Volkswagen ID.3: General information, paint. General information

• Painting parking aid sender
• Work instruction for window flange area – component with window flange damage, identifiable on substrate
• Pre-treatment of bonded surfaces when renewing laser-welded roofs
• Corrosion protection measures for wing surface in contact with wheel housing liner
• Notes on treating corroded fold areas
• Corrosion protection for body components, add-on components and welded components
• Adaptive cruise control (ACC)
• Work instruction for window flange area – New part and component without window flange damage
• Painting instructions for bumper cover in area of lane change assist control unit and front corner radar
• Dangers from natural gas fuel tank
• Preparation
• Paint drying
• Vehicle identification at reception
• Layer depths
• Structure of a three-coat paint finish, waterborne base coat
• Paintwork structure for solid-colour paint finish, conventional
• Paintwork structure for solid-colour paint finish, waterborne base coat
• Structure of metallic and pearlescent finish, waterborne base coat
• Structure of a two-coat paint finish, conventional
• Structure of the 2010-process finish, waterborne base coat
• Paintwork structure, base coat
• Paintwork structure, matt effect
• General approach to dealing with areas sanded through to the substrate (bare-metal surface)
• Reduced paint structure in engine compartment and inside of bonnet
• Work instructions for underbody and anti-chip coating
• Work instruction for window flange area

Painting parking aid sender

Painting parking aid sender

Conditions

Important

● Foil-wrapping of the parking aid sensor -arrow- is not permissible.

● To avoid malfunctions of the parking aid sensor, observe the following parameters when painting:

Painting new parts

Important

● Maximum layer thickness: 125 µm; measurement of layer depth is essential following application of paint.

● Maximum hardening temperature: 1 hour at 90°C.

Painting used parts

Important

● Remove old finish/sand only as far as primer layer. Minimum layer depth of 5 to 10 µm must be maintained.

● Maximum layer thickness: 125 µm; measurement of layer depth is essential following application of paint.

● Maximum hardening temperature: 1 hour at 90°C.

Electrical conductivity

Important

● Paint or paint mist must not get into connectors.

● Proper pin contact must be guaranteed after painting.

Cleaning

Important

● Immersion in cleaning solutions without previous masking of the plug terminals is prohibited.

Checking function

Important

● Connect vehicle diagnostic tester, and check function → Rep. gr.97; Lines; Vehicle diagnosis, testing and information system.

Paintwork repair structure and layer depth

1 - Primed new part with replacement part Primer: 2 to 10 µm

2 - Surfacer: 30 to 40 µm

3 - Unicolour base coat: 10 to 20 µm

4 - Metallic/pearl effect base coat: 20 to 25 µm

5 - Clear coat: 35 to 50 µm

In addition, observe → Rep. gr.00; Offset colours.

Painting area

1 - The painting area -1- of the sensor is the front and side face of the membrane. The painting area on the sides ranges from a minimum of 3 mm to a maximum of 4 mm from the front face of the membrane towards the rear.

2 - No paint is permitted in this area.

Work instruction for window flange area – component with window flange damage, identifiable on substrate

Work instruction for window flange area – component with window flange damage, identifiable on substrate

– Clean window flange thoroughly using silicon remover.

– Dry-sand damaged area with P100 sandpaper.

– Clean substrate using silicon remover.

– Apply 2-pack wash primer LHV 043 000 A2 to damaged area.

– Once flash-off time of 10 minutes at object temperature of 20°C has elapsed, apply 2-pack HS Performance surfacer.

– Observe drying time of 2-pack HS Performance surfacer at object temperature of +60°C.

Important

● 60 to 150 µm: 15 to 20 minutes

● 150 to 250 µm: 20 to 25 minutes

– Note additional information → Chapter „2-pack HS Performance surfacer“.

– Alternatively, 2-pack HS wet-on-wet surfacer can also be used. If applicable, observe relevant information → Chapter „2-pack HS wet-on-wet surfacer“.

– Note additional information → Chapter „2K wash primer“.

– Dry-sand surfacer lightly with P400 to P500 grit sandpaper. Take particular care not to sand through.

– Clean with silicone remover.

– Mask off bonding surface on window flange with suitable, heat and solvent-resistant adhesive tape to avoid adhesive residue.

– If necessary, paint window opening in same colour as vehicle.

– To avoid building of sharp edges, remove adhesive tape from window flange after last spray cycle.

Pre-treatment of bonded surfaces when renewing laser-welded roofs

Pre-treatment of bonded surfaces when renewing laser-welded roofs

– Using P180 sandpaper, dry-sand cathodic dip coated bonding surface (roof) down to bare metal.

– Using P180 sandpaper, dry-sand bonding surface (roof side member) down to bare metal.

– Prime bare metal spots beyond bonding surfaces using 2-pack wash primer LHV 043 000 A2, then apply 2-pack HS Performance surfacer.

– Clean bonding surface with silicone remover.

– Restore paintwork structure according to instructions from manufacturer.

Corrosion protection measures for wing surface in contact with wheel housing liner

Corrosion protection measures for wing surface in contact with wheel housing liner

Note

Corrosion protection measure in the groove of the wing must be carried out on every new replacement part without additional sealant applied at the factory.

Note

The additional sealant is intended to prevent the wheel housing liner from potentially “scouring” the groove of the wing.

– Apply surfacer in inner and outer area of wing.

– Once the surfacer has dried, apply sealant D 511 500 A2 in contact area of wheel housing liner and groove of wing, and spread it evenly.

– Dimension -a- 20 mm

Height of seal

– Dimension -b- 10 mm

Width of seal

Dimension -b- can vary because the width of the edge of the groove differs among wings. Always make sure that the entire edge of the groove is sealed.

Notes on treating corroded fold areas

Notes on treating corroded fold areas

Examples for corrosion are given for the fold area of bonnet, door or rear lid as an example.

– Remove corrosion using pneumatic brush grinder set -VAS 6446- or brush grinder set -VAS 6776-.

– Smooth off transitions using sandpaper (P360 to P400 grit).

– Clean substrate using silicon remover.

– After corrosion repairs and before sealing, always isolate substrate using 2-pack wash primer LHV 043 000 A2, and treat it with 2-pack HS Performance surfacer thereafter.

– As soon as the surfacer has dried, treated areas must be dry-sanded using P400 to P500 sandpaper. When sanding, take particular care not to “sand through”.

– Clean sanded surfaces with silicon remover.

– After sanding the dry surfacer, metal edges in fold area must be sealed with fine joint sealant → Chapter „Sealing materials“.

– Make sure that fine joint seals are identical in appearance to original seam seals, as specified in → Vehicle-specific paintwork information for the particular vehicle.

– Joint seals must be restored in such a way that their appearance and thickness correspond to the original condition.

– To avoid damage or malfunctions, brush seam seals smooth in area of attachments.

– Remove soiling from specified areas with joint seals.

Important

● Water drainage holes must remain clear.

● All threaded studs and welded nuts with metric threads as well as all other studs and contact areas for assembly must be functional following the extent of the sealing work.

● Joint sealant must never be applied to bare metal. Substrates must always be treated with surfacer first.

– Restore paintwork structure according to instructions from manufacturer.

– Seal cavities all around fold area using suction feed spray gun -V.A.G 1538-.

Note

Repair is only considered effective if the fold area has been sealed airtight from the inside so that no moisture can penetrate.

Cavity sealing, rear lid

Cavity sealing, bonnet

Cavity sealing, door

Corrosion protection for body components, add-on components and welded components

Corrosion protection for body components, add-on components and welded components

→ Chapter „Painting parking aid sender“

→ Chapter „Painting instructions for bumper cover in area of lane change assist control unit and front corner radar“

Warranty claims

Warranty claims cannot be considered as justified if:

♦ damage to the body or the paint has not been promptly repaired in accordance with the manufacturer's specification.

♦ corrosion perforation is directly attributable to the fact that earlier bodywork repairs were performed without genuine replacement parts and genuine material and/or using procedures that did not comply with the manufacturer’s specifications.

♦ paintwork defects caused by the owner (e.g. insufficient care or accident damage that was not repaired in accordance with the manufacturer's stipulations).

Wing

♦ Coat the wing entirely on the inside. Apply one spray coat wet-on-wet for this.

♦ On vehicles with wheel housing liners, apply additional abrasion protection to wheel arch → Chapter „Corrosion protection measures for wing surface in contact with wheel housing liner“. Original wings are usually provided with sealing material already applied.

Seal inside of wheel arch and web plate with cavity sealant D 330 KD 1 A2 prior to assembly.

Doors

♦ Doors must also be fully coated on the inside.

♦ Seal inside of door with cavity sealant.

Hatches/bonnets/tailgates

♦ The procedure is the same as that for wings and doors.

♦ Seal inner sides with cavity sealant.

Ball studs

♦ Restore paintwork structure if bear metal spots have formed in area of ball studs.

♦ Apply opaque coat of paint to ball studs.

Welded parts

All welded parts, except for the roof, must be fully primed and surfaced on the inside. Visible inner surfaces must be coated with one wet-on-wet spray pass and one spray pass of clear coat; if necessary, this should be done before welding in.

Bare weld flanges or damaged welded components must be coated with INOX spray D 007 600 A1 or zinc spray D 007 500 A2 beforehand. After painting, cavities are to be fully protected with cavity sealant.

It is important not to perform any of the required sealing operations until having carried out the prescribed paint work, to ensure maximum protection against corrosion.

All parts that form cavities, such as pillars, struts, side panels, etc., must be coated with cavity sealant.

Coat all parts, which are factory-coated with noise-damping or anti-chip material, e.g. wheel housing, floor panel, front and rear cross panel or outer side member) as follows:

♦ Wheel housings and underbody with spray-on seam seal

♦ Use foundation material to smooth over larger gaps and deeper layers.

♦ Coat sill panel area, bottom of side panel and corners of cross panels with anti-chip coating

Materials

♦ Wax-based underseal D 316 D38 A2

♦ → Chapter „Anti-corrosion materials“

Adaptive cruise control (ACC)

Adaptive cruise control (ACC)

Important

All changes to the surface, such as retrospective paintwork, application of stickers and similar, may result in malfunction!

● When performing paint repairs or part replacements on vehicles with ACC, do not paint the trim. The ACC system located behind may become inoperable due to the thickness of the added paint layer.

● The cover above the adaptive cruise control sender in the bumper grille consists of radar-permeable material. The cover is heatable, in order to prevent functions from being impaired by snow and ice.

Work instruction for window flange area – New part and component without window flange damage

Work instruction for window flange area – New part and component without window flange damage

– Clean window flange thoroughly using silicon remover.

– Sand down cathodic dip coat using non-woven abrasive web (red).

– Corrosion protection under the windows must also be intact. Any damage to the window flange caused by disassembly tools must be repaired prior to applying top coat or adhesive.

– Apply 2-pack HS Performance surfacer.

Before installing the window, it is crucial to ensure that the paintwork materials used on the window flange have completely dried. Otherwise the adhesive will delaminate. Use of a radiant heater or maintenance of a correspondingly longer waiting time is recommended.

All vehicles (continued)

– Observe drying time of 2-pack HS Performance surfacer at object temperature of +60°C.

Important

● 60 to 150 µm: 15 to 20 minutes

● 150 to 250 µm: 20 to 25 minutes

– Additional information → Chapter „2-pack HS Performance surfacer“.

– Alternatively, 2-pack HS wet-on-wet surfacer can also be used. If applicable, observe relevant information → Chapter „2-pack HS wet-on-wet surfacer“.

– Due to reduced adhesion strength of matt painted surfaces, the adhesive area of the window flange must be masked off before top coat is applied. Apply the required window adhesive onto the surfacer layer.

– Before window primer is applied, the bonding area must be sanded with a non-woven abrasive web. Dry-sand surfacer lightly with P400 to P500 grit sandpaper. Take particular care not to sand through.

– Clean with silicone remover.

– Mask off bonding surface on window flange with suitable, heat and solvent-resistant adhesive tape. This prevents adhesive residue.

– If necessary, paint window opening in same colour as vehicle.

– To avoid sharp edges, remove adhesive tape from window flange after last spray cycle.

Painting instructions for bumper cover in area of lane change assist control unit and front corner radar

Painting instructions for bumper cover in area of lane change assist control unit and front corner radar

Check using vehicle identification number, e.g. the PR number, if the vehicle is equipped with a radar system in the bumper.

A definite external indication for a fitted lane change assist is e.g.:

♦ a warning lamp -arrow- in the exterior mirror or

♦ a warning lamp in the mirror glass.

Radar sensors

The radar sensors can be located behind the rear bumper cover, for example. Refer to the vehicle-specific repair guide on driver assist systems for information on the exact fitting location of the radar sensors.

Bumper cover in area of lane change assist control unit

Overview is shown for left side of vehicle as an example. Right side is a mirror image, depending on type and equipment of vehicle.

Foil-wrapping is not permissible in area of lane change assist control unit -1-.

To avoid malfunctions of lane change assist -1-, always observe following parameters when painting bumper cover -2-:

Important

● Maximum layer thickness of 150 µm must not be exceeded in area before lane change assist -1-.

● Do not carry out plastic repairs within radius of -x- = 25 cm.

● Do not carry out filling work within radius of at least -x- = 25 cm.

● Triple painting of bumper cover -2- is not permissible.

● Before painting, make a microsection in adjacent area to make sure that bumper cover -2- has not previously been repainted.

● Spot repairs in area of lane change assist -1- area not permissible.

● Use a piece of masking paper to prevent overspray from settling on inside of bumper.

Diagnostic tester-assisted calibration in after-sales

The installation position of the radar sensor will be altered result of removal and installation.

Always perform a follow-up after-sales service calibration using → Vehicle diagnostic tester.

Dangers from natural gas fuel tank

Dangers from natural gas fuel tank

The pressure in the gas tank must not exceed the maximum of 260 bar. For a full tank, this means an increase in temperature to a maximum of 60°C.

In order not to exceed 70°C, vehicles must not remain in a paint dryer or (in drying mode) in a combination booth for longer than 60 minutes at 80°C.

Preparation

Preparation

♦ Employees in the painting facility must be made aware of the potential danger of overheating in the gas tanks.

♦ A reliable indication of whether or not the vehicle is a gas-powered vehicle can be obtained from the vehicle identification number (VIN) enquiry in → ELSA.

♦ If no VIN enquiry has been initiated, take note of specific gas indications on the vehicle rear, the wing, the door sill area, the gear knob or in the instrument cluster.

♦ Work may only be carried out on vehicles that are technically leakproof.

Paint drying

Paint drying

♦ The temperature of the natural gas system and the gas tank must not exceed +60°C.

♦ If repair materials are used which require force drying for longer than the permitted 60 minutes, they must be dried using alternative methods, such as, for example, infrared radiant heaters.

Observe all warnings and notes on natural gas vehicles in the Workshop Manual → Rep. gr.00

Vehicle identification at reception

Vehicle identification at reception

High- voltage, hybrid electric vehicles and battery electric vehicles are equipped with high-performance lithium-ion batteries and other high-voltage components, such as, for example, the power and control electronics for electric drive, the air conditioner compressor and the high-voltage cables.

Vehicles must therefore be identified as soon as they are received so that employees in the paintshop can be notified of the potential dangers.

Layer depths

Layer depths

♦ The specifications of the coat thickness are approximate because the thickness can vary depending on the painted location, the colour of the paint and the differences between horizontal and vertical surfaces.

♦ The specifications may be exceeded for individual vehicles which have been repainted once or several times.

Structure of a three-coat paint finish, waterborne base coat

Structure of a three-coat paint finish, waterborne base coat

1 - Sheet steel

2 - Zinc phosphate

3 - Electrophoretic finish

4 - Water-based surfacer

5 - Waterborne base coat – colour-determining base coat

6 - Waterborne base coat – effect layer

7 - 2-pack clear coat

Coat thickness approx. 80 to 140 µm

Paintwork structure for solid-colour paint finish, conventional

Paintwork structure for solid-colour paint finish, conventional

1 - Sheet steel

2 - Zinc phosphate

3 - Electrophoretic primer

4 - Intermediate surfacer

5 - 2-pack solid top coat

Coat thickness approx. 80 to 120 µm

Paintwork structure for solid-colour paint finish, waterborne base coat

Paintwork structure for solid-colour paint finish, waterborne base coat

1 - Sheet steel

2 - Zinc phosphate

3 - Electrophoretic finish

4 - Water-based surfacer

5 - Waterborne base coat

6 - 2-pack clear coat

Coat thickness approx. 80 to 130 µm

Structure of metallic and pearlescent finish, waterborne base coat

Structure of metallic and pearlescent finish, waterborne base coat

1 - Sheet steel

2 - Zinc phosphate

3 - Electrophoretic finish

4 - Water-based surfacer

5 - Metallic or pearlescent waterborne base coat

6 - 2-pack clear coat

Coat thickness approx. 80 to 130 µm

Structure of a two-coat paint finish, conventional

Structure of a two-coat paint finish, conventional

1 - Sheet steel

2 - Zinc phosphate

3 - Electrophoretic finish

4 - Intermediate surfacer

5 - Uni (solid-colour) top coat

6 - 2-pack clear coat

Layer thickness approx. 100 µm

Structure of the 2010-process finish, waterborne base coat

Structure of the 2010-process finish, waterborne base coat

1 - Sheet steel

2 - Zinc phosphate

3 - Electrophoretic finish

4 - Waterborne base coat – functional layer

5 - 2-pack clear coat

Coat thickness approx. 80 to 120 µm

Paintwork structure, base coat

Paintwork structure, base coat

Panels galvanised on both sides

Only in this way can the cathodic protection and the barrier effect of the zinc layer work together to provide optimum results. In particular, the cut edges which are less well protected by paint, subject to thinning of the paint coating at the edge, are provided with additional protection.

Make sure that:

Important

● all metal edges are deburred when body repairs are carried out.

● zinc layer/cathodic dip coat is fully present on unpainted inner surfaces.

● inner weld flanges and sanded-through spots are treated with INOX spray D 007 600 A1 or zinc spray D 007 500 A2.

Filling

Note the differing base surface requirements.

Important

● Metal filler requires a bare-metal base surface that is as rough as possible. The best adhesion and anti-corrosion results are achieved using the brush grinder set -VAS 6446-.

● Spray and polyester fillers have a hydrophilic effect, i.e. they absorb moisture like a sponge. Bare-metal surfaces must therefore be isolated. Use 2-pack wash primer LHV 043 000 A2 and, subsequently, 2-pack HS Performance surfacer for surface isolation before filling.

Product information:

♦ → Chapter „Corrosion protection measures for wing surface in contact with wheel housing liner“

Primer

Primer is the most important component in the corrosion protection system, as it prevents water and oxygen from getting to the metal surface. Genuine replacement parts are usually coated with black or grey cathodic dip paint. What type of primer is used depends on the application.

Important

● Cathodic dip coat is not resistant to ultraviolet radiation or acid. Body components located in vulnerable areas, such as the vehicle front end, wings and wheel housings, must therefore be coated with one spray pass of base coat and clear coat on the inside as well. For inner body surfaces on components such as the roof or side panels which are covered completely it is sufficient to touch up scratches and bare metal surfaces with glass/paint primer. In cases of doubt, the production status applies.

● When taking delivery of painted body panels, ensure that they have no surface rust. It may be necessary to clean them or sand them down.

● Sanded-through spots or weld seams must be coated as soon as possible with an anti-corrosion primer.

♦ Areas that have been sanded through to the substrate (bare-metal surfaces), and those that have been subject to corrosion repairs, must generally be primed with the 2-pack wash primer LHV 043 000 A2, followed by the 2-pack HS Performance surfacer.

♦ When using 2-pack wash primer LHV 043 000 A2, note that it must always be mixed anew before applying, and that a dry layer thickness of at least 10 –12 µm is required.

Product information:

♦ → Chapter „Priming metal“

♦ → Chapter „Priming plastic materials“

Surfacer

The surfacer only plays a secondary role in terms of corrosion protection. Nevertheless, use of the right surfacer for customer service is essential.

Function:

♦ Surfacer protects the body against stone chips. Therefore, make sure that the surfacer layer is of the appropriate depth in the area exposed to stone chips.

♦ Surfacer is used to prepare surfaces. Scoring can be levelled out.

♦ Coloured surfacer improves the concealment of shades with weak tones.

Product information:

♦ → Chapter „Surfacer“

PVC joint sealing and undersealing

Important

● Joint seals must be restored in such a way that their appearance and thickness correspond to the original condition.

● To avoid damage or faulty operation, brush seam seals smooth near parts which must be attached.

● Water drainage holes must remain clear.

● All threaded studs and welded nuts with metric threads as well as all other studs and contact areas for assembly must be functional following the extent of the sealing work.

● Sealant must never be applied to bare metal. Substrates must always be treated with surfacer first.

To prevent water from penetrating into flanges, panel folds in critical areas of the body are sealed with paste-form, solvent-free PVC. A varying thickness of PVC layer is also sprayed onto precisely defined zones on the external floor pan and in the wheel housings to protect against stone chips and prevent droning.

Important

● Always isolate areas on which a corrosion damage has been repaired, as well as any bare-metal surfaces, using 2-pack wash primer LHV 043 000 A2, and treat them with 2-pack HS Performance surfacer thereafter.

● Make sure the underseal layer is of the specified thickness.

Product information:

♦ → Chapter „Underseal“

♦ → Chapter „AKR 311 KD1 05 chip-resistant coating“

♦ → Chapter „AKR 311 KD1 10 chip-resistant coating“

♦ → Chapter „Sealing materials“

Base coat

The primary role of the base coat is decorative. It plays only a secondary role in terms of corrosion protection.

The paints have varying concealing power depending on their pigmentation. Observe manufacturer's instructions.

Data sheets:

♦ → Chapter „2-pack top coats“

♦ → Chapter „AquaPlus top coats“

♦ → Chapter „AquaPremium top coats“

♦ → Chapter „ReadyMix top coats“

Clear coat

The primary role of the clear coat is decorative. Clear coat, as well, makes only a minor contribution to corrosion protection. Clear coat protects the top coat or the base coat against ultraviolet radiation and from environmental impact, e.g. from the acid contained in bird droppings.

Product information:

♦ → Chapter „Clear coats“

Wax sealing

Wax/ cavity sealing plays a key role in terms of corrosion protection. Various materials are available in the service department, according to the area of application. The outstanding protection offered by these materials is based on the following properties:

♦ Hydrophobicity (non-absorbent)

♦ Good adhesion

♦ No undermining by rust

♦ Permeability to water vapour some 1,500 times less than a paint coating of the same thickness.

Product information:

♦ → Chapter „Anti-corrosion materials“

♦ → Chapter „Underseal“

Paintwork structure, matt effect

Paintwork structure, matt effect

Technology

Vehicles with a matt effect are generally only painted with a matt clear coat. Application is done either directly onto the base coat or to an existing clear coat.

Application in excessively dry conditions poses the risk of clouding due to uneven flash-off or due to the spray mist not being absorbed. Larger surfaces should therefore be painted early in the morning. It may be necessary to postpone the application for a few days.

Colour matching, base coat

The matt structure of the clear coat makes it difficult to clearly identify the colour and the effect pigments of the base coat. It is therefore recommended to prepare some sample panels in advance with two to three types of base coat.

Colour matching, matt clear coat

Despite measuring the degree of gloss, three different matt finishes should still be applied.

The use of a glossmeter is recommended.

Application

The following instructions are recommended to achieve a homogeneous matt effect:

Important

● To reach the calculated level of matting, the clear coat must be mixed on the scales.

● The spraying distance to the object is slightly greater than with the standard application so that the spray mist atomisation can be used to the maximum effect.

● With horizontal replacement parts, the two spray passes should be applied in a crosswise pattern to avoid streaking.

● Make sure that spray passes featheredge evenly, and that an adequately wet spray film is applied.

● For larger components, do not overlap the 2nd spray pass in the overlap zone of the 1st spray pass, but offset it accordingly.

● If possible, a full paint job should be divided into sections. In other words, the vehicle body should be painted separately from the attachments in order to prevent overlapping and spray mist.

● Note that the matt finish may change over time.

General rule:

Important

● Spot Repair is not possible.

● Air drying is not recommended.

● Touch-up paintwork is normally required.

● Usually, the only way to treat matt surfaces that have acquired an undesirable sheen is to apply a new coat of paint.

Avoiding dust inclusions

Since matt clear coats cannot be reworked, the following instructions must be observed to avoid dust inclusions:

Important

● The vehicle must be completely clean on the outside. An underbody wash or cleaning with a steam cleaner is recommended.

● Paint booths should also be in an absolutely clean condition. Bring forward an imminent filter change if necessary. But then only begin with the second or third application as a great deal of dust is generated after the filter is changed.

● After sanding, blow off the components thoroughly and clean them with a silicone remover.

● Mask off the vehicle suitably. Cover paint stands.

● Just before applying the base coat, clean the components to be painted again using duster -VAS 6177-.

General approach to dealing with areas sanded through to the substrate (bare-metal surface)

General approach to dealing with areas sanded through to the substrate (bare-metal surface)

Important

● Areas sanded through to the substrate must be primed with the 2-pack wash primer LHV 043 000 A2, followed by the treatment with the 2-pack HS Performance surfacer.

Reduced paint structure in engine compartment and inside of bonnet

Reduced paint structure in engine compartment and inside of bonnet

Important

● Depending on the model, the paint in the "engine compartment and on the inside surface of the bonnet" may differ from the exterior paintwork in structure and colour. This deviation is production-related and does not constitute a defect. The aim is to re-establish the production standard.

Work instructions for underbody and anti-chip coating

Work instructions for underbody and anti-chip coating

Important

● Repairs are carried out to reconstruct the structure of the underbody and the anti-chip coating according to the original condition in appearance and thickness.

● Water drainage holes must remain clear.

● All threaded studs and welded nuts with metric threads as well as all other studs and contact areas for assembly must be functional following the extent of the sealing work.

Accident damage – parts replacement

– Clean new part with slow-drying silicone remover.

– Roughen factory primer using emery pad.

– Clean again using slow-drying silicone remover.

– Apply 2-pack wash primer LHV 043 000 A2 to exposed metal spots.

– Dry (observe drying time).

– Apply 2-pack HS Performance surfacer.

– Dry (observe drying time).

– Dry-sand surfacer using orbital sander with P400 to P500 dry sandpaper and dust collector. Take particular care not to sand through.

– Clean surface with slow-drying silicone remover.

– Apply suitable anti-chip coating → Chapter „AKR 311 KD1 05 chip-resistant coating“ or → Chapter „AKR 311 KD1 10 chip-resistant coating“.

– Dry (observe drying time).

– Rework/smooth the structure, as necessary.

– Clean base surface using LSW 019 000 A5 aqueous silicone remover.

– Create paint structure with a top coat or with base coat and clear coat.

Repairs to damage caused by accidents

– Clean damaged component/surface thoroughly.

– Remove undercoating using brush grinder set -VAS 6446-.

– Beat dents out of damaged area, and sand it down to bare metal.

– Remove corrosion, if there is any, using brush grinder set -VAS 6446-. Finely sand transitions while doing so.

– Clean substrate with slow-drying silicone remover.

– Apply LHV 043 000 A2 wash primer.

– Dry (observe drying time).

– Apply 2-pack HS Performance surfacer.

– Dry (observe drying time).

– Sand surfacer.

– Clean substrate with slow-drying silicone remover.

– Apply a suitable filler.

– Sand filler using P80 to P240 grit sandpaper. While so, liberally sand featheredge areas.

– Clean substrate with slow-drying silicone remover.

– Apply LHV 043 000 A2 wash primer.

– Apply 2-pack HS Performance surfacer.

– Dry (observe drying time).

– Dry-sand surfacer in stone-chipping protection zone with P400 to P500 sandpaper. Take particular care not to sand through.

– Clean surface with slow-drying silicone remover.

– Apply suitable anti-chip coating → Chapter „AKR 311 KD1 05 chip-resistant coating“ or → Chapter „AKR 311 KD1 10 chip-resistant coating“.

– Dry (observe drying time).

– Rework/smooth the structure, as necessary.

– Dry-sand entire surfaced area with dry P400 to P500 grit sandpaper.

– Clean base surface using LSW 019 000 A5 aqueous silicone remover.

– Create paint structure with a top coat or with base coat and clear coat.

Cracks in stone chip protection

Carry out repairs according to description → Repairs to damage caused by accidents.

Damage caused by stone impact (stone chips, grit, etc.)

– Thoroughly clean damaged area.

– Lightly sand damaged surfaces using emery pad. Dry-sand deeper chips with P120 to P240 grit sandpaper.

– Clean substrate with slow-drying silicone remover.

– Apply 2-pack wash primer LHV 043 000 A2 to exposed metal spots.

– Dry (observe drying time).

– Apply 2-pack HS Performance surfacer.

– Dry (observe drying time).

– Dry-sand surfacer with P400 to P500 grit sandpaper. Take particular care not to sand through.

– Clean substrate with slow-drying silicone remover.

– Apply suitable anti-chip coating → Chapter „AKR 311 KD1 05 chip-resistant coating“ or → Chapter „AKR 311 KD1 10 chip-resistant coating“.

– Dry (observe drying time).

– Rework/smooth the structure, as necessary.

– Clean surface using LSW 019 000 A5 aqueous silicone remover.

– Create paint structure with a top coat or with base coat and clear coat.

Work instruction for window flange area

Work instruction for window flange area

Important

● Repainting is only permissible if the same colour is used.

● If the window aperture needs to be repainted, the bonding surface on the window flange must first be masked off all around.

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