SKODA Citigo 2012, Fabia 2000, Fabia II 2007, Fabia II 2009, Fabia II 2011 Workshop Manual
...
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Service
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Workshop Manual
Citigo 2012 ➤ , Fabia 2000 ➤ ,
Fab
ia II 2007 ➤ , Fabia II 2009 ➤ ,
Fabia II 2011 ➤ , Fabia III 2015 ➤ ,
Karoq 2018 ➤ , Kodiaq 2017 ➤ ,
Octavia 1997 ➤ , Octavia II 2004 ➤ ,
Octavia II 2010 ➤ , Octavia III 2013 ➤ ,
Octavia III 2014 ➤ , Rapid 2011 ➤ ,
Rapid NH 2013 ➤ , Rapid NH 2014 ➤ ,
Roomster 2006 ➤ , Superb 2002 ➤ ,
Superb II 2008 ➤ , Superb III 2015 ➤ ,
Yeti 2010 ➤ , Yeti 2011 ➤
Paint - general information
Edition 10.2017
Service Department. Technical Information
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List of Workshop Manual Repair Groups
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Re
pai r G r o up
00 - Technical data
Service
Technical information should always be available to the foremen and mechanics, because their
careful
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2017 ŠKODA AUTO a. s. D4B8064A3AF
constant adherence to the instructions is essential to ensure vehicle road-worthiness and
and
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Paint - general information - Edition 10.2017
Contents
00 - Technical data .
1 Safety instructions .
1.1 Safety measures when painting vehicles that use natural gas . . . . . . . . . . . . . . . . . . . . . . 1
2 General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Structure of original paintwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Structure of customer service paintwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Different paintwork structure for engine compartment and inside of front flap . . . . . . . . . . 5
2.4 Photo documentation of the reported paint damage according to the ŠKODA standard to
create the DISS paint report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.5 Work instructions for underseal and anti-chip coating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.6 Instructions for repairing fold corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.7 Painting the parking aid transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.8 Adaptive cruise control (ACC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3 Original products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1 Paint products for customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2 Filler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3 Corrosion prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.4 Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.5 Underseal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.6 Protection against stone chipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.7 Underbody sealing wax . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.8 Sealant materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.9 Cleaning agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.10 SprayMax system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4 Workshop equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.2 Dust-retention cloths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5 Repairing rims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5.1 Colors approved for repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Contents i
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ii Contents
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Paint - general information - Edition 10.2017
00 – Technical data
1 Safety instructions
(SRL001128; Edition 10.2017)
⇒ “1.1 Safety measures when painting vehicles that use natural
gas”, page 1
1.1 Safety measures when painting vehicles that use natural gas
DANGER!
Danger of death if drying temperatures are too high! High tem‐
peratures increase the pressure in the natural gas or LPG fuel
tank. If the pressure is too high, a natural gas or LPG tank may
explode and cause death or serious injuries.
High temperatures trigger the thermal fuse of the shut-off valve
on natural gas fuel tanks. A pressure increase as a result of
high temperature triggers the pressure relief valve in LPG fuel
tanks. Gas escapes from the natural gas or LPG fuel tank and
may ignite, in particular in the presence of sparks, and cause
explosive flames. This can cause death or serious injuries.
♦ Parts that convey gas should never be exposed to tem‐
peratures above +60°C.
♦ For drying above +60°C in the drying furnace, all natural
gas or LPG fuel tanks must be removed and all gas lines
must be flushed.
♦ For infrared drying, parts that convey gas in the high pres‐
sure reservoir system should never be exposed to tem‐
peratures above +60°C.
The safety instructions for working on vehicles with an LPG or
natural gas system must be followed.
⇒ Engine; 00 technical data; safety instructions
⇒ Engine; 00 Specifications; CNG - General information
Removing and installing the fuel tank.
⇒ Engine; Rep. gr. 20 ; fuel supply, operation
1. Safety instructions 1
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2 General Instructions
⇒ “2.1 Structure of original paintwork”, page 2
⇒ “2.2 Structure of customer service paintwork”, page 3
⇒ “2.3 Different paintwork structure for engine compartment and
inside of front flap”, page 5
⇒ “2.4 Photo documentation of the reported paint damage ac‐
cording to the ŠKODA standard to create the DISS paint report”,
page 5
⇒ “2.5 Work instructions for underseal and anti-chip coating”,
page 7
⇒ “2.6 Instructions for repairing fold corrosion”, page 9
⇒ “2.7 Painting the parking aid transmitter”, page 11
⇒ “2.8 Adaptive cruise control (ACC)”, page 12
2.1 Structure of original paintwork
Structure of solid paint, water-based
Layer thickness: approx. 80-130 µm
1 - Steel sheet
2 - Zinc phosphating
3 - Electrophoretic coating
4 - Water-based filler
5 - Water-based paint
6 - 1K clear coat (Citigo - 2K clear coat)
Structure of metallic and pearl colour paint, water-based
Layer thickness: approx. 80-130 µm
1 - Steel sheet
2 - Zinc phosphating
3 - Electrophoretic coating
4 - Water-based filler
5 - Water-based metallic/pearl colour
6 - 1K clear coat (Citigo - 2K clear coat)
Note
♦
The approximate layer thickness may vary depending on tone
and indicates differences depending on position, as well as
vertical and horizontal surfaces.
♦
The values may be exceeded for some vehicles in two or more
coats are applied. However, this does not need to be commu‐
nicated.
2 Rep. gr.00 - Technical data
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2.2 Structure of customer service paintwork
Galvanized sheets on both sides
Note
♦
Ensure that:
♦
all sheets edges are adequately deburred for body repairs.
♦
inner surfaces not to be painted have a complete zinc CDP
layer.
♦
internal weld flanges and sanded-through areas are touched
up with e.g. InoxSpray - D 007 600 A1- .
Applying filler
Filler compounds are now essential for bodywork and in the paint
shop to restore contour. When applying filler, the different sub‐
strate requirements must be observed.
Product information
♦
⇒ “3.2 Filler”, page 13
Primer
The primer is the most important part of the anti-corrosion system,
because is prevents water and oxygen reaching the metal sur‐
face. Original spare parts are normally coated with a black or
yellow CDP.
Note
♦
Sanded-through areas and weld seams must be re-coated
with corrosion protection as soon as possible.
♦
The CDP primer is not resistant to UV or acid. Spare parts
must therefore also be painted from the inside.
♦
After repairing corrosion and in general for any bare metallic
substrate, you must insulate with e.g. 2K wash primer - LHV
043 000 A2- or -LLS MAX 230 M1- , then fill with 2K HS per‐
formance filler .
Product information
⇒ “3.3 Corrosion prevention”, page 18
♦
Filler
♦ The filler makes sure that the entire coating system adheres
well to the body part to be painted.
♦ The filler serves as the substrate for the top coat, levels out
unevenness in areas that have already been worked and de‐
termines the
against chipping and also acts as a barrier/substrate insula‐
tion, which is essential for corrosion protection.
quality of the top coat. The filler protects the body
2. General Instructions 3
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PVC seam sealing and underseal
Note
♦
For repair, the joint seal must be restored to its original thick‐
ness.
♦
To avoid damage and failures, the seal welds in the area of
the assembly-specific add-on parts must be coated smoothly.
♦
Water drain holes must be left clear.
♦
All threaded bolts and weld nuts with M-thread and all other
bolts and contact surfaces for assembly must be fully func‐
tional all along the seal.
♦
The sealant material must not be applied to bare sheet metal,
but only on to filled substrates.
♦
To prevent water ingress into the flanges, the sheet fold is
sealed with pasty, solvent-free PVC at critical points of the
body. A layer of PVC with varying thickness is also sprayed
onto accurately defined areas of the underbody and in the
wheelhousings as protection against chipping and for sound
absorption.
♦
Before sealing/applying underseal, the surface must always
be thoroughly primed and filled.
♦
After repairing corrosion and in general for any bare metallic
substrate, you must insulate with e.g. 2K wash primer - LHV
043 000 A2- or -LLS MAX 230 M1- , then fill with 2K HS per‐
formance filler .
♦
The specific layer thicknesses for the underseal must be ob‐
served.
Product information
♦
⇒ “3.5 Underseal”, page 26
♦ ⇒ “3.6 Protection against stone chipping”, page 37
♦ ⇒ “3.8 Sealant materials”, page 49
Base coat
The base coat is primarily decorative.
The paints provide different coverage depending on pigment con‐
tent. The manufacturer's instructions must be followed.
Clear coat
The clear coat is primarily decorative. The clear coat protects the
top coat/base
pollution, such as acid in bird droppings.
Wax preservation/cavity preservation
Wax preservation/cavity preservation plays an essential role in
corrosion protection. Depending on application, there are various
materials available for customer service. These materials provide
excellent protection because they have the following properties:
♦ They are hydrophobic (water-repellent).
♦ They have good adhesion.
♦ No corrosion creep.
♦ Water vapour permeates through them at a rate approx. 1500
times lower than a layer of paint of the same thickness.
coat against ultraviolet radiation and environmental
4 Rep. gr.00 - Technical data
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Product information
♦ ⇒ “3.4 Preservation”, page 22
♦ ⇒ “3.7 Underbody sealing wax”, page 44
2.3 Different paintwork structure for engine compartment and inside of front flap
The paint in the “engine compartment and the inside of front flap”
may be
external paint, depending on model. The difference is productionrelated and is not a defect. The state as produced must be
restored.
different in terms of paintwork structure and tone from the
2.4 Photo documentation of the reported
paint damage according to the ŠKODA
standard to
Basic requirements for photo documentation of reported paint
damage
Note
create the DISS paint report
♦
Proper photo documentation is a basic requirement for the
DISS paint report to be approved, reimbursement and pro‐
cessing of the complaint.
♦
The photo documentation must also be created if an analysis
is required by the ŠKODA AUTO - TSC specialist on location
by the dealer.
– This group of mandatory photos must always be prepared, so
that the photo documentation that is prepared is clear and al‐
ways transparent for dealer and the manufacturer.
Vehicle identification number
Mileage
2. General Instructions 5
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General overview
Reported part with the damage marked
Detailed image of damage with attached -label with ruler-
Label with ruler
6 Rep. gr.00 - Technical data
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Paint - general information - Edition 10.2017
– Print photo at actual size (test dimensions of image frame: 132
x 157mm).
–
Cut out -label with ruler-.
2.5 Work instructions for underseal and an‐
ti-chip coating
Note
♦
For repair, the structure of the underseal and anti-chip coating
must be restored to original thickness and appearance.
♦
Water drain holes must be left clear.
♦
All threaded bolts and weld nuts with M-thread and all other
bolts and contact surfaces for assembly must be fully func‐
tional all along the seal.
Damage following an accident (spare part replacement)
– Clean new part with silicone remover .
– Roughen the factory primer.
– Clean again with silicone remover .
2. General Instructions 7
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– Apply e.g. 2K wash primer - LHV 043 000 A2- or -LLS MAX
230 M1- to sanded-through areas.
– Leave to dry (note drying time).
– Then filler with 2K HS performance filler .
– Leave to dry (note drying time).
– Dry filler and sand with sandpaper (P400-500), avoiding sand‐
ing through.
–
Clean surface with silicone remover .
– Apply suitable anti-chip coating
⇒ “3.6 Protection against stone chipping”, page 37 .
– Leave to dry (note drying time).
– Touch up/smooth structure slightly, if necessary.
– Clean substrate with silicone remover .
– Then filler with 2K HS performance filler .
– Leave to dry (note drying time).
– Dry and roughen filler.
– Clean surface with silicone remover .
– Then establish structure with base and clear coat.
Damage following an accident (repair)
– Thoroughly clean damaged component/surface.
– Remove undercoat with e.g. brush grinder - VAS 6446- or -
VAS 6776- .
– Flatten damaged area and sand down to the blank metal.
– Remove any
-VAS 6776- , then fine-sand (P180-240).
– Clean substrate with silicone remover .
– Apply e.g. 2K wash primer - LHV 043 000 A2- or -LLS MAX
230 M1- .
– Leave to dry (note drying time).
– Then filler with 2K HS performance filler .
– Leave to dry (note drying time).
– Roughen with sandpaper (P320).
– Clean substrate with silicone remover .
– Apply suitable filling paste.
– Sand filling paste with sandpaper (P80-P240), thoroughly
sanding transitions at the same time.
– Clean substrate with silicone remover .
– Apply e.g. 2K wash primer -LHV 043 000 A2- or -LLS MAX
230 M1- .
– Then filler with 2K HS performance filler .
– Leave to dry (note drying time).
– Roughen with sandpaper (P400-500).
– Clean surface with silicone remover .
– Apply suitable anti-chip coating
⇒ “3.6 Protection against stone chipping”, page 37 .
corrosion with e.g. brush grinder - VAS 6446- or
8 Rep. gr.00 - Technical data
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– Touch up/smooth structure slightly, if necessary.
– Clean substrate with silicone remover .
– Then filler with 2K HS performance filler .
– Leave to dry (note drying time).
– Dry and roughen filler.
– Clean surface with silicone remover .
– Then establish structure with base and clear coat.
2.6 Instructions for repairing fold corrosion
Corrosion at the fold edges, e.g. on bonnet, door or rear lid
– Remove areas of corrosion with e.g.
⇒ “4.1.6 Brush emitter , e.g. VAS 6446 or VAS 6776 ”,
page 94 or
⇒ “4.1.7 Brush grinder set , e.g. VAS 6776 ”, page 95 .
– Sand out transitions with sandpaper P360-P400.
– Clean substrate with silicone remover .
– After repairing corrosion and before sealing, the substrate
must be
LLS MAX 230 M1- , then filled with 2K HS performance filler .
– After applied filler has dried, sand the filled area with sandpa‐
per while dry (P400-500), avoiding “sanding through” in all
cases. Then clean all sanded areas with silicone remover .
– The fold edges of the sheet metal must then be sealed All
sheet overlaps must be sealed with sealing compound
⇒ “3.8 Sealant materials”, page 49 . The fine joint seal must
be compared
hicle.
insulated with 2K wash primer -LHV 043 000 A2- or -
with the original conditions of the applicable ve‐
Paint - general information - Edition 10.2017
Note
♦
For repair, the joint seal must be restored to its original thick‐
ness and appearance.
♦
To avoid damage and failures, the seal welds in the area of
the assembly-specific add-on parts must be coated smoothly.
♦
Water drain holes must be left clear.
♦
All threaded bolts and weld nuts with M-thread and all other
bolts and contact surfaces for assembly must be fully func‐
tional all along the seal.
♦
The sealant material must not be applied to bare sheet metal,
but only on to filled substrates.
– The rest of the paintwork structure must be restored according
to the manufacturer's specifications.
2. General Instructions 9
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– Apply preservation coating around the edge of the fold area
using e.g.
⇒ “4.1.8 Pressurised cap gun , e.g. V.A.G 1538 ”, page 96
(cavity) ⇒ “3.4 Preservation”, page 22 .
Area of cavity preservation on rear lid as example
Area of cavity preservation on bonnet as example
Area of cavity preservation on a door as example
10 Rep. gr.00 - Technical data
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2.7 Painting the parking aid transmitter
To prevent malfunctions of the parking aid transmitter, the follow‐
ing parameters must be complied with when painting:
Painting a new part
♦ Maximum layer thickness: 125µm; you must measured the
layer thickness after painting
♦ Maximum hardening temperature: 1 hour at 90°C
Painting an old part
♦ Only remove paint (sand) down to primer
♦ Minimum layer thickness of 5-10µm must be maintained
♦ Maximum layer thickness: 125µm
♦ Maximum hardening temperature: 1 hour at 90°C
Electrical conductivity
♦ Paint or paint mist must not get into the plug.
Functional test:
♦ Connect vehicle diagnosis tester and test function ⇒ Electrical
System -
measurement and information system .
general notes; Rep. gr. 97 ; Lines; vehicle diagnosis,
Repair paintwork structure and layer thicknesses
1 - Primed new part with spare part primer: 2 - 10 μm
2 - Filler: 30 to 40 µm
3 - Uni base coat: 10 - 20 μm
4 - Metallic base coat / pearl effect: 20 - 15 μm
5 - Clear coat: 35 to 50 µm
Paint area
1 - The paint area of the sensors is the face and side surface
of the membrane. The side surface is painted by at least
3mm to maximum 4mm from the face of the membrane to
the rear.
2 - There must be no paint is this area.
2. General Instructions 11
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2.8 Adaptive cruise control (ACC)
Note
♦
For vehicles with ACC, the trim in the right cover part of the
front bumper must not be painted when applying repair paint
or replacement. The ACC system behind it may cease to func‐
tion if the thickness of the paint layer increases.
♦
The cover of the transmitter for cruise control in the bumper
trim grille is made of radar-permeable material. The cover can
be heated to avoid functional impairment in case of snow or
ice.
♦
All changes to the surface, such as subsequent painting, stick‐
ers and other items attached subsequently may cause mal‐
functions.
Control unit for clearance control
The illustration shows the adaptive cruise control unit . This may
be different for other vehicle models.
1 - Adapter plate
2 - Mounting bracket
3 - Mounting hole
4 - Vertical adjustment screw:
5 - Trim
6 - Transmitter for cruise control/adaptive cruise control unit
7 - Horizontal adjustment screw:
12 Rep. gr.00 - Technical data
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3 Original products
⇒ “3.1 Paint products for customer service”, page 13
⇒ “3.2 Filler”, page 13
⇒ “3.3 Corrosion prevention”, page 18
⇒ “3.4 Preservation”, page 22
⇒ “3.5 Underseal”, page 26
⇒ “3.6 Protection against stone chipping”, page 37
⇒ “3.7 Underbody sealing wax”, page 44
⇒ “3.8 Sealant materials”, page 49
⇒ “3.9 Cleaning agent”, page 56
⇒ “3.10 SprayMax system”, page 61
3.1 Paint products for customer service
Note
♦
ŠKODA AUTO notes that only ŠKODA AUTO original prod‐
ucts or products from paint suppliers approved by the manu‐
facturer can be used for warranty work and must be used
according to the manufacturer's instructions. Only these prod‐
ucts meet the requirements to maintain the paint warranty.
♦
In the case of paint claims for paint applications using products
approved by the manufacturer from paint suppliers, warranty
claims must be made to the applicable supplier of the paint
materials (via the importer).
3.2 Filler
⇒ “3.2.1 2K steel filler set”, page 13
⇒ “3.2.2 2K diamond aluminium filler”, page 15
3.2.1 2K steel filler set
Designation
♦ 2K steel filler set - DA 787 300 A2Product description
This filler is a polyester filler with a metal powder mixture for cre‐
ating correctly
This filler is an especially good substitute for lead filling solder.
This filler is easy to apply and to sand, is very strong and heatresistant, and so is especially suitable for overpainting.
Application instructions
Base surface
Suitable base surfaces:
♦ Steel
♦ Metallic base surfaces in general
♦ Galvanised sheet steel
contoured surfaces on highly stressed body areas.
3. Original products 13
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Preparing base surfaces:
– Thoroughly degrease
must be prepared with e.g.
⇒ “4.1.6 Brush emitter , e.g. VAS 6446 or VAS 6776 ”,
page 94 . This means down to the bare metal with grit P40.
– Clean again with a silicone remover before working over.
Processing
and sand base surface. The substrates
Filling
Mixing ratio
– The two components are mixed at a ratio of 1 part by volume
liquid hardener to 2.5-3 parts by volume powder or 10 grams
liquid
hardener
product.
Note
and 58 grams powder to make a suitable filler
Avoid excessive liquid hardener as it will reduce the final strength
and adhesive characteristics of the filler.
Processing time:
– Pot life is approx. 4-6 minutes at +20°C.
Reaction temperature:
– The reaction temperature must be at least +5°C.
14 Rep. gr.00 - Technical data
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Drying
– Hardening with short-wave infrared heater
♦ Flash off for approx. 10 minutes at +20°C.
♦ Pre-curing: 10 minutes at approx. 50°C
♦ 1st stage curing: 10 minutes at 75°C
♦ 2nd stage curing: 10 minutes at 85°C
Paint - general information - Edition 10.2017
Suitability for sanding:
– Then sand with dry sandpaper (grit P80) to contour or use the
body plane.
Storage
guaranteed storage stability is 12 months from date of man‐
The
ufacture. It can be processed on or before the date indicated on
label if stored in unopened, original containers at +20°C.
Storage conditions
– Store in a cool and dry place. Storage temperature: +20°C.
Note
♦
Process only in well ventilated spaces.
♦
You are advised to wear protective gloves and a dust mask.
♦
A sanding dust extraction system is recommended.
3.2.2 2K diamond aluminium filler
Designation
♦ 2K diamond aluminium filler, powder - DA 004 200 A2♦ 2K diamond aluminium filler, powder - DA 004 201 A1♦ 2K diamond aluminium filler, powder - DA 004 211 A1-
3. Original products 15
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Product description
This filler is a polyester filler for universal application, and is es‐
pecially suited to aluminium sheet repairs.
It is designed for use in automobile repairs.
This filler is easy to apply and to sand, is very strong and heat-
resistant
Application instructions
Suitable base surfaces:
♦ Aluminium
Preparing base surfaces:
– Carefully degrease base surface.
– Carefully sand base surface.
– Carefully degrease base surface.
16 Rep. gr.00 - Technical data
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Mixing ratio:
– The two components are mixed at a ratio of 1 part by volume
liquid hardener to 2.5-3 parts by volume powder or 10 grams
liquid hardener
and 25 grams powder to make a suitable filler
product.
Processing
Application:
– Filling
Note
Avoid excessive liquid hardener as it will reduce the final strength
and adhesive characteristics of the filler.
Processing time:
– The pot life is approx. 4-6 minutes at +20°C room temperature.
Reaction temperature:
– at least +5 ℃
Drying
– Flash off for approx. 10 minutes
– Hardening with short-wave infrared heater
♦ Pre-hardening: 10 minutes at 50 °C
♦ 1st stage curing: 10 minutes at 75 °C
♦ 2nd stage curing: 10 minutes at 85 °C
3. Original products 17
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Suitability for sanding:
– Then sand with dry sandpaper (grit P80) to contour or use the
body plane.
Note
♦
Only process in a well-ventilated space.
♦
You are advised to wear protective gloves and a dust mask.
♦
A sanding dust extraction system is recommended.
Storage
The guaranteed storage stability is 12 months from date of man‐
ufacture. It can be processed on or before the date indicated on
label if stored in unopened, original containers at +20°C.
Storage conditions
– Store in a cool and dry place.
– Storage temperature: +20°C.
3.3 Corrosion prevention
⇒ “3.3.1 2K wash primer”, page 18
3.3.1 2K wash primer
Designation
♦ 2K wash primer - LHV 043 000 A2Product description
This 2K wash primer is a zinc chromate- and phenol-free acid-
hardening two-component wash primer.
♦ Outstanding corrosion protection based on its passivating
characteristics
♦ For metallic substrates, in particular aluminium and galvanised
steel sheets
♦ Easy to process
♦ Shade: Olive grey
Application instructions
Base surface
Suitable base surfaces:
♦ Bare sheet steel, cleaned and sanded
♦ Cleaned and sanded galvanised or electroplated steel panels
or soft aluminium
♦ Sanded factory primer
18 Rep. gr.00 - Technical data
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♦ Well-sanded factory paint or old paint (with the exception of
thermoplastic paint)
♦ Surfaces prepared with 2K polyester products and then finely
sanded
Preparing base surfaces:
– Clean carefully with silicone remover .
– Clean and sand factory paint or old paint, completely remove
any rust spots and spot-sand the transitions to the old paint.
– Use a suitable cleaning agent to ensure a clean, residue-free
surface prior to reworking.
Mixing ratio:
– 1:1 by volume with 2K additive solution - LHA 004 000 A2Processing time:
– Ready-to-spray preparation: 8-10 hours at +20°C
Note
Material must be mixed and applied on the same day.
3. Original products 19
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Application “Spray application”
– Processing viscosity: 4mm at +20°C, DIN 53211
Processing viscosity: 4 mm “Compliant” and “HVLP” gravity feed
spray gun:
DIN 4 mm: 16 - 18 seconds
– Adjust the spray nozzle (see manufacturer data): “Compliant”
1.2 - 1.4 mm.
Adjust the spray nozzle (see manufacturer data): “HVLP” 1.3
–
- 1.5 mm.
– Spraying pressure (see manufacturer's instructions): “Compli‐
ant” 2.0...2.5 bar.
– Adjust the atomiser pressure (see manufacturer data): “HVLP”
0.7 bar.
– The specified layer thickness is 8-12 µm.
20 Rep. gr.00 - Technical data
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Drying
Air drying at +20°C room temperature, can be over-sprayed after
30 minutes
Caution
Forced drying and infrared drying are not possible, because
they cause issues with intercoat adhesion.
Working over
After the flash-off time at +20°C, can be over-sprayed with 2K HS
filler.
Then can be overpainted with:
♦ Water-based base coat
♦ 2K top coat
Caution
Do not use with polyester, epoxy or water-thinnable products
for subsequent processing.
Do not use on thermoplastic paintwork.
Do not rework directly with water-based base coat or 2K HS
top coat.
Personal protective equipment:
♦ Comply with the safety datasheet
♦ Wear personal protective equipment during the application
process
Storage
The guaranteed storage stability is 24 months from date of man‐
ufacture. It can be processed on or before the date indicated on
label if stored in unopened, original containers at +20°C.
3. Original products 21
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3.4 Preservation
⇒ “3.4.1 Preservative wax”, page 22
⇒ “3.4.2 Cavity preservation agent”, page 23
⇒ “3.4.3 Preservative wax (spray can)”, page 26
3.4.1 Preservative wax
Designation
♦ Preservative wax - AKR 321 M15 4♦ Preservative wax - AKR 321 M16 10Product description
Preservative wax - AKR 321 M15 4- and preservative wax - AKR
321 M16 10- is a sprayable, wax-based rust corrosion inhibitor.
When dry it forms an adhesive, flexible, tear and water-resistant
film that is virtually colourless.
Because the drip point of the dried material is above 100°C, no
running or dripping is to be anticipated, even within the engine
compartment.
The dry film bonds securely to bare and painted sheet metal.
Application instructions
Application
♦ Used as preservation for automotive seams, surfaces and
cavities.
♦ Its light colour makes it especially suitable for protecting
seams on the bonnet and in the luggage compartment.
♦ This material is also a favoured product for treating cleaned
engine compartments.
Processing
Note
♦
Before starting work it is important to consult the safety regu‐
lations for information on mandatory precautions and sugges‐
ted safety procedures.
♦
All standard safety precautions for chemical products must be
observed, even when using substances not subject to special
labelling requirements.
– Before being treated, the parts should be thoroughly cleaned
and dried, and rust should be removed.
– Shake can before use. Spray on preservative wax and allow
to dry. The product should not be sprayed onto visible external
surfaces, as the dry layer produces a dull effect.
Caution
When this wax protectant is applied to engine compartments
in motor vehicles and engines in other devices, the engines
should not be started until the wax has thoroughly aired. There
is a risk that the evaporating solvent will explode!
22 Rep. gr.00 - Technical data
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Technical data
Colour Transparent in thin layers
Odour Mild odour
Viscosity (DIN
12 - 14 s
53211, 4mm)
Drip point approx. 100 °C.
Cleaning with white spirit, cold cleaner or paraffin
Processing
+15 °C to +30 °C
temperature
3.4.2 Cavity preservation agent
Designation
♦ Cavity preservation agent - D 330 KD1 A2♦ Cavity preservation agent - D 330 KD2 A1Product description
Cavity preservation agent - D 330 KD1 A2- and cavity preserva‐
tion agent
agent for sealing cavities and enclosed areas with a high solid
content.
It is available as a thoroughly dispersed thixotropic solution de‐
signed to provide optimal protection in areas that are difficult to
access and narrow areas between sheet-metal surfaces.
The cavity preservation agent penetrates and disperses moisture;
it contains a high proportion of rust inhibitors.
The cavity preserving agent atomizes very fine during spraying,
has extremely good creep properties, penetrates well into the
spaces to be protected (e.g.: welds) and does not leak too much
from the lower seams.
Although this material can be applied at any temperature above
10°C, the penetrating ability is improved if both product and body
are allowed to stabilise at “room temperature”.
After curing, the material forms a flexible, water-resistant film,
transparent beige in colour.
Application instructions
Application
♦ Primarily used at the workshop to spray cavities, to comple‐
ment existing cavity protection treatment on new vehicles, to
post-treat cavity protection treatments and after repairs fol‐
lowing accidents.
- D 330 KD2 A1- is a solvent-containing anti-corrosion
Note
♦
Before starting work it is important to consult the safety regu‐
lations for information on mandatory precautions and sugges‐
ted safety procedures.
♦
All standard safety precautions for chemical products must be
observed, even when using substances not subject to special
labelling requirements.
Processing the cavity preservation agent - D 330 KD1 A2♦ The cavity preservation agent - D 330 KD1 A2- is easy to apply
using the suction-feed spray gun and the appropriate probe
attachments.
3. Original products 23
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♦ The application pressure with the suction-feed spray gun is
5-6 bar.
♦ If stored for longer periods or at temperatures under +10 °C,
the material becomes more thixotropic. However, it becomes
less thixotropic again during spraying at normal application
temperatures. The product displays its usual properties after
spraying.
The material pressure governor should be set to 5 bar.
Note
Depending upon the type of cavity being treated, the drying proc‐
ess may extend over a number of days. Adequate ventilation
should be provided during drying.
Processing the cavity preservation agent - D 330 KD2 A1♦ Trim panels and components should be removed when pos‐
sible. Any rust should be removed as thoroughly as possible.
♦ The tube-equipped spray attachment in the cap is installed to
reach areas that are difficult to access (semi-cavities in doors,
etc.).
♦ The material should be at room temperature for application.
♦ If stored for longer periods or at temperatures under +10 °C,
the material becomes more thixotropic. This is why it is impor‐
tant to shake the can vigorously before use, with the agitator
ball audible within the can.
♦ With the can held upright, an even layer is sprayed onto the
dust and grease-free body part.
♦ When the “applicator tube” is being used, it can be slowly ro‐
tated in all directions during the spray application.
♦ The applicator with its circular nozzle pattern allows finely dis‐
persed and even application on surfaces such as vehicle floor
panels, and thereby restores a flawless appearance.
Note
The cavity preservation agent - D 330 KD2 A1- is a product that
contains flammable propellant. You must ensure that cavities are
ventilated before they are closed again (e.g. door trims) and that
the whole vehicle is ventilated during the drying phase. Depend‐
ing upon the type of cavity being treated, the drying process may
extend over a number of days.
Caution
Functional parts, such as brake and exhaust systems, must not
be sprayed!
Rubber and plastic parts should also not be sprayed.
Cleaning
♦ Escaping drips of preservation agent can easily be wiped
away.
♦ The plastic cleaner - D 195 850 A1- , for example, is suitable
for cleaning the material when it has dried on to surfaces.
♦ Larger areas can be cleaned with the steam cleaner. Splashes
on painted surfaces should be removed immediately.
24 Rep. gr.00 - Technical data
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Technical data for the cavity preservation agent - D 330 KD1 A2-
Colour Transparent beige
Odour Typical, distinctive odour
Solid matter
approx. 60 % (active ingredient)
content
Consistency Thixotropic
Durability min. 100 μm
Suitability for
No permanent changes in the paint
use with top
coats
Can be re‐
Dried material can be easily removed
moved after
24 hours
Properties in
No dripping
drying oven
(1.5 h at 90 °
C)
Resistance to
No cracking
cold
Resistance to
No corrosion
corrosion
Processing
+10 °C to +25 °C
temperature
Application
-40 °C to +90 °C
temperature
Technical data for the cavity preservation agent - D 330 KD2 A1-
Colour Transparent beige (almost transparent)
Odour Typical, distinctive odour
Solid matter
approx. 60 % (active ingredient)
content
Drip point of
approx. 150 °C.
solid
Consistency Thixotropic
Durability min. 100 μm
Penetration >16 cm
Suitability for
No permanent changes in the paint
use with top
coats
Can be re‐
Dried material can be easily removed
moved after
24 hours
Properties in
No dripping
drying oven
(1.5 h at 90 °
C)
Resistance to
No cracking
cold
Resistance to
No corrosion
corrosion
Processing
+10 °C to +25 °C
temperature
Application
temperature
-40 °C to +90 °C (+120 °C for short periods up
to 1 hour)
3. Original products 25
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3.4.3 Preservative wax (spray can)
Designation
♦ Preservative wax - D 308 SP5 A1Product description
The preservative wax - D 308 SP5 A1- provides optimal corrosion
protection for corrosion-susceptible areas on bodywork such as
double panels (folds, gaps, flanges), edges and surfaces.
This long-life corrosion protection has very good penetration qual‐
ities and excellent adhesion to metallic surfaces.
It is suitable for applying to and removing from the top coat and
is also compatible with rubber and plastic components.
Application instructions
Application
♦ The recommended dry layer thickness is approx. 30 μm.
Technical data
Propane-bu‐
tane content
Active ingre‐
dient content
Solvent con‐
tent
Viscosity
(DIN 53211,
4mm)
Drip point (of
solid)
Cleaning with white spirit
Processing
temperature
Flash point
PM (DIN EN
22719)
Colour Light beige
Application
temperature
Resistance
to cold
45 - 49%
22 - 26 %
27 - 31 %
16 - 22 s
> 150 °C
+18 °C to +25 °C
+27 to +33 ℃
+10 °C to +30 °C
up to -30 °C
3.5 Underseal
⇒ “3.5.1 Long-life underseal D 314 D36 M2 grey”, page 26
⇒ “3.5.2 Long-life underseal D 314 D37 M2 black”, page 29
⇒ “3.5.3 Long-life underseal D 314 D38 M2 light”, page 32
3.5.1 Long-life underseal - D 314 D36 M2grey
Designation
♦ Long-life underseal - D 314 D36 M2- grey
26 Rep. gr.00 - Technical data
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