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:
Maximum permitted gross combination weight
First read and observe the introductory information
and safety warnings
All data in the official vehicle documents take precedence over these data. All
data in this manual apply to the basic model. The vehicle data sticker in the service
schedule and the official vehicle documents show which ...
Using the menus in the instrument cluster
Fig. 13 Vehicles without multifunction
steering wheel: press button ① in the windscreen wiper lever to confirm the menu
point and rocker switch ② to change the menu
Fig. 14 Vehicles with multifunction
steering wheel: control buttons for menus in the instrument cluster
First read and ob ...
Symbols in the roof
Symbol
Meaning
Interior lights and reading lights
Electric panorama sliding/tilting glass roof
...
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