Volkswagen Polo Service & Repair Manual: Corrosion Protection for Body, Attached and Welded Parts

Volkswagen Polo Service & Repair Manual / General Paint Information / General Information / Corrosion Protection for Body, Attached and Welded Parts

Attachments

Coat the insides of the fenders, doors, covers and lids completely. A spray application wet in wet procedure is sufficient.

Before assembly, the seal the inside of the attachments with cavity sealant (refer to → Chapter „Preservation“) so as to recreate the original state. Refer to »Vehicle-Specific Paint Information«.

Vehicles with wheel housing liners must have an additional chafe protection on the wheel housing. Refer to → Chapter „Fender Corrosion Repair Measures, in Wheel Housing Liner Contact Area“.

Welded Parts

All welded parts except the roof are to be completely primed and filled on the inside. The visible inner surfaces must be coated with a spray application of base pant and clear coat. If necessary perform this before welding. In case of doubt, the production status applies.

If sealing is required this is to take place after the specified paint structure.

Coat all parts that form cavities, such as pillars, braces, side panels, etc., with cavity sealant. Refer to → Chapter „Preservation“.

All parts in the series production that are coated with noise-damping or stone chip protection material (for example wheel housing, floor panel, front/rear cross panels or outer side sill) need to be coated as follows:

Wheel housings and underbody with sprayable weld sealant. Refer to → Chapter „Sealing Materials“.

Even out large creases or thick layers with base material Adhesive Sealant -D 511 500 A2-.

Sill panel region, lower side panel, rear cross panel corners with stone chip protection. Refer to → Chapter „Stone Chip Protection“.

Fold Corrosion Servicing Notes

Corrosion on the Fold Edges, for Instance on the Hood, Door or also the Rear Lid – Remove the corroded areas with → Ch ...

Parking Aid Sensor, Painting

The following parameters must be met when painting to avoid malfunctions in the parking aid sensor (parking aid system): New Part, Painting ...

Other materials:

Wires with Cross Section up to 0.35 mm 2, Repairing
Special tools and workshop equipment required Crimping Pliers - .35-2.5mm -VAS1978/1A- Wiring Harness Repair - Crimping Head - .35-2.5mm -VAS1978/1-1- When repairing wires with a cross- ...

Refrigerant Circuit Repair Information
WARNING When performing work on refrigerant circuit, observe all generally applicable safety precautions and pressure vessel regulations. Cautio ...

Empty Refrigerant Circuit
– Remove malfunctioning component. – Remove the A/C compressor. – Remove oil drain plug from A/C compressor. Note To speed up refrigerant oil drai ...