SKODA Citigo 2012, Fabia 2000, Fabia II 2007, Fabia II 2009, Fabia II 2011 Workshop Manual

...

Service

Workshop Manual

Citigo 2012 , Fabia 2000 , Fabia 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

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

Service Department. Technical Information

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Service

List of Workshop Manual Repair Groups

Repair Group

00 - Technical data

Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.

No reproduction without prior agreement from publisher.

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Paint - general information - Edition 10.2017

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1	Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1
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

Contents i

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Paint - general information - Edition 10.2017

ii Contents

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00 – Technical data

1Safety instructions

(SRL001128; Edition 10.2017)

“1.1 Safety measures when painting vehicles that use natural gas”, page 1

1.1Safetymeasureswhenpaintingvehicles 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.

Hightemperaturestriggerthethermalfuseoftheshut-offvalve 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

with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.	1. Safety instructions	1
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2General 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

2.1Structure 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.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted ♦ Thevaluesmaybeexceededforsomevehiclesunlessintwoauthorisedormoreby ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability

coats are applied.However, this does not need towithber spectcommuto the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

nicated.

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2.2Structure 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

Theprimeristhemostimportantpartoftheanti-corrosionsystem, 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 A2or -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.

Protected♦ Theby copyrightfiller. servesCopying forasprivatetheorsubstratecommerci l purposes,for thein parttoporcoat,in whole,levelsis not permioutted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respectunevennessto the correctnessin areasof informationthatinhavethis documalreadynt. Copyrightbeenby workedŠKODA AUTOandA. Sde.

terminesthequalityofthetopcoat.Thefillerprotectsthebody against chipping and also acts as a barrier/substrate insula tion, which is essential for corrosion protection.

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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 A2or -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

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted

♦ “3.8 Sealant materials”,unlesspageuthorised49 by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

Base coat

The base coat is primarily decorative.

Thepaintsprovidedifferentcoveragedependingonpigmentcon tent. The manufacturer's instructions must be followed.

Clear coat

The clear coat is primarily decorative. The clear coat protects the topcoat/basecoatagainstultravioletradiationandenvironmental 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 materialsavailableforcustomerservice.Thesematerialsprovide 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.

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Product information

♦“3.4 Preservation”, page 22

♦“3.7 Underbody sealing wax”, page 44

2.3Different paintwork structure for engine compartment and inside of front flap

The paint in the “engine compartment and the inside of front flap” may be different in terms of paintwork structure and tone from the externalpaint,dependingonmodel.Thedifferenceisproductionrelated and is not a defect. The state as produced must be restored.

2.4Photo documentation of the reported paint damage according to the ŠKODA standard to create the DISS paint report

Basic requirements for photo documentation of reported paint damage

Note

♦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

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General overview

Reported part with the damage marked

Detailed image of damage with attached -label with ruler-

Label with ruler

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Protected by copyright. Copying for private or commercial unless authorised by ŠKODA AUTO A. S. ŠKODA

with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

–Printphotoatactualsize(testdimensionsofimageframe:132 x 157mm).

–Cut out -label with ruler-.

2.5Work 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 .

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–Apply e.g. 2K wash primer - LHV 043 000 A2or -LLS MAX 230 M1to sanded-through areas.

–Leave to dry (note drying time).

–Then filler with 2K HS performance filler .

–Leave to dry (note drying time).

–Dryfillerandsandwithsandpaper(P400-500),avoidingsand 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 6446or - VAS 6776- .

– Flatten damaged area and sand down to the blank metal.

– Remove any corrosion with e.g. brush grinder - VAS 6446or -VAS 6776- , then fine-sand (P180-240).

– Clean substrate with silicone remover .

– Apply e.g. 2K wash primer - LHV 043 000 A2or -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.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted

–Sand fillingunlesspasteauthorisedwith bysandpaperŠKODA AUTO(P80A. S. Š-KODAP240),AUTOthoroughlyA. S. does not guarantee or accept any liability sanding transitionsw th respectatothet e correctnsamesstimeof information. in this document. Copyright by ŠKODA AUTO A. S.

–Clean substrate with silicone remover .

–Apply e.g. 2K wash primer -LHV 043 000 A2or -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 .

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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.

2.6Instructions 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 insulated with 2K wash primer -LHV 043 000 A2or -

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

Protected by copyright. C pying for private or commercial purposes, in part or in whole, is not permitted cases. Thenunlesscleanauthorisedall sandedby ŠKODAareasAUTO Awith. S. ŠKODAsiliconeAUTOremoverA. S. does not. guarantee or accept any liability

with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

– 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 with the original conditions of the applicable ve hicle.

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.

–Therestofthepaintworkstructuremustberestoredaccording to the manufacturer's specifications.

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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

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2.7Painting 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:

♦Connectvehiclediagnosistesterandtestfunction Electrical System-generalnotes;Rep.gr. 97;Lines;vehiclediagnosis, measurement and information system .

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

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with4 -respectMetallicto the correctnessbase coatof information/ pearlin thiseffect:do ument20. Copyright- 15 μmby ŠKODA AUTO A. S.

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.

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2.8Adaptive 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 orreplacement.TheACCsystembehinditmayceasetofunc 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.

♦Allchangestothesurface,suchassubsequentpainting,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:

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3Original 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

3.1Paint 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.

♦Inthecaseofpaintclaimsforpaintapplicationsusingproducts approved by the manufacturer from paint suppliers, warranty claims must be made to the applicable supplier of the paint materials (via the importer).

3.2Filler

“3.2.1 2K steel filler set”, page 13

“3.2.2 2K diamond aluminium filler”, page 15

3.2.12K 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 atingcorrectlycontouredsurfacesonhighlystressedbodyareas. This filler is an especially good substitute for lead filling solder.

This filler is easy to apply and to sand, is very strong and heat-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted resistant,unless au horisedandbysoŠKODAis especiallyAUTO A. S. ŠsuitableKODA AUTOforA. Soverpainting. do s not guarantee. or accept any liability

with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

Application instructions Base surface Suitable base surfaces:

♦Steel

♦Metallic base surfaces in general

♦Galvanised sheet steel

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Preparing base surfaces:

–Thoroughly degrease and sand base surface. The substrates 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

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 and 58 grams powder to make a suitable filler product.

Note

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: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted

– The reaction temperature must be atunlessleastauthorised+5°C. by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

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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

Suitability for sanding:

–Then sand with dry sandpaper (grit P80) to contour or use the body plane.

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.

Note

Protected by copyright. Copying for private or commercial purposes, in part or in whole,

unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or ♦ Process onlywithinrespectwelltoventilatedthe correc nessspacesof information. in this document. Copyright by ŠKODA

♦ You are advised to wear protective gloves and a dust mask. ♦ A sanding dust extraction system is recommended.

3.2.22K 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-

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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 heatresistant

Application instructions Suitable base surfaces: ♦ Aluminium Preparing base surfaces:

– Carefully degrease base surface.

– Carefully sand base surface.

– Carefully degrease base surface.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or

with respect to the correctness of information in this document. Copyright by ŠKODA

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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:

–Thepotlifeisapprox.4-6minutesat+20°Croomtemperature. 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

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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.

3.3Corrosion prevention

“3.3.1 2K wash primer”, page 18

3.3.12K wash primer

Designation

♦ 2K wash primer - LHV 043 000 A2Product description

This 2K wash primer is a zinc chromateand phenol-free acidhardening two-component wash primer.

♦Outstanding corrosion protection based on its passivating characteristics

♦Formetallicsubstrates,inparticularaluminiumandgalvanised steel sheets

♦Easy to process

♦Shade: Olive grey

Application instructions

Base surface

Suitable base surfaces: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted

♦ Bare sheet steel, cleaned and sandedunless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

♦Cleaned and sanded galvanised or electroplated steel panels or soft aluminium

♦Sanded factory primer

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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.

Protected by copyright. Copying for private or commercial

unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability

– Use a suitable cleaning agent towithensurere pect toatheclean,correctnessresidueof information-freein this 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.

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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.

–Adjusttheatomiserpressure(seemanufacturerdata):“HVLP”

0.7bar.

–The specified layer thickness is 8-12 µm.

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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.

Protected by copyright. Copying for private or commercial purposes, in part or in whole,

unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

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3.4Preservation

“3.4.1 Preservative wax”, page 22

“3.4.2 Cavity preservation agent”, page 23

“3.4.3 Preservative wax (spray can)”, page 26

3.4.1Preservative 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 10is 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.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted

– Before being treated, the partsunless autshouldorised bybeŠKODAthoroughlyAUTO A. S.cleanedŠKODA AUTO A. S. does not guarantee or accept any liability and dried, and rust should bewithremovedr spect to the. correctness of information in this document. Copyright by ŠKODA AUTO A. S.

– Shake can before use. Spray on preservative wax and allow todry.Theproductshouldnotbesprayedontovisibleexternal 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!

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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

3.4.2Cavity preservation agent

Designation

♦Cavity preservation agent - D 330 KD1 A2-

♦Cavity preservation agent - D 330 KD2 A1Product description

Cavity preservation agent - D 330 KD1 A2and cavity preserva tion agent - D 330 KD2 A1is a solvent-containing anti-corrosion 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.

Thecavitypreservationagentpenetratesanddispersesmoisture; 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.

byNotec pyright. Copying for private or commercial purposes, in part or in whole, is not permitted authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability

with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

♦ 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-

♦Thecavitypreservationagent-D330KD1A2-iseasytoapply using the suction-feed spray gun and the appropriate probe attachments.

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♦The application pressure with the suction-feed spray gun is 5-6bar.Thematerialpressuregovernorshouldbesetto5bar.

♦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.

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 A1is 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.

CautionProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability

with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

Functionalparts,suchasbrakeandexhaustsystems,mustnot 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.

♦Largerareascanbecleanedwiththesteamcleaner.Splashes on painted surfaces should be removed immediately.

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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	-40 °C to +90 °C (+120 °C for short periods up
temperature	to 1 hour)	Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
temperature	to 1 hour)	unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability

		with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

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3.4.3Preservative wax (spray can)

Designation

♦ Preservative wax - D 308 SP5 A1Product description

Thepreservativewax-D308SP5A1-providesoptimalcorrosion protection for corrosion-susceptible areas on bodywork such as double panels (folds, gaps, flanges), edges and surfaces.

Thislong-lifecorrosionprotectionhasverygoodpenetrationqual 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	45 - 49%
tane content
Active ingre	22 - 26 %
dient content
Solvent con	27 - 31 %
tent
Viscosity	16 - 22 s
(DIN 53211,
4mm)
Drip point (of	> 150 °C
solid)
Cleaning	with white spirit
Processing	+18 °C to +25 °C
temperature
Flash point	+27 to +33
PM (DIN EN
22719)
Colour	Light beige
Application	+10 °C to +30 °C
temperature		Protected by copyright. Copying for private	or commercial purposes, in part or in whole, is not permitted
Resistance	up to -30 °C	with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.
		unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
to cold

3.5Underseal

“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

3.5.1Long-life underseal - D 314 D36 M2grey

Designation

♦ Long-life underseal - D 314 D36 M2grey

26 Rep. gr.00 - Technical data

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+ 76 hidden pages

SKODA Citigo 2012, Fabia 2000, Fabia II 2007, Fabia II 2009, Fabia II 2011 Workshop Manual

1. Safety instructions

2General Instructions

2.1Structure of original paintwork

2.2Structure of customer service paintwork

2.3Different paintwork structure for engine compartment and inside of front flap

2.4Photo documentation of the reported paint damage according to the ŠKODA standard to create the DISS paint report

2.6Instructions for repairing fold corrosion

2.7Painting the parking aid transmitter

2.8Adaptive cruise control (ACC)

3Original products

3.1Paint products for customer service

3.2Filler

3.2.12K steel filler set

3.2.22K diamond aluminium filler

3.3Corrosion prevention

3.3.12K wash primer

3.4Preservation

3.4.1Preservative wax

3.4.2Cavity preservation agent

3.4.3Preservative wax (spray can)

3.5Underseal