SECTION 18: BODY
PA1553
1
CONTENTS
1. VEHICLE EXTERIOR............................................................................................................................6
2. VEHICLE STRUCTURE........................................................................................................................9
3. VEHICLE EXTERIOR MAINTENANCE................................................................................................9
3.1 CORROSION PREVENTION .................................................................................................................9
3.2 PREVENTIVE MAINTENANCE SCHEDULE ...........................................................................................10
3.3 RUST INHIBITOR APPLICATION .........................................................................................................10
4. COMMON FIBERGLASS REPAIR PROCEDURE.............................................................................15
4.1 REPAIR USING FIBERGLASS CLOTH .................................................................................................15
4.2 REPAIR USING FIBERGLASS PASTE..................................................................................................15
4.3 TYPICAL FIBERGLASS REPAIR PROCEDURE......................................................................................16
5. COMMON PAINTING PROCEDURE..................................................................................................17
5.1 NEW PAINT CARE ...........................................................................................................................17
5.2 PAINT TOUCHUP .............................................................................................................................17
5.3 PAINTING........................................................................................................................................18
5.3.1 Safety ....................................................................................................................................18
5.3.2 Surface Preparation And Paint Application...........................................................................18
6. W5 MTH EXTERIOR FINISHING AND BODY REPAIR.....................................................................19
6.1 ZONE 1 ..........................................................................................................................................20
6.1.1 Front Bumper.........................................................................................................................20
6.1.2 Front Crest.............................................................................................................................20
6.1.3 Headlights..............................................................................................................................21
6.1.4 Rear View Mirrors..................................................................................................................21
6.1.5 Windshield Wipers.................................................................................................................22
6.1.6 Windshield.............................................................................................................................22
6.1.7 Front face Body Panel...........................................................................................................24
6.1.8 Entrance Door .......................................................................................................................24
6.1.9 Front Electrical & Service Compartment Door ......................................................................25
6.1.10 Upper Lateral Window...........................................................................................................25
6.1.11 Front Cap...............................................................................................................................26
6.2 ZONE 2 ..........................................................................................................................................26
6.2.1 Upper Side Panel ..................................................................................................................26
6.2.2 Fixed Windows......................................................................................................................26
6.2.3 Electric Awning Windows ......................................................................................................27
6.2.4 Electric Sliding Windows .......................................................................................................30
6.3 ZONE 3 ..........................................................................................................................................33
6.3.1 Rear Cap ...............................................................................................................................33
6.3.2 Engine Compartment Doors..................................................................................................33
6.3.3 Rear Bumper .........................................................................................................................34
6.4 ZONE 4 ..........................................................................................................................................35
6.4.1 Rear Fender ..........................................................................................................................35
6.4.2 Engine Compartment R.H. Side Door...................................................................................35
6.4.3 Engine Radiator Door............................................................................................................36
6.4.4 R.H. Side Rear Service Compartment Door .........................................................................37
6.5 ZONE 5 ..........................................................................................................................................37
6.5.1 Baggage Compartment Doors ..............................................................................................38
6.5.2 Condenser Compartment Door.............................................................................................39
6.5.3 Evaporator Compartment Door.............................................................................................39