1994 MAZDA MX-5 Workshop Manual

PLASTIC BODY PARTS Procedure for Repairing Polypropylene Fascia Damaged paint Hole or crack through surface Crack more than 150mm (5.90 in) long or broken I I surface I I surface I I 1 I Fascia I 1 Fascia I not visible I I visible I 1 Smooth dakaged area I Remove paint Apply aluminum tape on reverse side or bum~er Weld damaged area I Rough sand damaged m Degrease damaged 1 area , 1 + Apply polypropylene primer to damaged area Apply repair filler to damaged area and dry , Sand damaged area and smooth I Apply polypropylene primer to damaged area and let dry 1 Spray primer surfacer on damaged area and dry I + + t Sand partial or complete surface of fascia I 1 1 1 Spray entire fascia surface with I polypropylene primer ( Spray primer surfacer on fascia and dry -- 4 1 Sand surface of fascia I I and smooth I -- - -- Degrease fascia I .) 4 4 4 Spray matching body color paint on fascia and dry Gartner Banana

PLASTIC BODY PARTS d Repair of Polypropylene Fascia Repair of polypropylene fascia having flaws that have reached the surface of the polypropylene and are too serious to be restored by the painting. I Hole Crack Flaw A - A' Section B - B' /a - c, Section D-D' Section @ Top coat layer O Primerlsurfacer layer @ Primer layer @ Polypropylene layer I 1. Cut the rough edges around the flaw with a knife to make it smooth. Sand the area with a sander to make an angle of about 45". A - A' B - B' Section D - D' Section ,,/Cut with knife / / / / Make angle with sander - / I L h, 45" - 45" angle necessary for deposit of polypropylene welding rod Gartner Banana

PLASTIC BODY PARTS 2. Weld damaged area For repair of a cracked area, melt the crack together a heat gun and a special attach- ment. - B' section Melt area with heat gun C - C' Attachment Section after melting For repair of a hole, degrease the area and apply aluminum tape on the reverse side of the damaged area. A - A' Section Degrease surface ~lumin;m tape 3. Melt the polypropylene welding rod with a heat gun and deposit it in the cracked area. B - B' C - C' Section Welding rod (Polypropylene) / - - (Polypropylene) Melt this area Note a) Heat the shaded area to melt it. b)Take care not to excessively melt the welding rod. If the part is welded with the welding rod melted like jelly, the welding strength will be lowered. c) Hold the heat gun 10-20mm (0.39-0.79 in) away from the part that will be welded. d)Do not move the welding rod until the welded part cools. A - A' Section Welding rod (Polypropylene) Welding rod (Polypropylene) / I TOP view Tape Gartner Banana

PLASTIC BODY PARTS 4. Sand the surface of the polypropylene little by little since it is easily melted even by the abrasion heat. If melted, remove the melted area. Sand the areas to which repair filler will be applied. I Do not sand part continuously Area where repair filler will be applied Paint Remove paint and roughen surface 5. Apply polypropylene primer uniformly to an area larger than the repaired area with a brush. It will take about 10 minutes to dry at a 20°C (68°F). Apply primer ~ol~~ro~~lene primer 6. Mix the main agent and the stiffening agent in a ratio of one to one. Apply the mixed repair filler to the damaged area. Note a) When mixing the main and stiffening agents, do not allow bubbles to form. b)The repair filler hardens fast (about 5 minutes). Proceed with the work immediate- ly after mixing. c) Allow about 30 minutes to dry at 20°C (68°F) before sanding. Repair filler . ,Do not mix air V@// Polypropylene surface The repair filler is a two part epoxy adhesive. When the repair filler hardens, it will provide a good finish with the same flexibility as the polypropylene. The repair filler for a urethane fascia is also a two part adhesive; however, this is different from the repair filler for a polypropylene fascia. Do not use the wrong repair filler. Gartner Banana

PLASTIC BODY PARTS 7. Sand the area with #180-#240 sandpaper. . . Note a) If excessive force is applied to the area when sanding, the surface will not become smooth. b)lf there is fuzz around the repaired area melt it with a heat gun. 8. Degrease the painted surface. 9. Mix the primer and the hardener at a ratio of one to one. Apply primer to the repaired area and the surface of the fascia with a brush or spray. Polypropylene primer Primer hardener 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. 10. Dry the part. Gartner Banana

Gartner Banana

-pp - - ------ - - - - - - -~ I LAYOUT OF CONTENTS I DISPOSITION 7YPOGRAPHIOUE DE CONTENU I nlSPOSlClON DEL CONTENIDO / ANORDNUNG DES 1Nt1ALTS U.S.A. Catalog No. AU-NA04-03 a The followrng IS il tvpical exornplc of the layout of contents on Mazda m~crofrctlr :)arts ca1aIog Voicr trn cxe:nple typlquc de la disposition typc!yraphique de contenu clar~s les m:crofrctles de catalogue des pieces de Mazda El slgulentc es trn qeinplo ripico de la disposition dcl conten~rlo crl una microfrcha del catalogo de rur)ur!stos dt: Mazda. Folgcndos ist ein typlsct~es Ueispie! der Inhaltsariordnuny des t\'razcia.~41krof1~tie~Teiiekataloys. 0 Remark : Tho nems listed under@ nave been deletod from each fiche since Dec. '93 @ Lsywt of contents Disposition Typo 0 graphique de Contcnu Disposicibn del conten~do Anordnung Per I~ilidlr: r'ictorial lndex Index p3r Schdmas lndicc: Grdfico lllu~trisrler lndex Illustration & Text Il.ustrst~ons e* Texrrr . \lurtrt..ibn y 7'thtc Abbildung und Te:r @ . Master Section No. lndex . Indc

PICTORIAL INDEX VALVE SYSfE# -- I I400 GASOLINE ENGINE 4-CYLINDER (112) P CNC t NE CUAGGE. cw7aoC svsr EM b 6115111 IElSL (A1 1 - - ... . .. ,.' . .' -- ... ..>'UFC'---i, - ..-.--CCII,Y..IC m39w I 't'RAWSHISSJOf4 GEARS :NANliE CON l ROC SYSTER -.*-.- IWCIAL. 1 Gartner Banana