Mazda 5. Manual — part 83
09–80E–8
BODY STRUCTURE [PLASTIC BODY PARTS]
14—16 seconds/viscosimeter 20
°C {68 °F}
Note
• Mix the solutions at the specified ratio.
c. Spray pressure
300—400 kPa {3—4 kg/cm
2
, 43—57 psi}
d. Standard film thickness
30—40
µ
e. Spray method
Spot-spray primer surfacer on bumper three of four times
12. Air drying 20
°C {68 °F} — 8 hours minimum.
Forced drying 60
°C {140 °F} — 1 hour
13. Lightly sand the complete surface of the bumper with #400—#600 sandpaper. Do not expose the surface of the
polypropylene. (Wet or dry sanding is acceptable.)
14. Wipe the complete surface of the bumper with degreasing agent. Quickly wipe the surface with a clean rag to
degrease it.
15. Apply a matching coat of body color to the polypropylene bumper.
Note
• Be sure to use only urethane primer for a urethane bumper and polypropylene primer for a polypropylene
bumper. Other paints for repairing a polypropylene bumper are the same as those for the urethane
bumper.
16. Air drying 20
°C {68 °F} — 8 hours minimum.
Forced drying 60
°C {140 °F} — 1 hour
Note
• Let the part air dry when possible as forced drying could cause bubbles in the top coat.
End Of Sie
PLASTIC LIFTGATE
DPE098062010B01
Characteristics of Plastic Liftgate
• The material for the outer panel of the liftgate is polycarbonate; acrylonitrile-butadience styrene resin (ABS-
resin), and the material for the inner panel is glass fiber; polypropylene.
• The liftgate has a bonded structure of outer and inner panels.
Configuration of Shipped Parts
• The liftgate is shipped with the rear No.2 wiring harness and the complex antenna assembled and bonded.
• The outer panel surface of the liftgate is not painted. However, it is coated with primer like a bumper.
• A hole cover is affixed to the back monitor camera installation hole on the outer panel with double-sided
adhesive tape. A waterproof pad is affixed to the back monitor camera installation hole on the inner panel.
Repair Points
• Scratches are repairable. Holes and cracks are not repairable.
Urethane primer surfacer
Softener
Hardner
Mixture A
Mixture B
100
30
4
1
YMU980PD2
BODY STRUCTURE [PLASTIC BODY PARTS]
09–80E–9
09
Caution
• Because the outer and inner panels are bonded, damage to the inner frame is not repairable.
• To install the back monitor camera, perform the following procedure:
— Remove the hole cover installed to the new liftgate using a flathead screwdriver.
— Remove the waterproof pad.
End Of Sie
REPAIRABLE RANGE OF POLYCARBONATE; ABS-RESIN LIFTGATE
DPE098062010B02
Repairable damage on the liftgate is as follows:
Repairable Liftgate
1. Scratches on the liftgate
HOLE COVER
WATERPROOF PAD
HOLE COVER
W-SIDED ADHESIVE TAPE
A
A
A-A
DPE0980B132
09–80E–10
BODY STRUCTURE [PLASTIC BODY PARTS]
Unrepairable Liftgate
1. Damages other than scratches (cracks, holes, cuts) on the liftgate
End Of Sie
CPJ0980B150
CPJ0980B151
BODY STRUCTURE [PLASTIC BODY PARTS]
09–80E–11
09
REPAIR OF POLYCARBONATE; ABS-RESIN LIFTGATE
DPE098062010B03
Caution
• Masking tape has been affixed to the adhesive application area. Paint the body color without
removing the masking tape.
Smooth and feather damaged area
Clean and degrease
Apply putty (applicable to resin)
(Apply primer and let dry)
(May be necessary depending on paint manufacturer)
Procedures vary depending on paint manufacturer
Follow paint manufacturer's instructions
Let dry and smooth putty
Sand surface for urethane primer surfacer
Sand surface
Clean and degrease
Apply primer
Apply urethane surfacer, let it dry, grind, and sand surface for top coating
Clean and degrease liftgate
Top-coat liftgate and let dry
Finish
Scratch on painted surface
Crack, hole, cut, or completely damaged
Replace the damaged liftgate
Caution
·
For materials used for repair (such as putty, primer surfacer, and top coating paint), follow manufacturer's
instructions
·
Because the liftgate has a bonded structure of outer and inner panels, mask the inner panel securely.
DPE0980B152
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