Mitsubishi Delica: Rust in floor sills and rear wheel arches

The L400 Delica has known rust-prone areas in the outer floor sills and inner and outer rear wheel arches. The sill sections trap moisture and road debris, while the rear wheel arches are subject to stone chip damage that breaks through the factory paint and allows rust to establish. Vehicles used in coastal regions of New Zealand or those that have spent time in Japan's snowbelt provinces (where road salt is used) are significantly more affected. Structural sill rust can compromise the vehicle's rigidity and lead to WOF rejection. Rust in wheel arches is cosmetic in early stages but can spread to the structural chassis rails if left untreated.

• Bubbling or blistering paint on the outer sill below the doors
• Soft or perforated metal in the rear wheel arch detected by probing
• Musty smell inside the cabin or visible water ingress staining on the cargo floor

1. 1

   From underneath, probe the floor sill sections with a screwdriver for softness or perforation.

2. 2

   Check the outer sill paint surface for bubbling or rippling, which indicates subsurface rust.

3. 3

   Inspect the inner rear wheel arch by pulling back any carpet or liner in the cargo area.

4. 4

   Check around the rear door rubber seal channels for hidden rust.

5. 5

   Pay particular attention on right-hand examples imported from the Japanese coastal prefectures.

Parts involved: Body corrosion.

$600 to $3,500 at New Zealand independent workshop rates. That is for this job on its own, not for the car.

An estimate, in NZD, for the repair as normally carried out. What a specific car costs depends on which part has failed and what it damaged on the way — treat this as the floor for a negotiation, not a quote.

• “Has the vehicle had any rust repair work done, and do you have records?”
• “Where was the vehicle used or stored in Japan before import, and was it in a coastal or snowbelt area?”
• “Can the vehicle be placed on a hoist for a full underside inspection before purchase?”

The failure described above is documented in published sources — owner forums, technical service bulletins, recall notices and workshop write-ups — held in our fault database. The inspection instructions and the cost estimate are KickTyres’ own interpretation of them, and it is a starting point for an inspection rather than a manufacturer statement.