Dodge Sprinter. Manual — part 308
aligned and sealed. If component alignment or seal-
ing is necessary, refer to the appropriate section of
this group for proper procedures.
WATER LEAK TESTS
WARNING: DO NOT USE ELECTRIC SHOP LIGHTS
OR TOOLS IN WATER TEST AREA. PERSONAL
INJURY CAN RESULT.
When the conditions causing a water leak have
been determined, simulate the conditions as closely
as possible.
• If a leak occurs with the vehicle parked in a
steady light rain, flood the leak area with an open-
ended garden hose.
• If a leak occurs while driving at highway speeds
in a steady rain, test the leak area with a reasonable
velocity stream or fan spray of water. Direct the
spray in a direction comparable to actual conditions.
• If a leak occurs when the vehicle is parked on an
incline, hoist the end or side of the vehicle to simu-
late this condition. This method can be used when
the leak occurs when the vehicle accelerates, stops or
turns. If the leak occurs on acceleration, hoist the
front of the vehicle. If the leak occurs when braking,
hoist the back of the vehicle. If the leak occurs on left
turns, hoist the left side of the vehicle. If the leak
occurs on right turns, hoist the right side of the vehi-
cle. For hoisting recommendations (Refer to LUBRI-
CATION
&
MAINTENANCE/HOISTING
-
STANDARD PROCEDURE).
WATER LEAK DETECTION
To detect a water leak point-of-entry, do a water
test and watch for water tracks or droplets forming
on the inside of the vehicle. If necessary, remove inte-
rior trim covers or panels to gain visual access to the
leak area. If the hose cannot be positioned without
being held, have someone help do the water test.
Some water leaks must be tested for a considerable
length of time to become apparent. When a leak
appears, find the highest point of the water track or
drop. The highest point usually will show the point of
entry. After leak point has been found, repair the
leak and water test to verify that the leak has
stopped.
Locating the entry point of water that is leaking
into a cavity between panels can be difficult. The
trapped water may splash or run from the cavity,
often at a distance from the entry point. Most water
leaks of this type become apparent after accelerating,
stopping, turning, or when on an incline.
MIRROR INSPECTION METHOD
When a leak point area is visually obstructed, use
a suitable mirror to gain visual access. A mirror can
also be used to deflect light to a limited-access area
to assist in locating a leak point.
BRIGHT LIGHT LEAK TEST METHOD
Some water leaks in the luggage compartment can
be detected without water testing. Position the vehi-
cle in a brightly lit area. From inside the darkened
luggage compartment inspect around seals and body
seams. If necessary, have a helper direct a drop light
over the suspected leak areas around the luggage
compartment. If light is visible through a normally
sealed location, water could enter through the open-
ing.
PRESSURIZED LEAK TEST METHOD
When a water leak into the passenger compart-
ment cannot be detected by water testing, pressurize
the passenger compartment and soap test exterior of
the vehicle. To pressurize the passenger compart-
ment, close all doors and windows, start engine, and
set heater control to high blower in HEAT position. If
engine can not be started, connect a charger to the
battery to ensure adequate voltage to the blower.
With interior pressurized, apply dish detergent solu-
tion to suspected leak area on the exterior of the
vehicle. Apply detergent solution with spray device or
soft bristle brush. If soap bubbles occur at a body
seam, joint, seal or gasket, the leak entry point could
be at that location.
DIAGNOSIS AND TESTING - WIND NOISE
Wind noise is the result of most air leaks. Air leaks
can be caused by poor sealing, improper body compo-
nent alignment, body seam porosity, or missing plugs
in the engine compartment or door hinge pillar areas.
All body sealing points should be airtight in normal
driving conditions. Moving sealing surfaces will not
always seal airtight under all conditions. At times,
side glass or door seals will allow wind noise to be
noticed in the passenger compartment during high
cross winds. Over compensating on door or glass
adjustments to stop wind noise that occurs under
severe conditions can cause premature seal wear and
excessive closing or latching effort. After a repair pro-
cedure has been performed, test vehicle to verify
noise has stopped before returning vehicle to use.
VISUAL INSPECTION BEFORE TESTS
Verify that floor and body plugs are in place and
body components are aligned and sealed. If compo-
nent alignment or sealing is necessary, refer to the
appropriate section of this group for proper proce-
dures.
ROAD TESTING WIND NOISE
(1) Drive the vehicle to verify the general location
of the wind noise.
23 - 2
BODY
VA
(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
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