VW Golf manuals

Volkswagen Golf Service & Repair Manual: Paintwork in Aftersales

Panels galvanised on both sides
Earlier attempts at flanged pairings have resulted in the fact that only panels that are galvanised on both sides are used now. 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.
  Please make sure
  that when repairing bodywork all metal edges are properly deburred.
  that zinc/electrophoretic primer layer is fully present on unpainted inner surfaces.
  that inner weld flanges and sanded-through spots are treated with INOX spray -D 007 600 A1-.
To restore the contours of bodywork surfaces, filler materials are nowadays considered as an integral part of bodyshop construction and paintshop operations. Please be sure to allow for the differing base surface requirements.
Product information:
  → Chapter „Filler“
The primer is the most important component in the corrosion protection system, as it prevents water and oxygen from getting to the metal surface. Genuine Parts are usually coated with black electrophoretic primer. What type of primer is used depends on the application.
  Sanded-through spots or weld seams must be re-covered with an anti-corrosion primer as soon as possible.
  The electrophoretic primer coating is not resistant to UV and acid. Consequently, replacement parts must also be painted from the inside.
  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 then apply 2-pack HS Performance surfacer.
Product information:
  → Chapter „Priming metal“
  → Chapter „Priming plastic materials“
The surfacer plays only a secondary role in terms of corrosion protection. Nevertheless, use of the right surfacer in Aftersales is essential.
  Surfacer protects the body against stone chips. So make sure the surfacer layer is of the appropriate depth in the area exposed to stone chipping.
  Surfacer is used to prepare surfaces. Scoring can be levelled out.
  Coloured surfacer improves the coverage of shades with poor coverage.
Product information:
  → Chapter „Surfacer“
PVC seam sealing and undersealing
  •   Seam seals made during repair work must be identical in appearance and thickness to the original seam seals.
  •   To avoid damage or faulty operation, brush seam seals smooth near attachments 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 surfaces for assembly must be functional following the extent of the sealing work.
  • Sealant must never be applied to bare metal. Substrates must always be coated 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.
  Before sealing/applying underseal, always insulate the surface with primer and surfacer.
  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 then apply 2-pack HS Performance surfacer.
  Make sure the underseal layer is of the specified thickness.
Product information:
  → Chapter „Underbody protection“
  → Chapter „Stone chip guard“
  → Chapter „Sealing materials“
Top coat/base coat
The primary role of the top coat/base coat is decorative. It plays only a secondary role in terms of corrosion protection.
The paints have varying coverage depending on their pigmentation. Pay attention to the manufacturers' specifications.
Product information:
  → Chapter „Top coats“
Clear coat
The primary role of the clear coat is decorative. The clear coat likewise plays only a secondary role in terms of corrosion protection. The clear coat protects the base coat against UV radiation and from environmental damage such as by the acid in bird droppings.
Product information:
  → Chapter „Clear coats“
Wax sealing/cavity sealing
Wax/cavity sealing plays a key role in terms of corrosion protection. Various materials are available in Aftersales, according to the area of application. The outstanding protection offered by these materials is based on the following properties:
  Hydrophobic (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 „Wax-based underseal“
Reduced paint structure in engine compartment and inside of bonnet
Depending on the model, the paint in the “engine room and on the inside of the bonnet” may deviate in structure and colour from the exterior paint. This deviation is production-related and does not constitute a defect.
Paintwork structure of a factory finish
Structure of a solid-colour (uni) paint finish, conventional Coat thickness approx. 80-120 µm 1 -  Sheet steel ...

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 an ...

Other materials:

Test and measurement work that can be performed using a pressure gauge
Displays on the pressure gauge 1 -  Temperature scale for refrigerant R134a CF3–CH2F or CH2F–CF3. 2 -  Pressure scale In addition to the pressure scale, the pressure gau ...

Detecting leaks
External damage can cause leaks in the refrigerant circuit. Because a small leak will involve only small quantities of refrigerant, leaks should be checked for using an electronic leak detector or by introducing a leak detection additive to the refrigerant circuit. Electronic leak detectors ca ...

Removing and fitting head restraints
Fig. 48 Removing the front head restraint Fig. 49 Removing the rear head restraint First read and observe the introductory information and safety warnings Every seat is fitted with a head restraint. The front head restraints are intended solely for use with the front seats, and the centr ...

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