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:
Checking with Restrictor, Reservoir and A/C Compressor Regulator Valve
-N280-, Externally Regulated A/C Compressor
Note
Connecting service station. Refer to
→ Chapter „Connecting Service Station“.
Observe test requirements. Refer to
→ Chapter „Pressures, Checking“.
–
...
Technical Requirements
Factory-Installed Trailer Hitch
If the vehicle was already delivered from the factory with a
trailer hitch, all of the technical and legal requirements for
towing a trailer have already been taken into account.
Note that a »13-pin« trailer ...
Flat Spots
What is a Flat Spot From Standing?
Terms like flat portion, flattening, are also used as a term
for flat spots from standing.
Flat spots from standing cause vibration, like an
incorrectly balanced wheel. It is important ...
© 2016-2025 Copyright www.vwpolo.net
