Volkswagen Polo Service & Repair Manual: Repair Instructions for the Underbody and Stone Chip Protection
 Note
| The underbody and stone chip protection structure must be
restored back to its original layer strength and appearance
during a repair. |
| 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. |
| Damage Caused by an Accident (Part Replacement) |
| – |
Clean the new part with Silicone Remover, Long. |
| – |
Sand the factory primer (sanding pad). |
| – |
Clean again using Silicone Remover, Long. |
| – |
Apply Two-Part Wash Primer -LHV 043 000 A2- to sanded
through areas. |
| – |
Dry (note drying time). |
| – |
Then fill with Two-Part HS Performance Filler. |
| – |
Dry (note drying time). |
| – |
Dry-sand the filler with sandpaper (P400-P500), making sure
not to sand through. |
| – |
Clean the surface with Silicone Remover, Long. |
| – |
Apply a suitable Stone Chip Protection. Refer to
→ Chapter „Stone Chip Protection“. |
| – |
Dry (note drying time). |
| – |
If necessary, smoothen the texture. |
| – |
Clean the base surface with Silicone Remover, Water-Based. |
| – |
Apply the paint structure with top, base and clear coats. |
| Damage Caused by an Accident (Repair) |
| – |
Always clean damaged components/surfaces. |
| – |
Remove the underbody protection using Pneumatic Brush
Grinder Set -VAS6446-. |
| – |
Remove the damaged area and sand down to the bare metal. |
| – |
Remove the existing corrosion using the Pneumatic Brush
Grinder Set -VAS6446- while doing so finely sand the overlapping
areas. |
| – |
Clean the base surface with Silicone Remover, Long. |
| – |
Apply Two-Part Wash Primer -LHV 043 000 A2- |
| – |
Dry (note drying time). |
| – |
Then fill with Two-Part HS Performance Filler. |
| – |
Dry (note drying time). |
| – |
Clean the base surface with Silicone Remover, Long. |
| – |
Apply suitable filling paste. |
| – |
Sand the filling paste with sandpaper (P80-P240) while
liberally sanding the transition areas. |
| – |
Clean the base surface with Silicone Remover, Long. |
| – |
Apply Two-Part Wash Primer. |
| – |
Then fill with Two-Part HS Performance Filler. |
| – |
Dry (note drying time). |
| – |
Dry-sand the filler in the stone chip protection area with
sandpaper (P400-P500), making sure not to sand through. |
| – |
Clean the surface with Silicone Remover, Long. |
| – |
Apply a suitable Stone Chip Protection. Refer to
→ Chapter „Stone Chip Protection“. |
| – |
Dry (note drying time). |
| – |
If necessary, smoothen the texture. |
| – |
Sand the complete filler surface with sand paper
(P400-P500). |
| – |
Clean the base surface with Silicone Remover, Water-Based. |
| – |
Prepare the paint structure with top, base and clear coats. |
| Cracks in the Stone Chip Protection |
Note
| Repairs should be performed according to description “damage
caused by an accident (repair)”. |
| Damage caused by Stone Impact (Gravel, Grit, etc.) |
| – |
Clean the damaged areas thoroughly. |
| – |
Sand the damaged surfaces with sandpaper. If damage is deep,
dry-sand with P120-P240 sandpaper. |
| – |
Clean the base surface with Silicone Remover, Long. |
| – |
Apply Two-Part Wash Primer -LHV 043 000 A2- to sanded
through areas. |
| – |
Dry (note drying time). |
| – |
Then fill with Two-Part HS Performance Filler. |
| – |
Dry (note drying time). |
| – |
Dry-sand the filler with sandpaper (P400-P500), making sure
not to sand through. |
| – |
Clean the base surface with Silicone Remover, Long. |
| – |
Apply a Suitable Stone Chip Protection (refer to
→ Chapter „Stone Chip Protection“) to the damaged
areas If damage is extensive, refinish the entire surface. |
| – |
Dry (note drying time). |
| – |
If necessary, smoothen the texture. |
| – |
Clean the surface with Silicone Remover, Water-Based. |
| – |
Apply the paint structure with top, base and clear coats. |
|
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 d ...
Dry sand the cataphoretic primer on the roof adhesive surface
-item 6-
→ Item down to the bare metal using P180 sandpaper.
...
Other materials:
Leaks or Internal Damage, for Example Noises or No Output
Note
For vehicles with an electrically-driven A/C compressor,
de-energize the high voltage system before removing the A/C
compressor. Refer to
→ Electrical System Hybrid; Rep. Gr.93.
–
Dischar ...
Tire Pressure Sensor and Metal Valve, Removing and Installing
Special tools and workshop equipment
required
Torque Wrench 1410 -VAG1410- and Torque Wrench 1331 5-50Nm
-VAG1331-
–
Place metal valve with rubber seal through rim from inside.
...
Refrigerant Still in Circuit
Discharge the refrigerant circuit.
–
Remove malfunctioning component, flush with compressed air,
collect escaping refrigerant oil.
–
The new component is to be filled with the amount of
refrig ...
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