Volkswagen Polo Service & Repair Manual: Customer Service Paint Paint Structure
| Galvanized Sheet Metal on Both Sides |
| Previous attempts to match flanges have led to the use of
only galvanized sheet metal on both sides. Only here do the
cathodic protection and the zinc coating barrier effect work
optimally together. The cut edges that are poorly protected with
paint (thinning edges) are additionally protected. |
 Note
| all metal edges are properly deburred when performing a body
collision repair |
| the zinc and cataphoretic layer is completely present on the
interior surfaces that are not painted. |
| the inner weld flange and sanded-through areas are reworked
with Inox Spray -D 007 600 A1-. |
| To reestablish the contour of the body surfaces, the
smoothing materials today in car body construction and in the
paint finishing system are considered to be essential. Pay
attention to the different preparations for the base surface. |
| Refer to
→ Chapter „Filling Paste“. |
| The primer is the most important component of the corrosion
protection system, because it prevents water and oxygen from
accessing the metal surface. Original replacement parts are
normally coated with a black cataphoretic primer. The primer
type is dependent on the area of application. |
Note
| Sanded-through areas or weld seams are to be recoated as
quickly as possible with a corrosion protection primer. |
| The cataphoretic primer is not UV and acid resistant.
Therefore replacement parts must also be painted from the
inside. |
| After a corrosion repair, insulate the bare metallic base
surface with Two-Part Wash Primer -LHV 043 000 A2- and then fill
with Two-Part HS Performance Filler. |
| Refer to
→ Chapter „Primer Metal“. |
| Refer to
→ Chapter „Plastic Primer“. |
| The filler contributes to corrosion protection to a lesser
extent. A suitable filler is, however, essential in service. |
| Filler protects the body from stone impact. Therefore pay
attention to the appropriate layer thickness in the stone chip
protection area. |
| Filler serves as surface preparation. Sanding scratches can
be smoothed out. |
| Colored filler improves the coverage of colors with poor
covering properties. |
| Refer to
→ Chapter „Filler“. |
| PVC Sealed Seams and Underbody Protection |
Note
| When repairing, the seam sealant is to be returned to
replicate stock visual appearance and layer thickness. |
| Sealing seams near attachments to be installed must be
applied smoothly In order to avoid damage and malfunctions. |
| Water drain holes must remain free. |
| All threaded pins and weld nuts with M-threads, as well as
all other pins and contact surfaces for the assembly must be
functional after the sealant application. |
| The sealing material cannot be applied on blank sheet metal,
but rather on filled surfaces. |
| To prevent any water from entering the flange, the notch is
sealed with paste-like, solvent-free PVC in critical areas on
the body. A PVC coating of different thickness is sprayed on
specified areas on the underbody and in the wheel housings to
protect against stone impact and engine humming. |
Note
| Before sealing/applying underbody protection, always
insulate the surface with primer and filler. |
| After a corrosion repair, insulate the bare metallic base
surface with Two-Part Wash Primer -LHV 043 000 A2- and then fill
with Two-Part HS Performance Filler. |
| For the underbody protection, pay attention to the specified
layer thickness. |
| Refer to
→ Chapter „Underbody Protection“. |
| Refer to
→ Chapter „Stone Chip Protection“. |
| Refer to
→ Chapter „Sealing Materials“. |
| For the top coat/base paint, the decorative application is
the prime consideration. This contributes to corrosion
protection to a lesser extent. |
| Depending on the pigment content, the colors have different
coverage. Observe the manufacturer's instructions. |
| Refer to
→ Chapter „Top Coats“. |
| For the clear lacquer, the decorative application is the
prime consideration. The clear lacquer also contributes to
corrosion protection to a lesser extent. The clear lacquer
protects the top coat/base paint against UV radiation and
environmental pollution such as acidic bird droppings. |
| Refer to
→ Chapter „Clear Coats“. |
| Conservation Wax/Cavity Sealant |
| The conservation wax/cavity sealants play a decisive role
for corrosion protection. Depending on the area of application,
different materials are available in customer service. The
exceptional protective effects of these materials is based on
the following characteristics: |
| Hydrophobic (water repellent) |
| Water vapor permeability approximately 1,500 times lower
than with a paint coating of the same thickness |
| Refer to
→ Chapter „Preservation“. |
| Refer to
→ Chapter „Wax Underbody Protection“. |
|
|
|
| Reduced Paint Structure in Engine
Compartment and Inner Hood |
|
Note
| The paintwork in the “engine compartment and the inner hood”
may differ from the paint structure and color on the exterior
paintwork. This variation is production-related and should not
be deemed defective. |
|
|
|
Structure of a Solid-Color Paint System, Conventional
Approximately 80-120 µm thick
1 -
Steel Panel
...
Note
The underbody and stone chip protection structure must be
restored back to its original layer strength and appearance
during a repair.
...
Other materials:
An economic driving style
First read and observe the introductory information
and safety warnings Changing gear earlier
In principle, the highest gear is always the most economical gear. A rule of
thumb for most vehicles: at a speed of 30 km/h (19 mph) drive in 3rd gear, at 40
km/h (25 mph) in 4th gear and at 50 km/ ...
Refrigerant Circuit Connections with Valve for Switches
Note
For switching pressures, removing and installing switches
and switch arrangement and version, see vehicle-specific
refrigerant circuit.
Refer to
→ Rep. Gr.87.
...
Diesel
First read and observe the introductory information
and safety warnings Diesel
Diesel fuel must comply with the European standard EN 590 (in Germany DIN EN
590) .
The service intervals are shorter if you use diesel with a high sulphur content
⇒ BookletService schedule, . A Volkswa ...
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Factory Paint Paint Structure
Repair Instructions for the Underbody and Stone Chip Protection