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GENERAL INFORMATION 00 SECTION 00–00 Toc of SCT INFORMATION 00-00 GENERAL 00–00 GENERAL INFORMATION HOW TO USE THIS MANUAL 00–00–2 Efficient Replacement of Body Panels 00–00–2 Symbols of Panel Replacement 00–00–2 Body Dimensions (Flat-plane Dimensions) 00–00–3 Body Dimensions (Straight-line Dimensions) 00–00–4 Symbols of Body Dimensions 00–00–4 SERVICE PRECAUTIONS 00–00–5 Arrangement of Workshop 00–00–5 Safety Precautions 00–00–5 Vehicle Protection 00–00–5 Remove Dangerous Articles 00–00–5 Use of Pulling Equipment 00–00–5 Prevent Short Circuits 00–00–6 EFFICIENT REMOVAL OF BODY PANELS 00–00–6 Body Measurements 00–00–6 Prevention of Body Deformation 00–00–6 Selection of Cut-and-join Locations 00–00–7 Removal of Associated Parts 00–00–7 Rough Cutting of Damaged Panel INSTALLATION PREPARATIONS Rough Cutting of New Parts Determination of Welding Method Making Holes for CO2 Arc Welding Application of Weld-through Primer EFFICIENT INSTALLATION OF BODY PANELS Checking Preweld Measurements And Watching Welding Notes Spot Welding Notes Checking Weld Strength ANTICORROSION, SOUND INSULATION, AND VIBRATION INSULATION Body Sealing Application of Undercoating Application of Rust Inhibitor Application of Floor Silencer ABBREVIATION 00–00–7 00–00–7 00–00–7 00–00–7 00–00–8 00–00–8 00–00–8 00–00–8 00–00–9 00–00–9 00–00–10 00–00–11 00–00–11 00–00–11 00–00–11 00–00–12 00–00–12 End of Toc 00–00–1 cardiagn.com Toc of SCT GENERAL INFORMATION HOW TO USE THIS MANUAL C3U000000000B01 Efficient Replacement of Body Panels • This section contains information on the body panels in regard to the welding types, number of spot welds, and cut-and-join locations that are necessary for panel removal and installation • The type of weld and position are indicated by symbols • Some sections have notes concerning the operation being performed Thoroughly read and understand the notes before carrying out any procedures Example REAR FENDER PANEL REMOVAL Shows operation section Shows procedure, caution and note Caution Avoid cutting with a flame as the insulator (shaded) is flammable 1.The rear fender panel and wheel house are joined with glue at the wheel arch line NOTE Drill the 24 weld locations indicated by (A), from the room side Shows a dimensions BRAZE WELDING Shows a cross location CUT-AND-JOINT LOCATION B A cardiagn.com A 250mm {9.84in} B ROUGH CUT LOCATION 17 ROUGH CUT LOCATION 30mm {1.18in} (A)24 19 Shows number of weld Shows a insulator Shows welding region A-A BOTTOM SIDE B-B Shows a cross CUT-AND-JOINT LOCATION MZZ2010B001 Symbols of Panel Replacement • The following symbols are used to indicate the type of weld that is used when replacing body panels SYMBOL MEANING SYMBOL MEANING Spot welding Continuous MIG welding (Cut-and-join location) CO2 arc welding (plug welding) Braze welding CO2 spot welding Rough cut location MZZ2010B002 00–00–2 GENERAL INFORMATION Body Dimensions (Flat-plane Dimensions) • Flat-plane dimensions are the dimensions measured by projecting certain reference points onto a plane surface • When there are no specific indications, the standard points and dimensions are symmetrical in regard to the center of the vehicle • The hypothetical lines may differ according to the vehicle model Example Shows vehicle section 00–00 When there are no specific indications, all of units are in millimeters (mm) UNDERBODY FLAT-PLANE DIMENSIONS mm {in} The dimensions on the left and right in regard to the center of the vehicle are different A B G H 1,060 {41.73} 1,089 {42.87} 1,220 {48.03} 690 {27.17} 800 {31.50} F E D C J I 185 {7.28} Point symbol A B C D E 489 {19.27} 315 {12.40} 425 {16.73} Crossmember No,1 standard hole Front side frame standard hole Front suspension mounting block surface hole center Front suspension mounting bolt Front frame rear standard hole Point symbol φ 16 {0.62} F G φ 16 {0.62} M14 {0.55} 700 {27.58} 716 {28.21} 320 {12.62} Hole diameter or bolt or nut size mm {in} φ 80 {3.14} 624 {24.56} 98 {3.86} 1,240 {48.82} 55 {2.19} Designation 547 {21.54} 587 {23.11} 487 {19.19} 527 {20.75} 609 {24.00} 1,211 {47.68} 725 {28.55} Shows hypothetical standard line 619 {24.38} Shows point symbol Designation Front frame rear standard hole Rear side frame standard hole H Link bracket I Rear suspension housing J Rear side frame standard hole Hole diameter or bolt or nut size mm {in} φ 18 {0.62} φ 16 {0.62} 17 × 29.5 {0.66×1.16} φ 12 {0.47} Shows slot φ 16 {0.62} φ 16 {0.62} Shows hole diameter Shows bolt size MZZ2010B003 00–00–3 cardiagn.com Shows dimension 918 {38.14} 1,162 {45.78} 485 {19.09} 1,030 {40.55} 495 {19.48} Shows outline drawing GENERAL INFORMATION Body Dimensions (Straight-line Dimensions) • Straight-line dimensions are the actual dimensions between two standard points • When there are no specific indications, the standard points and dimensions are symmetrical in regard to the center of the vehicle Example ROOM STRAIGHT-LINE DIMENSIONS (2) Shows dimension location Shows vehicle section Shows outline drawing B G C Shows point symbol I 11 D F H , F , E E A 10 , H Shows position and shape of the points , A Fr cardiagn.com Shows details of the standard point location Shows point indication Without apostrophe:RH With apostrophe:LH , B-B C-C Fr , D-D Fr , E-E Fr Fr F-F , G-G , , Fr , H-H I-I Fr Fr Fr Measured location Dimension mm {in} 1,184 {46.61} 1,064 {41.89} 919 {36.18} 690 {27.17} 1,185 {46.65} 901 {35,47} 607 {23.90} Shows dimension Measured location 10 11 B-B' C-C' D-D' Dimension mm {in} 1,642 {64.65} 1,463 {57.60} 1,667 {65.63} 1,672 {65.83} 1,037 {40.83} 1,290 {50.79} 1,208 {47.56} No indication are shown within the outline drawing MZZ2010B004 Symbols of Body Dimensions • The following symbols are used to indicate the standard points SYMBOL MEANING Center of circular hole SYMBOL (arrow only) MEANING Bolt tip Center elliptical hole Center of rectangular-shaped hole Notch Edge of rectangular-shaped hole Panel seam, bead, etc MZZ2010B016 End Of Sie 00–00–4 GENERAL INFORMATION SERVICE PRECAUTIONS C3U000000000B02 Arrangement of Workshop • Arrangement of the workshop is important for safe and efficient work Safety Precautions • Protective head covering and safety shoes should always be worn Depending upon the nature of the work, gloves, safety glasses, ear protectors, face shield, etc., should also be used 00–00 Welding glasses Ear protectors Weldlng gloves Cotton gloves Safety shoes Dust mask Safety glasses Face shield Vehicle Protection • Use seat covers and floor covers • Use heat-resistant protective covers to protect glass areas and seats from heat or sparks during welding • Protect items such as moldings, garnishes, and ornaments with tape when welding MZZ2036B002 Remove Dangerous Articles • Remove the fuel tank before using an open flame in that area Plug connection piping to prevent fuel leakage MZZ2036B003 Use of Pulling Equipment • When using pulling equipment, keep away from the pulling area and use safety wires to prevent accidents Safety wires MZZ2036B004 00–00–5 cardiagn.com MZZ2036B001 GENERAL INFORMATION Prevent Short Circuits • Turn the ignition switch to the LOCK position • Disconnect the battery cables Battery cable MZZ2036B005 • Securely connect the welding machine ground near the welding area Ground MZZ2036B006 EFFICIENT REMOVAL OF BODY PANELS C3U000000000B03 Body Measurements • Before removal or rough-cutting, first measure the body at and around the damaged area against the standard reference dimension specifications If there is deformation, use frame repair equipment to make a rough correction MZJ2038B001 Prevention of Body Deformation • Use a clamp or a jack for removal and reinforce at and around the rough-cutting location to prevent deforming of the body MZJ2038B002 00–00–6 cardiagn.com End Of Sie GENERAL INFORMATION Selection of Cut-and-join Locations • For parts where complete replacement is not feasible, careful cutting and joining operations should be followed If the location to be cut is a flat area where there is no reinforcement, the selected cutting location should be where the welding distortion will be minimal 00–00 MZJ2038B003 Removal of Associated Parts • Protect moldings, garnishes, and ornaments with tape when removing associated parts End Of Sie Wiring harness Rough cut location Cut-and-join location MZZ2038B001 INSTALLATION PREPARATIONS C3U000000000B04 Rough Cutting of New Parts • For cut-and-join areas, allow for an overlap of 30—50 mm {1.18—1.97 in} with the remaining area on the body side and then rough-cut the new parts 30-50mm{1.18-1.97in} Over lap 30-50mm{1.18-1.97in} Over lap Body side rough cut location New part rough cut location MZZ2038B002 Determination of Welding Method • If the total thickness at the area to be welded is mm {0.12 in} or more, use a CO2 gas shielded-arc welder to make the plug welds 3mm {0.12in}or more MZZ2038B003 00–00–7 cardiagn.com Rough Cutting of Damaged Panel • Verify that there are no parts (such as pipes, hoses, and wiring harness) nearby or on the opposite side of a panel which could be damaged by heat • For cut-and-join areas, allow for an overlap of 30—50 mm {1.18—1.97 in} and then rough-cut the damaged panel GENERAL INFORMATION Making Holes for CO2 Arc Welding • For places that cannot be spot welded, make a hole for CO2 arc welding using a punch or drill as follows (mm {in}) Panel thickness (ø) 0.60—0.90 {0.02—0.03} 0.91—1.20 {0.04—0.05} 1.21—1.80 {0.051—0.07} 1.81—4.50 {0.071—0.17} Hole diameter (ø) {0.19} {0.23} {0.31} 10 {0.39} • Grind the shaded section indicated in the diagram below and create a hole in the part where the 3—4 plates are put together Also, weld the plates together tightly so that gaps not develop φ10mm{0.39in} 30° 30° Outer panel Middie panel MZZ2038B004 Application of Weld-through Primer • For treatment against corrosion, remove the paint grease, and other material from the portion of new part and body to be welded, and apply weld-through primer End Of Sie MZJ2038B008 EFFICIENT INSTALLATION OF BODY PANELS C3U000000000B05 Checking Preweld Measurements And Watching • Align to the standard reference dimensions, based upon the body dimensions illustration, so that new parts are installed in the correct position MZJ2038B009 00–00–8 cardiagn.com Inner panel GENERAL INFORMATION Welding Notes • For the number of weld points, welding should be performed in accordance with the following reference standards Spot welding Original weld Pitch: 50mm{1.97in} Repair weld Pitch: within 35mm{1.38in} 00–00 Original number of welds x 1.3 or more CO2 arc welding Original spot weld If 3mm {0.12in} or more Repair weld Original number of welds or more MZZ2038B005 70 - 120° D t MZZ2038B009 • Because the weld strength is affected by the shape of the spot welder tip, the optimum condition of the tip should always be maintained • Spot welds should be made at points other than the originally welded points MZJ2038B012 • Before spot welding, make a trial weld using the same material as the body panel to check the weld strength Test piece method Nagget diameter :4/5 of tip MZZ2038B006 00–00–9 cardiagn.com Spot Welding Notes • The shape of the spot welder tip is D=(2×t)+3 If the upper panel thickness is different from that of the under panel, adjust to the thinner one GENERAL INFORMATION Checking Weld Strength • Installation locations of the engine, chassis, and seat belts are designated as important safety locations for weld strength Check weld strength by driving a chisel between the panels at every fourth or fifth weld spot, and every tenth regular weld location Chisel dimensions 25mm {0.98in} 20° 8mm{0.31in} Weld location Within 5mm {0.20in} MZZ2038B007 • Drive the chisel between the panels according to the number of panels as shown below • To determine weld strength, drive the chisel between the panel and check whether the panels come apart If the panels come apart, make another weld near the original weld • Restore the shape of the checked area End Of Sie Two panels Weld location One location Three panels Weld location Two location Four panels Weld location Three location MZZ2038B008 00–00–10 cardiagn.com Within 5mm {0.20in} BODY STRUCTURE [DIMENSIONS] End Of Sie CABIN SIDE FRAME STRAIGHT-LINE DIMENSIONS C3U098070010B01 4SD I F 10 D 12 13 11 25 M K 23 H 14 20 22 21 B 16 J 19 G C A 15 17 18 26 24 E 09–80D L B3E0980B018 C D,E F,I D E F Fr Fr J G,H G K Fr Fr Fr L I M H Fr Fr Fr Fr Fr B3E0980B019 Measured location 10 11 12 13 Dimensions mm {in} 642 {25.28} 719 {28.31} 916 {36.06} 882 {34.72} 1,325 {52.17} 1,133 {44.61} 1,125 {44.29} 595 {23.43} 1,500 {59.06} 1,192 {46.93} 1,079 {42.48} 399 {15.71} 884 {34.80} Measured location 14 15 16 17 18 19 20 21 22 23 24 25 26 Dimensions mm {in} 712 {28.03} 808 {31.81} 1,434 {56.46} 865 {34.06} 988 {38.90} 947 {37.28} 795 {31.30} 548 {21.57} 1,101 {43.35} 857 {33.74} 342 {13.46} 637 {25.08} 1,212 {47.72} 09–80D–9 cardiagn.com B A BODY STRUCTURE [DIMENSIONS] 5HB F I J 15 16 G 21 24 L 25 13 B 22 10 20 23 K 19 C A 17 18 11 D 14 12 H 26 E M B3E0980B020 C D,E F,I D E F Fr Fr G J J,K G,H Fr Fr L I Fr M K H Fr Fr Fr Fr B3E0980B021 Measured location 10 11 12 13 End Of Sie 09–80D–10 Dimensions mm {in} 642 {25.28} 719 {28.31} 916 {36.06} 882 {34.72} 1,325 {52.17} 1,133 {44.61} 1,125 {44.29} 595 {23.43} 1,500 {59.06} 1,192 {46.93} 1,079 {42.48} 399 {15.71} 884 {34.80} Measured location 14 15 16 17 18 19 20 21 22 23 24 25 26 Dimensions mm {in} 712 {28.03} 598 {23.54} 766 {30.16} 865 {34.06} 988 {38.90} 930 {36.61} 939 {36.97} 795 {31.30} 548 {21.57} 1,162 {45.75} 1,108 {43.62} 857 {33.74} 342 {13.46} cardiagn.com B A BODY STRUCTURE [DIMENSIONS] ROOM STRAIGHT-LINE DIMENSIONS (1) C3U098070001B01 A E B F H I 09–80D C G D B3E0980B022 A B C Fr Fr F G Fr D Fr Fr H Fr E Fr I Fr Fr B3E0980B023 Measured location Dimensions mm {in} 1033 {40.67} 957 {37.68} 765 {30.12} 1339 {52.72} Measured location H-H’ I-I’ Dimensions mm {in} 1154 {45.43} 1003 {39.49} 1485 {58.46} 1466 {57.72} End Of Sie 09–80D–11 cardiagn.com BODY STRUCTURE [DIMENSIONS] ROOM STRAIGHT-LINE DIMENSIONS (2) C3U098070001B02 4SD A E F B G I H C D B3E0980B024 A B C D E,F E Fr Fr G Fr Fr H F Fr I Fr Fr Fr B3E0980B025 Measured location 09–80D–12 Dimensions mm {in} 1,046 {41.18} 908 {35.75} 816 {32.13} 1,081 {42.56} Measured location I-I’ Dimensions mm {in} 1,211 {47.68} 1,079 {42.48} 787 {30.98} 1,510 {59.45} cardiagn.com BODY STRUCTURE [DIMENSIONS] 5HB A E H B F I J D B3E0980B026 A B C D E Fr Fr F Fr Fr G H Fr I J Fr Fr Fr Fr Fr B3E0980B027 Measured location Dimensions mm {in} 1,046 {41.18} 908 {35.75} 816 {32.13} 1,088 {42.83} 928 {36.54} Measured location J-J’ Dimensions mm {in} 787 {30.98} 1,328 {52.28} 1,373 {54.06} 1,510 {59.45} End Of Sie 09–80D–13 cardiagn.com G C 09–80D BODY STRUCTURE [DIMENSIONS] REAR BODY STRAIGHT-LINE DIMENSIONS C3U098070002B01 4SD A , A , B B , C C , D D 10 , E 11 E B3E0980B028 A B C D E Fr Fr , E Fr Fr Fr Fr B3E0980B029 Measured location 09–80D–14 Dimensions mm {in} 1,007 {39.65} 781 {30.75} 1,190 {46.85} 800 {31.50} 425 {16.73} 851 {33.50} Measured location 10 11 Dimensions mm {in} 679 {26.73} 1,436 {56.54} 620 {24.41} 1,191 {46.89} 720 {28.35} cardiagn.com BODY STRUCTURE [DIMENSIONS] 5HB , A A , B B 09–80D , C C D B3E0980B030 A Fr B C Fr , D Fr D Fr Fr B3E0980B031 Measured location Dimensions mm {in} 700 {27.56} 871 {34.29} 1,114 {43.86} 688 {27.09} Measured location Dimensions mm {in} 1,474 {58.03} 596 {23.46} 1,190 {46.85} 720 {28.35} End Of Sie 09–80D–15 cardiagn.com , D BODY STRUCTURE [PLASTIC BODY PARTS] 09–80E BODY STRUCTURE [PLASTIC BODY PARTS] PLASTIC PARTS HEAT RESISTING TEMPERATURE 09–80E–1 REPAIRABLE RANGE OF POLYPROPYLENE BUMPERS 09–80E–2 Repairable Bumpers 09–80E–2 POLYPROPYLENE BUMPER REPAIR 09–80E–3 PROCEDURE 09–80E–4 End of Toc PLASTIC PARTS HEAT RESISTING TEMPERATURE Code WINDSHIELD MOULDING COWL GRILLE FRONT COMBINATION LIGHT RADIATOR GRILLE LENS HOUSING STANDA RD 4SD SPORT STANDA RD 5HB SPORT FRONT BUMPER FRONT FLAP FRONT SIDE MAKER LIGHT OUTSIDE MIRROR LENS HOUSING BASE OUTER PANEL SIDE PROTECTOR SIDE STEP MOLDING ROOF MOULDING REAR BUMPER REFLECTOR REAR COMBINATION LIGHT OUTER HANDLE HIGH-MOUNT BRAKE LIGHT LENS HOUSING LENS HOUSING LEVER BASE LENS HOUSING LIFTGATE GARNISH 4SD REAR SPOILER BELTLINE MOLDING SHROUD PANEL 5HB UPPER LOWER Material Name PVC PP PC PP POLYVINYLCHLORIDE POLYPROPYLENE POLYCARBONATE POLYPROPYLENE AES AES 80 {176} POLYCARBONATE-ABS 80 {176} AES 80 {176} ABS POLYPROPYLENE POLYETHLENE ACRYLIC POLYCARBONATE-PBT AAS ABS POLYVINYLCHLORIDE POLYPROPYLENE AES POLYPROPYLENE ACRYLIC ABS ACRYLIC AES POLYCARBONATE-PBT POLYCARBONATE-PET POLYCARBONATE POLYPROPYLENE POLYPROPYLENE ABS SMC POLYPROPYLENE AES POLYPROPYLENE 80 {176} 100 {212} 75 {167} 75 {167} 80 {176} 88 {190} 88 {190} 80 {176} 75 {167} 80 {176} 100 {212} 75 {167} 70 {158} 80 {176} 70 {158} 80 {176} 80 {176} 130 {266} 95 {203} 95 {203} 90 {194} 90 {194} 90 {194} 90 {194} 100 {212} PC/ABS AES ABS PP PE PMMA PC-PBT AAS ABS PVC PP AES PP PMMA ABS PMMA AES PC-PBT PC-PET PC PP PP ABS SMC PP AES PP Note • The application of temperatures higher than heat resisting temperatures may result in part deformation End Of Sie 09–80E–1 09–80E cardiagn.com Part Name C3U098050000B01 Heat resisting Temperature°°C{F°°} 95 {203} 95 {203} 130 {266} 90 {194} BODY STRUCTURE [PLASTIC BODY PARTS] REPAIRABLE RANGE OF POLYPROPYLENE BUMPERS C3U098050000B02 The three types of damaged bumpers shown below are considered repairable Although a bumper which has been damaged greater than this could also be repaired, it should be replaced with a new one because such repair would detract from the looks and quality of the bumper In addition, such repair is not considered reasonable in terms of work time Repairable Bumpers A bumper with a hole less than 50 mm {1.97 in} in diameter YMU980PCM YMU980PCN A bumper with a crack less than 100 mm {3.94 in} in length that is less than half of the width of the bumper End Of Sie YMU980PCP 09–80E–2 cardiagn.com A bumper with a crack less than 100 mm {3.94 in} in length BODY STRUCTURE [PLASTIC BODY PARTS] POLYPROPYLENE BUMPER REPAIR C3U098050000B03 cardiagn.com 09–80E YMU980PCQ End Of Sie 09–80E–3 BODY STRUCTURE [PLASTIC BODY PARTS] PROCEDURE C3U098050000B04 YMU980PCR Cut the rough edges around the damage with a knife to make it smooth Sand the area with a sander to make an angle of about 45° YMU980PCS 09–80E–4 cardiagn.com Repair of polypropylene bumpers having damage that has reached the surface of the polypropylene and are too serious to be restored by painting only BODY STRUCTURE [PLASTIC BODY PARTS] Weld the damaged area • For repair of a cracked area, melt the crack together with a heat gun and a melting attachment YMU980PCT • For repair of a hole, degrease the area on both sides of the bumper and apply aluminium tape on the reverse side of the damage area YMU980PCU Melt the polypropylene welding rod with a heat gun and deposit it the cracked area YMU980PCV Note • Heat the shaded area to melt it • Take care not to overly melt welding rod If the part is welded with the welding rod melted like jelly, the welding strength will be reduced • Hold the heat gun 10—20 mm {0.39—0.79 in} from the part being welded • Do not move the welding rod until the welded parts cool YMU980PCW 09–80E–5 cardiagn.com 09–80E BODY STRUCTURE [PLASTIC BODY PARTS] Sand the surface of the polypropylene gradually as it is easily melted by the abrasion heat Sand the area to which repair agent will be applied YMU980PCX YMU980PCY Mix the main agent and the stiffening agent in a ratio of one to one Apply the mixed repair agent to the damaged area Note • When mixing the main and stiffening agents, take care not to allow bubbles to form • The repair agent hardens quickly (about minutes); proceed with the work immediately after mixing the agents • Allow about 30 minutes to dry (20 °C {68 °F}) before sanding YMU980PCZ The repair agent is a two part epoxy adhesive When the repair agent hardens, it will provide a good finish with the same flexibility as the polypropylens The repair agent for a urethane bumper is also a two part adhesive compound However, this is different from that for a polypropylene bumper If the incorrect repair agent is used, the repair will be faulty 09–80E–6 cardiagn.com Uniformly apply polypropylene primer with a brush to an area larger than the repaired area Allow to dry about 10 minutes at 20 °C {68 °F} BODY STRUCTURE [PLASTIC BODY PARTS] Sand the area with #180—240 sandpaper Note • If excessive force is applied to the area when sanding, the surface will be damaged • If fuzz remains around the repaired area, melt it with a heat gun 09–80E Degrease the painted surface Mix the primer and the hardener at a ratio of one to one Apply the primer to the repaired area and the surface of the bumper with a brush or spray YMU980PD1 Use the primer within 16 hours after it is mixed Note • Polypropylene primer will dissolve even after drying if it is wiped with solvent Use only water to clean around the primer 10 Allow the part to dry 09–80E–7 cardiagn.com YMU980PD0 BODY STRUCTURE [PLASTIC BODY PARTS] YMU980PD2 Note • Mix the solutions at the specified ratio c Spray pressure 300—400 kPa {3—4 kg/cm2, 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} — hours minimum Forced drying 60 °C {140 °F} — 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} — hours minimum Forced drying 60 °C {140 °F} — hour Note • Let the part air dry when possible as forced drying could cause bubbles in the top coat End Of Sie 09–80E–8 cardiagn.com 11 Add the softener to the urethane primer surfacer and spray it on the repaired area a Mixing method Urethane primer surfacer + Softener Mixture A Mixture A + hardener Mixture B Dilute mixture B with thinner to spray on bumper b Viscosity 14—16 seconds/viscosimeter 20 °C {68 °F}