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:
Stowage compartment
on the front passenger side
Fig. 97 Stowage compartment on the front
passenger side
Fig. 98 Open stowage compartment on the
front passenger side
First read and observe the introductory information
and safety warnings
Opening and closing the stowage compartment
To open, pull up the opening lever .
To close ...
Lifting the vehicle with the jack
Fig. 168 Jacking points for the
vehicle jack (mirrored on the right-hand side of the vehicle)
Fig. 169 Vehicle jack at the rear
left-hand side of the vehicle
First read and observe the introductory
information and safety warnings
The jack may be applied only at the jacking points shown (m ...
Checklist
The following actions must always be carried out in the given
order in preparation for filling a tyre :
If you get a flat tyre, park your
vehicle on a firm and level surface at a safe distance from the flow of
traffic.
Apply the handbrake firmly Braking,
stopping and parking B ...
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Customer Service Paint Paint Structure
Adhesive Surface Pretreatment when Replacing Laser-Soldered Roofs