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Volkswagen Golf Service & Repair Manual: Instructions for work on underbody and stone chip protection

Volkswagen Golf Service & Repair Manual / General information, paint / General notes / Instructions for work on underbody and stone chip protection

  Note
  The structure of the underbody and stone chip protection is to be reconstructed to conform 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 surfaces for assembly must be functional following the extent of the sealing work.
Accident damage (replacement parts)
–  Clean new part with slow-drying silicone remover.
–  Roughen factory basecoat using an emery pad.
–  Clean part with slow-drying silicone remover again.
–  Apply 2-pack wash primer -LHV 043 000 A2- to any bare metal spots.
–  Dry (observe drying time).
–  Then, apply 2-pack HS Performance surfacer.
–  Dry (observe drying time).
–  Dry sand filler with P400 to P500 sandpaper, taking care not to sand through.
–  Clean surface with slow-drying silicone remover.
–  Apply a suitable anti-chip coating → Chapter „Stone chip guard“.
–  Dry (observe drying time).
–  Rework and/or smooth structure as needed.
–  Clean substrate with aqueous silicone remover.
–  Complete paintwork structure with top coat or a base coat and clear coat.
Accident damage (repair by removing dents)
–  Clean damaged component/surface thoroughly.
–  Remove undercoating using brush grinder set -VAS 6446-.
–  Beat dents out of damaged area and sand down to bare metal.
–  Thoroughly remove any corrosion present using brush grinder set -VAS 6446-, taking care to finely sand transitions.
–  Clean substrate with slow-drying silicone remover.
–  Apply 2-pack wash primer -LHV 043 000 A2-.
–  Dry (observe drying time).
–  Then, 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 sandpaper, liberally sanding featheredge areas.
–  Clean substrate with slow-drying silicone remover.
–  Apply 2-pack wash primer.
–  Then, apply 2-pack HS Performance surfacer.
–  Dry (observe drying time).
–  Dry sand surfacer in area of anti-chip coating with P400 to P500-grade sandpaper, taking care not to sand through.
–  Clean surface with slow-drying silicone remover.
–  Apply a suitable anti-chip coating → Chapter „Stone chip guard“.
–  Dry (observe drying time).
–  Rework and/or smooth structure as needed.
–  Dry-sand entire surfacer area with P400 to P500-grade sandpaper.
–  Clean substrate with aqueous silicone remover.
–  Create paint structure with a top coat or with base coat and clear coat.
Cracks in stone chip protection
  Note
Carry out repairs according to the description “Accident damage (repair by removing dents)”.
Damage caused by stone impact (stone chippings, grit, etc.)
–  Thoroughly clean damaged area.
–  Lightly sand damaged surfaces using emery pad. Dry sand deeper chips with P120 to P240 sandpaper.
–  Clean substrate with slow-drying silicone remover.
–  Apply 2-pack wash primer -LHV 043 000 A2- to any bare metal spots.
–  Dry (observe drying time).
–  Then, apply 2-pack HS Performance surfacer.
–  Dry (observe drying time).
–  Dry sand filler with P400 to P500 sandpaper, taking care not to sand through.
–  Clean substrate with slow-drying silicone remover.
–  Apply a suitable anti-chip coating → Chapter „Stone chip guard“ onto damaged areas. If the damage is extensive, the entire surface must be reworked.
–  Dry (observe drying time).
–  Rework and/or smooth structure as needed.
–  Clean surface with aqueous silicone remover.
–  Complete paintwork structure with a top coat or with base coat and clear coat.
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