY CAN RESULT.
•
DO NOT VENTURE UNDER A HOISTED VEHI-
CLE THAT IS NOT PROPERLY SUPPORTED ON
SAFETY
STANDS.
PERSONAL
INJURY
CAN
RESULT.
NOTE:
•
When holes must be drilled or cut in body pan-
els, verify locations of internal body components
and electrical wiring. Damage to vehicle can result.
•
Do not use abrasive chemicals or compounds
on undamaged painted surfaces around repair
areas. Damage to finish can result.
RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC PARTS TYPES
CODE
FAMILY NAME
COMMON TRADE NAME
TYPICAL APPLICATION
ASA
ACRYLONITRILE STYRENE
ACRYLITE
LURAN S
CONSOLES, GRILLES
ABS
ACRYLONITRILE BUTADI-
ENE STYRENE
TERLURAN
9
A” PILLARS, CONSOLES,
GRILLES
ABS/PC
ABS/PC ALLOY
PULSE, PROLOY, BAY-
BLEND
DOORS, INSTRUMENT PAN-
ELS
VA
BODY
23 - 3
CODE
FAMILY NAME
COMMON TRADE NAME
TYPICAL APPLICATION
ABS/PVC
ABS/PV ALLOY
PROLOY, PULSE, LUSTRAN,
CYCLOVIN
DOOR PANELS, GRILLES,
TRIM
BMC
BULK MOLDING COM-
POUND
BMC
FENDER EXTENSIONS
EMA
EHTYLENE METHYL ACRY-
LATE/IONOMER
SURLYN, EMA, IONOMER
BUMPER GUARDS, PADS
METTON
METTON
METTON
GRILLES, KICK PANELS,
RUNNING BOARDS
MPPO
MODIFIED POLYPHE-
NYLENE OXIDE
MPPO
SPOILER ASSEMBLY
PA
POLYAMID
ZYTEL, VYDYNE, PA, MIN-
LON
FENDERS, QUARTER PAN-
ELS
PET
THERMOPLASTIC POLYES-
TER
RYNITE
TRIM
PBT/PPO
PBT/PPO ALLOY
GERMAX
CLADDINGS
PBTP
POLYBUTYLENE
THEREPTHALATE
PBT, PBTP, POCAN, VALOX
WHEEL COVERS, FENDERS,
GRILLES
PBTP/EEBC
POLYBUTYLENE
THEREPTHALATE/EEBC
ALLOY
BEXLOY, “M”, PBTP/EEBC
FASCIAS, ROCKER PANEL,
MOLDINGS
PC
POLYCARBONATE
LEXAN, MERLON, CALIBRE,
MAKROLON PC
TAIL LIGHT LENSES, IP
TRIM, VALANCE PANELS
PC/ABS
PC/ABS ALLOY
GERMAX, BAY BLENDS,
PULSE
DOORS, INSTRUMENT PAN-
ELS
PPO
POLYPHENYLENE OXIDE
AZDEL, HOSTALEN, MAR-
LEX, PRFAX, NORYL, GTX,
PPO
INTERIOR TRIM, DOOR PAN-
ELS, SPLASH SHIELDS,
STEERING COLUMN
SHROUD
PPO/PA
POLYPHENYLENE/POLYA-
MID
PPO/PA, GTX 910
FENDERS, QUARTER PAN-
ELS
PR/FV
FIBERGLASS REINFORCED
PLASTIC
FIBERGLASS, FV, PR/FV
BODY PANELS
PS
POLYSTYRENE
LUSTREX, STYRON, PS
DOOR PANELS, DASH PAN-
ELS
RTM
RESIN TRANSFER MOLD-
ING COMPOUND
RTM
BODY PANELS
SMC
SHEET MOLDED COM-
POUND
SMC
BODY PANELS
TMC
TRANSFER MOLDING
COMPOUND
TMC
GRILLES
UP
UNSATURATED POLYES-
TER (THERMOSETTING)
SMC, BMC, TMC, ZMC, IMC,
XSMC, UP
GRILLE OPENING PANEL,
LIFTGATES, FLARESIDE
FENDERS, FENDER EXTEN-
SIONS
EEBC
ETHER/ESTER BLOCKED
CO-POLYMER
EEBC
BUMPERS
EEBC/PBTP
EEBC/POLYBUTYLENE
TEREPTHALATE
EEBC, PBTP, BEXLOY
BUMPER, ROCKER PANELS
23 - 4
BODY
VA
CODE
FAMILY NAME
COMMON TRADE NAME
TYPICAL APPLICATION
EMPP
ETHYLENE MODIFIED
POLYPROPYLENE
EMPP
BUMPER COVERS
EPDM
ETHYLENE/PROPROPY-
LENE DIENE MONOMER
EPDM, NORDEL, VISTALON
BUMPERS
EPM
ETHYLENE/PROPROPY-
LENE CO-POLYMER
EPM
FENDERS
MPU
FOAM POLYURETHANE
MPU
SPOILERS
PE
POLYETHYLENE
ALATHON, DYLAN,
LUPOLEN, MARLEX
-
PP
POLYPROPYLENE
(BLENDS)
NORYL, AZDEL, MARLOX,
DYLON, PRAVEX
INNER FENDER, SPOILERS,
KICK PANELS
PP/EPDM
PP/EPDM ALLOY
PP/EPDM
SPOILERS, GRILLES
PUR
POLYURETHANE
COLONELS, PUR, PU
FASCIAS, BUMPERS
PUR/PC
PUR/PC ALLOY
TEXIN
BUMPERS
PVC
POLYVINYL CHLORIDE
APEX, GEON, VINYLITE
BODY MOLDINGS, WIRE IN-
SULATION, STEERING
WHEELS
RIM
REACTION INJECTED
MOLDED POLYURETHANE
RIM, BAYFLEX
FRONT FASCIAS, MODULAR
WINDOWS
RRIM
REINFORCED REACTION
INJECTED MOLDED
PUR, RRIM
FASCIAS, BODY PANELS,
BODY TRIMS
TPE
THERMO POLYETHYLENE
TPE, HYTREL, BEXLOY-V
FASCIAS, BUMPERS, CLAD-
DINGS
TPO
THERMOPOLYOLEFIN
POLYTROPE, RENFLEX,
SANTOPRENE, VISAFLEX,
ETA, APEX, TPO, SHIELDS,
CLADDINGS
BUMPERS, END CAPS, TEL-
CAR, RUBBER, STRIPS,
SIGHT, INTERIOR B POST
TPP
THERMO-POLYPROPYLENE
TPP
BUMPERS
TPU
THERMOPOLYURETHANE,
POLYESTER
TPU, HYTREL, TEXIN, ES-
TANE
BUMPERS, BODY SIDE,
MOLDINGS, FENDERS, FAS-
CIAS
PANEL SECTIONING
If it is required to section a large panel for a plas-
tic repair, it will be necessary to reinforce the panel
(Fig. 1). To bond two plastic panels together, a rein-
forcement must overlap both panels. The panels
must be “V’d” at a 20 degree angle. The area to be
reinforced should be washed, then sanded. Be sure to
wipe off any excess soap and water when finished.
Lightly sand or abrade the plastic with an abrasive
pad or sandpaper. Blow off any dust with compressed
air or wipe with a clean dry rag.
Fig. 1 PANEL SECTIONING
1 - EXISTING PANEL
2 - NEW PANEL
3 - PANEL ADHESIVE
4 - BONDING STRIP
VA
BODY
23 - 5
When bonding plastic panels, Follow repair mate-
rial manufacturers recommendations. Be sure that
enough adhesive has been applied to allow squeeze
out and to fill the full bond line. Once the pieces
have been brought together, do not move them until
the adhesive is cured. The assembly can be held
together with clamps, rivets, etc. A faster cure can be
obtained by heating with a heat lamp or heat gun.
After the parts have been bonded and have had time
to cure, rough sand the seam and apply the final
adhesive filler to the area being repaired. Smooth the
filler with a spreader, wooden tongue depressor, or
squeegee. For fine texturing, a small amount of
water can be applied to the filler surface while
smoothing. The cured filler can be sanded as neces-
sary and, as a final step, cleanup can be done with
soapy water. Wipe the surface clean with a dry cloth
allowing time for the panel to dry before moving on
with the repair.
PANEL REINFORCEMENT
Structural repair procedures for rigid panels with
large cracks and holes will require a reinforcement
backing. Reinforcements can be made with several
applications of glass cloth saturated with structural
adhesive. Semi-rigid or flexible repair materials
should be used for semi-rigid or flexible backing rein-
forcement (Fig. 2) and (Fig. 3). Open meshed fiber-
glass
dry
wall
tape
can
be
used
to
form
a
reinforcement. The dry wall tape allows the resin to
penetrate through and make a good bond between
the panel and the adhesive. Structurally, the more
dry wall tape used, the stronger the repair.
Another kind of repair that can be done to repair
large cracks and holes is to use a scrap piece of sim-
ilar plastic and bond with structural adhesive. The
reinforcement should cover the entire break and
should have a generous amount of overlap on either
side of the cracked or broken area.
When repairing plastic, the damaged area is first
“V’d” out, or beveled. Large bonding areas are desir-
able when repairing plastic because small repairs are
less likely to hold permanently. Beveling the area
around a crack at a 20 degree angle will increase the
bonding surface for a repair (Fig. 4). It is recom-
mended that sharp edges be avoided because the
joint may show through after the panel is refinished.
• Panel repair for both flexible and rigid panels
are basically the same. The primary difference
between flexible panel repair and rigid panel repair
is in the adhesive materials used (Fig. 5).
• The technician should first decide what needs to
be done when working on any type of body panel.
One should determine if it is possible to return the
damage part to its original strength and appearance
without exceeding the value of the replacement part.
• When plastic repairs are required, it is recom-
mended that the part be left on the vehicle when
every possible. That will save time, and the panel
Fig. 2 SOFTENED EDGES
1 - SOFTENED EDGES
2 - PANEL ADHESIVE
3 - BONDING STRIP
Fig. 3 PANEL REINFORCEMENT
1 - PANEL ADHESIVE
2 - REINFORCEMENT
Fig. 4 BEVELING ANGLE - 20 DEGREE
23 - 6
BODY
VA
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