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:
Special Connector Systems
Note
If necessary, housing securing mechanisms (secondary locks)
must be released or removed using specified tool before
releasing the contacts. Refer to
→ Chapter „Secondary Lock“.
...
Paint Thickness Test -VAS5278
Definition:
Paint Thickness Test -VAS5278-
Product Description
The paint thickness test allows for exact and
interference-free layer thickness measuring of paint coats on
steel, iron or non-f ...
Rain/light sensor
Fig. 75 Windscreen wiper lever: setting
the rain/light sensor Ⓐ
Fig. 76 Sensitive surface of the rain/light
sensor
First read and observe the introductory information
and safety warnings
When the rain/light sensor is activated, it automatically controls the frequency
of the wiper inte ...
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Adhesive Surface Pretreatment when Replacing Laser-Soldered Roofs