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Volkswagen Polo Service & Repair Manual: Repair Instructions for the Underbody and Stone Chip Protection

Volkswagen Polo Service & Repair Manual / General Paint Information / General Information / 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).
–  Sand the filler.
–  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.
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