Workshop Manual Transporter 2016 22-29

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Vehicle-specific paint information

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Edition 11.2018
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
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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.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2018 Volkswagen AG, Wolfsburg D4B8063E4C6

Vehicle-specific paint information - Edition 11.2018
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Sanding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Seam sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Cavity sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Areas exposed to stone chipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Masked sectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Masking areas, front body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Masking areas, rear body . . . . . . . . . . . . . . . . . . e. n. A.G. ..V.ol.ks.w. a.g.en. A. G. . . . . . . . . . . . . . . . . . . 7
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4 Seam sealing . . . . . . . . . . . . . . . . . . . . .by. V. o.lk. . . . . . . . . . . . . . . . . . . . . n. o.t g. u. . . . . . . . . . . . 10
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4.1 Seam seals, front body . . . . . . . . . .or.is.e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ra.nt.e . . . . . . . . 10
h e
4.2 Seam seals, centre body . . . . . .s a.ut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o.r a.c . . . . . 14
s
4.3 Seam seals, rear body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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5 Underseal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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5.1 Underseal, body - overview with differing layer thickness . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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5.2 Underseal, protected areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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6 Cavity sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
h re
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6.1 Cavity sealing, body - overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
spec
es, in part or in w
6.2 Cavity sealing, doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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7 Paintwork repairs, California - roof reinforcement at front and rear . . . . . . . . . . . . . . . . . . 34
7.1 Damage patterns front roof reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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7.2 Paintwork structure front roof reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.3 Paintwork structure on cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
l purpos
7.4 Paint repair old front roof reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

7.5 Painting of contrasting shade for front roof reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . 49
nform
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7.6 Paint repair in storage area of pop-up roof at front roof reinforcement . . . . . . . . . . . . . . . . 53
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7.7 Paint repair side arms - front roof reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
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7.8 Painting instructions, roof reinforcement at front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
in t
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7.9 Paint repair rear roof reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

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8 Paintwork repairs, pop-up roof, California . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
um
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8.1 Damage scenarios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

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8.2 Paint repairs under and outside roof frame seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
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8.3 Paintwork repairs to inner corner reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
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9 Contrasting colours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
agen
Prote AG.
9.1 Contrasting colours, Transporter Caravelle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
9.2 Contrasting colours, Transporter Multivan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
9.3 Contrasting colours, Transporter California . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Contents i
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1 Explanation of symbols
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⇒ “1.1 Sanding”, page 1
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⇒ “1.2 Seam sealing”, page 1
⇒ “1.3 Cavity sealing”, page 3
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1.1 Sanding
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Avoid sanding through to substrate
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– It is recommended to carefully sand the marked area by hand
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1.2 Seam sealing

Sealing
– Apply sealant.
Fine seam sealing

– Fine seam seals require that the sealant extend at least 3 mm
from the seam in each direction and must have a height of 2
mm.
1. Explanation of symbols 1
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Coarse seam sealing
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– Coarse seam seals require that the sealant be applied at least
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Smoothing seals
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Brushing seals
– Sealant in the marked areas must be brushed following appli‐
cation.
Note
When brushing the sealant seam, ensure that the sheet metal
edges which are to be protected are not exposed and that the
metal is covered with a sufficiently thick layer of PVC.
Sealing the folded seam groove

– The marked areas must be closed following application of
sealant to the "U" of the folded seam.
Note
be covered with a sufficiently thick layer of PVC so that the groove
in the folded seam remains closed.
2 Rep. gr.00 - Technical data

1.3 Cavity sealing

Sealing cavities
– The marked areas must be sealed following body repair.
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1. Explanation of symbols 3
2 Areas exposed to stone chipping
Note
♦ The marked areas are exposed to stone chipping.

♦ When sanding these areas, note thickness of the paint struc‐
ture and avoid sanding through. This is the only way to ensure
long-term corrosion protection.
♦ It is recommended to carefully sand the marked area by hand
to avoid “sanding through” the cathodic dip primer.
Overview of body 1
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2. Areas exposed to stone chipping 5

3 Masked sectors
⇒ “3.1 Masking areas, front body”, page 6
⇒ “3.2 Masking areas, rear body”, page 7
3.1 Masking areas, front body
Note
♦ The subsequent descriptions should be adapted accordingly

for the double and single cabin depending on model and ver‐
sion.
♦ Threads, functional and joint surfaces that are not shown must
be covered as necessary.
Masking areas, engine compartment
A - Threads free of surfacer

and top coat paint
satelettronica
B - Contact surface free of wax
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Masking areas, underbody
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A - Contact surfaces free of wagen AG. Volkswagen AG doe

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3.2 Masking areas, rear body
Note
Threads, functional and joint surfaces that are not shown must be
covered as necessary.
Masking areas, underbody (panel van / Kombi)
3. Masked sectors 7
A - Contact surfaces free of

sealant
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Masking areas, underbody (double and single cabin)

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A - Contact surfaces free of

sealant
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3. Masked sectors 9
4 Seam sealing
⇒ “4.1 Seam seals, front body”, page 10
⇒ “4.2 Seam seals, centre body”, page 14
⇒ “4.3 Seam seals, rear body”, page 21
4.1 Seam seals, front body
Note
♦ When performing repair work, the seam sealing should be re‐

stored to match the original appearance and layer thickness.
♦ To avoid damage or faulty operation, brush seam seals
smooth near parts which must be attached.
♦ Water drainage holes must remain clear.
♦ All threaded studs and welded nuts with metric threads as well
as all other studs and contact surfaces for assembly must be
functional following the extent of the sealing work.
satelettronica
♦ Sealant must never be applied to bare substrates. Substrates
must always be surfaced first.
Seam seals, engine compartment
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Rep. gr.00 - Technical data
AG.
- Coarse seam sealing

❑ Coarse seam seals re‐
quire that the sealant be
applied at least 20 mm
wide and 2 mm high.
- Smoothing seals
❑ Sealant in the marked
areas must be smooth‐
ed following application.
1 - Contact surface for water
drain valve
❑ Keep free of sealant
- Dimension -x- = 7 mm
❑ The sealing surface for
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Seam seals, left wheel housing
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Illustration shows left side. The right side is the mirror image.
4. Seam sealing 11

wide and 2 mm high.
- Brushing seals
areas must be brushed
following application.
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Seam seals, A-pillar
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Note
When smoothing or brushing the sealant seam, ensure that the

sheet metal edges which are to be protected are not exposed.
The metal must be covered with a sufficiently thick layer of PVC.
4. Seam sealing 13
4.2 Seam seals, centre body

⇒ “4.2.1 Seam seals, middle body, roof”, page 14
⇒ “4.2.2 Seam seals, middle body, B-pillar”, page 16
⇒ “4.2.3 Seam seals, middle body, sliding door area”, page 18
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4.2.1 Seam seals, middle body, roof
ss
Seam seals, roof
o
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Note
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The subsequent description should be adapted accordingly for the »double« and »single cabin« depending on
thi
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wide and 2 mm high.
- Fine seam sealing
❑ Fine seam seals require
that the sealant extend
at least 3 mm from the
seam in each direction
and must have a height
of 2 mm.
satelettronica
AG. Volkswagen AG d
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Prote AG.
4. Seam sealing 15
4.2.2 Seam seals, middle body, B-pillar

Seam seals, left B-pillar
- Fine seam sealing

❑ Fine seam seals require n AG. Volkswagen AG do
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rrectness of i
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Note

Seam seals, right B-pillar

AG. Volkswagen AG d
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- Fine seam sealing byV
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❑ Fine seam sealshorequire
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Cop py
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Prote AG.
Note
4. Seam sealing 17
4.2.3 Seam seals, middle body, sliding door area

Seam seals, top sliding door frame
The right side is shown, depending on model and version the left
side is the mirror image.
- Fine seam sealing

of 2 mm.
- Brushing seals
to be watertight follow‐
ing application.
satelettronica
AG. Volkswagen AG d
agen oes
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or eo
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Note
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nform
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Seam seals, C-pillar lock reinforcement

o
n
c
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thi
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a
side is the mirror image.

iv
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Cop py
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pyri by
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o
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Prote AG.

- Fine seam sealing

of 2 mm.
- Smoothing seals
- Brushing seals
satelettronica
AG. Volkswagen AG d
agen oes
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rise nte
tho eo
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nl
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Note
nf
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or
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Seam seals step

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op
side is the mirror image. C py
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Prote AG.
4. Seam sealing 19
- Fine seam sealing

of 2 mm.
- Brushing seals
satelettronica
lkswage es n
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Note
rrectness of i
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nform
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t.
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Cop py
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pyri by
Vo
co lksw
by
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Prote AG.

4.3 Seam seals, rear body

⇒ “4.3.1 Seam seals, wheel housing”, page 21
⇒ “4.3.2 Seam seals, rear cross panel”, page 23
Note
♦ When performing repair work, the seam sealing should be re‐

satelettronica
4.3.1 Seam seals, wheel housing
Seam seals, left wheel housings (panel van / Kombi)
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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aut ra
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nl
pt
du
an
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
in t
or
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ate
do
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pyri by
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cted agen
Prote AG.
4. Seam sealing 21
Vehicle-specific paint
l wage
ksinformation - Edition 11.2018
es n
Vo ot gu
by ara
ed nte
- Coarse seam sealingoris eo
th
au ra
❑ Coarse seam
ss seals re‐ c
ce
le
un
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an
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wide and 2 mm high.
erm
ab
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- Brushing seals
wit
is n
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spec
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rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
va
satelettronica
i
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pr
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r
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t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note

4.3.2 Seam seals, rear cross panel

Seam seals, rear cross panel (panel van / Kombi)
- Fine seam sealing

of 2 mm.
- Smoothing seals
AG. Volkswagen AG d
agen oes
ksw
satelettronica
ol not
byV gu
ara
ed
ris nte
ho eo
aut ra
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nl
pt
du
an
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erm
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wit
, is n
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hole
spec
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When smoothing the sealant seam, ensure that the sheet metal Cop py
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be covered with a sufficiently thick layer of PVC. co Vo
by lksw
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Prote AG.
Seam seals, rear cross panel (double / single cabin)
4. Seam sealing 23

wide and 2 mm high.
- Fine seam sealing
of 2 mm.
- Brushing seals
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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un
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Note
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Cop py
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Prote AG.

5 Underseal
⇒ “5.1 Underseal, body - overview with differing layer thickness”,
page 25
⇒ “5.2 Underseal, protected areas”, page 27
5.1 Underseal, body - overview with differ‐

ing layer thickness
AG. Volkswagen AG d
Note agen oes
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♦ Underseal (stone deflector strip) applied during threpair
or work eo
must be identical in appearance and thickness s au
to the original ra
c
underseal. s
ce
e
nl
pt
du
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functional following the application of the underseal.
h re
hole
satelettronica
spec
Seam seals, rear cross panel (panel van / Kombi)
es, in part or in w
t to the co
a - Underseal
rrectness of i
❑ Layer thickness:
0.3 - 0.4 mm
l purpos
b - Underseal
nform
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0.6 - 1.1 mm
m
at
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c - Underseal
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ate
1.0 - 1.5 mm
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Cop py
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py by
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cted agen
Prote AG.
5. Underseal 25
Underseal overview (double cab)
a - Underseal
0.3 - 0.4 mm
b - Underseal
0.6 - 1.1 mm
c - Underseal
1.0 - 1.5 mm
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
d
satelettronica
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
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y li
erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
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nf
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m
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n in
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Underseal overview (single cab)

or
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Cop py
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py by
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Prote AG.

a - Underseal
0.3 - 0.4 mm
b - Underseal
0.6 - 1.1 mm
c - Underseal
1.0 - 1.5 mm
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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5.2 Underseal, protected areas

ce
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un
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an
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ab
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Note
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wit
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♦ Underseal (stone deflector strip) applied during repair work

hole
spec
must be identical in appearance and thickness to the original

es, in part or in w
underseal.
t to the co

rrectness of i
l purpos
functional following the application of the underseal.

nform
ercia
Underseal, side member, with sectional view

m
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Note
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thi
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iva
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The subsequent description should be adapted accordingly for the double and single cabin depending on model
r
rp
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and version.
fo
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Cop py
ht. rig
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py by
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5. Underseal 27
Transporter 2016 ➤ AG. Volkswagen AG d
agen oes
Vehicle-specific paint information - Edition
Vo11.2018
lksw not
g y ua
db ran
rise tee
a - Underseal tho or
au ac
❑ Layer thickness: ss
ce
e
0.3 - 0.4 mm
nl
pt
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❑ Smooth transition from
itte
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-a- to -c-
ab
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b - Underseal
wit
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❑ Layer thickness: hole
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0.6 - 1.1 mm
es, in part or in w
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c - Underseal
1.0 - 1.5 mm
rrectness of i
❑ Smooth transition from
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-c- to -a-
1 - Outer part of side panel
nform
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2 - Side member
m
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satelettronica
p
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Cop py
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Prote AG.
Underseal, rear right wheel housing (long wheelbase)

For vehicles with 3rd seat row

a - Underseal
0.3 - 0.4 mm
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
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tho eo
au ra
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ce
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un
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an
d
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ab
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satelettronica
ot
wit
, is n
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hole
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es, in part or in w
t to the co
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l purpos
nform
mercia
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tion in
r
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Cop py
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pyri by
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by
cted agen
Prote AG.
5. Underseal 29
6 Cavity sealing
⇒ “6.1 Cavity sealing, body - overview”, page 30
⇒ “6.2 Cavity sealing, doors”, page 31
6.1 Cavity sealing, body - overview
Note
The indicated areas have been treated with cavity sealant and
must be resealed following repairs.
Cavity sealing, overview (panel van / Kombi)
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
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orm
m
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n in
or c
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Cop py
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pyri by
Vo
co lksw
by
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Prote AG.
Cavity sealing, overview (double cab)
Note
The subsequent description should be adapted accordingly for the »single cabin« depending on model and
version.

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
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erm
ab
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wit
, is n
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hole
spec
es, in part or in w
t to the co
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l purpos
nform
ercia
satelettronica
m
at
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ion
c
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ate
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priv
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for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
6.2 Cavity sealing, doors
Note
The indicated areas have been treated with cavity sealant and
must be resealed following repairs.
Cavity sealing, doors

A front door is illustrated in the upper picture.
A rear door (double cabin) is illustrated in the lower picture.
6. Cavity sealing 31
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
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an
d
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ab
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is n
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satelettronica
spec
t to the co
rrectness o
cial p
f inform
mer
atio
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n
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n thi
te
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Cop py
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Cavity sealing, sliding door py by
co Vo
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Prote AG.

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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ris nte
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spec
t to the co
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cial p
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mer
atio
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n
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n thi
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
6. Cavity sealing 33
7 Paintwork repairs, California - roof re‐

inforcement at front and rear
⇒ “7.1 Damage patterns front roof reinforcement”, page 34
⇒ “7.2 Paintwork structure front roof reinforcement”, page 37
⇒ “7.3 Paintwork structure on cover”, page 42
AG. Volkswagen AG d
⇒ “7.4 Paint repair old front roof reinforcement”, page 45 agen oes
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byV gu
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⇒ “7.5 Painting of contrasting shade for front roof reinforcement”,
rised
nte
page 49 aut
ho eo
ra
ss c
⇒ “7.6 Paint repair in storage area of pop-up roof at front roof
ce
le
un
reinforcement”, page 53
pt
an
d
itte
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⇒ “7.7 Paint repair side arms - front roof reinforcement”, rm
ab
pe
page 56
ility
ot
wit
, is n
⇒ “7.8 Painting instructions, roof reinforcement at front”,
h re
hole
page 60
spec
es, in part or in w
⇒ “7.9 Paint repair rear roof reinforcement”, page 62
t to the co
satelettronica
DANGER!
rrectness of i
♦ The front roof reinforcement as well as the pop-up roof are
l purpos
made of aluminium alloy.

♦ When processing and sanding aluminium surfaces, there
nform
ercia
is a risk of explosion due to electrostatic discharge. Please

m
always observe the guidelines on “Working with explosive
a
com
tio
dusts”.
n in
r
te o
thi
♦ For this reason, aluminium surfaces may only be pro‐
s
iva
do
cessed with pneumatic tools, sanding media and extrac‐
r
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cum
tion units specially dedicated and approved for this
fo
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purpose.
n
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♦ Separate workspaces for working with aluminium are not ht. rig
rig ht
only recommended for safety reasons but also improve
py by
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by lksw
the processing results, as contact corrosion is prevented. cted agen
Prote AG.
Contact corrosion occurs, if the same tools are used for
processing both steel and aluminium parts. The surface
underneath the paintwork starts to corrode resulting in re‐
work or even in customer complaints.
♦ All this, however, can be prevented in an efficient manner
by using a separate workspace with tools specially desig‐
nated for being used only within this workspace.
7.1 Damage patterns front roof reinforce‐

ment
Note
♦ The front roof reinforcement is made of aluminium alloy. The

components of this alloy differ from each other with regard to
their positions in the electrochemical series. Thus, corrosion
of the front roof reinforcement occurs in spite of an intact (un‐
damaged) surface coating.
♦ When detected at an early stage and if the customer has made
a complaint, the affected parts can be repaired. A respective
permission to repair must always be obtained.

Possible damage to front roof reinforcement
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
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satelettronica
or eo
th
au ra
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un
pt
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rm
ab
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ot
wit
, is n
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es, in part or in w
t to the co
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l purpos
nform
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com
tion in
r
te o
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– Corrosion damage to the front roof reinforcement often arises

s
iva
in the vicinity of edges.

do
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cum
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♦ -1- Upper edge, transition/contact surface between front roof

en
ng
t.
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reinforcement and pop-up roof
Co
Cop py
t. rig
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♦ -2- Front edge, transition between front roof reinforcement and
ht
pyri by
Vo
windscreen
co lksw
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cted agen
Prote AG.
♦ -3- Side edge, transition between cover and canopy rail
Possible damage to pop-up roof
7. Paintwork repairs, California - roof reinforcement at front and rear 35

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
satelettronica
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Corrosion damage to the pop-up roof also often arises in the

vicinity of edges, starting beneath the circumferential seal of
the pop-up roof.
♦ -1- Edge area beneath circumferential seal
♦ -2- Rear edge area, above circumferential seal

7.2 Paintwork structure front roof reinforce‐ n AG. Volkswagen A

G do
ment yV
olks
wage es n
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u b ara
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oris e
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Note au ac
ss
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pt
♦ Upon delivery, the front roof reinforcement is always primed.
an
d
itte
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rm
ab
♦ Further processing of the front roof reinforcement (work which
pe
ility
affects original paintwork) is only permissible in the areas in‐
ot
wit
, is n
dicated below.
h re
hole
♦ The following painting procedure applies for new parts and
spec
must be adhered to without fail. es, in part or in w
t to the co
♦ When detected at an early stage, the affected parts can be
repaired. For an installed front roof reinforcement/removed
pop-up roof, the same painting procedure applies as that ap‐
rrectness of i
plicable for new parts.
l purpos
Processing front edge of roof
nform
ercia
satelettronica
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tion in
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t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– “Round off” -arrow- the pointed roof edge -2- of the front roof
reinforcement -1- using P80 sandpaper.

Note
The »round edge« will prevent the “thinning of the coating at the edge” when painting, thus enabling a greater
amount of the material to contribute to corrosion protection in the vicinity of the edge.
Sanding at transitions
satelettronica
AG. Volkswagen AG d
agen oes
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aut ra
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pt
du
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
– Lightly sand edge of roof -2- all round using P120-P240 sand‐
m
atio
m
paper.
o
n in
or c
thi
– Smooth off transitions to original coating -1- using P120-P240

te
sd
a
sandpaper.
iv
o
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rp
cu
o
– Thoroughly clean front roof reinforcement with silicone remov‐

f
en
ng
t.
yi
er - LVM 020 000 A5- or silicone remover, long - LVM 020 100
Co
op py
A5- .
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
Note
Proceed with great care to avoid sanding through original coating -1-.
Applying anti-corrosive intermediate layer

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
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un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
– Apply 2 to 3 spray passes of 2-pack pro basic filler to entire

, is n
h re
front area -1-. Adhere to intermediate flash-off time of 5-10 mi‐

hole
spec
nutes between spray passes.

es, in part or in w
t to the co
– The specified thickness for the dry film is 80 µm.

rrectness of i
Note
l purpos
♦ Adherence to the minimum coating thickness of 40 µm must be ensured.

♦ Make sure to apply sufficient material to the rounded edge at front of roof -arrow-.
nform
ercia
♦ Refer to technical data sheet for 2-pack pro basic filler ⇒ General paintwork information, commercial vehi‐
m
a
com
cles .
ion in
r
te o
thi
Drying
s
iva
do
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rp
cum
Flash-off time with force drying is at least 15 minutes.

fo
en
ng
t.
yi Co
Force drying is carried out at an object temperature of +60°C. Cop py
t. rig
gh ht
yri
For coating thickness of 80 µm, flash-off period is at least 30 mi‐ p by
co Vo
nutes.
by lksw
cted agen
Prote AG.
Finishing after flash-off

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
satelettronica
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
– Lightly sand 2-pack pro basic filler and smooth off transitions
thi
e
to original coating. Do not sand the rounded roof edge at front.

t
sd
iva
o
r
rp
cu
– Dry sand by hand using sandpaper (P400 to P500 grain) or

o
m
f
en
ng
abrasive fabric.
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Note
co Vo
by lksw
cted agen
Prote AG.
Proceed with great care to avoid sanding through!
Final coating

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
satelettronica
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Final coating of the front roof reinforcement or coating of the
2-pack pro basic filler is performed with:
♦ -1- 2-pack HS premium surfacer - LGF 013 007 A4- / -LVM
013 171 A4- , light grey/dark grey
♦ -2- 2-pack HS top coat , see colour code
♦ -3- 2-pack HS clear coat + 10% elastic additive - ALZ 011 001-
Note
♦ If a flat coat on the front roof reinforcement is necessary, use 2-pack IR premium filler - LSP 787 220 A1/
A2/A3- .
♦ Ensure that filler is not applied to “untreated” material but only over the 2-pack pro basic filler .
♦ Any "sand-throughs" as well as the filler material itself need to be isolated using 2-pack pro basic filler after
filling. Further painting procedure is then carried out as described.

7.3 Paintwork structure on cover

Cover painting information ⇒ page 42
Cover painting instructions ⇒ page 42
Cover painting information
Problem:
Cover not OK after painting .
♦ The cover is supplied primed, with its curved shape intact
♦ After painting, the cover cannot be placed
gen AG
. Volkswaon
genthe
AG dvehicle with‐
out it being stressed Volkswa oes
not
by gu
ara
Cause: ed nte
oris eo
th
♦ The cover’s shape changes during the painting au process, in‐
ra
c
ss
fluenced by temperature and storage.
ce
le
un
pt
an
d
Measures:
itte
y li
rm
ab
♦ Painting must be carried out in situ
pe
ility
ot
wit
, is n
♦ Storage must be carried out in situ
h re
satelettronica
hole
spec
♦ Drying must be carried out in situ
es, in part or in w
t to the co
♦ The cover must be checked after painting as per the painting
instructions
♦ If it is distorted, the part may not be installed
rrectness of i
Cover painting instructions
l purpos
WARNING
nform
mercia
Observe the notes on occupational health and safety in the

com
tio
paintwork manual.
n in
r
te o
thi
The regulations for safety at work plus the workplace regula‐

s
iva
do
tions apply for car bodies in mixed construction!

r
rp
cum
fo
en
ng
t.
yi Co
op py
Preparation for paintwork structure
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote
Note
AG.
♦ Since fixing during assembly of the cover is by means of suc‐

tion lifters (VAS 6801) and adhesive tape, painting must occur
approx. 7 - 9 days prior to installation.
♦ The new cover must be checked for damage and distortion
before processing.
– Clean cover from inside and outside with water-based silicone

remover .

– Rub down inner bonding surface from outer edge to dimension

-a- dry using a P280 - 320 sanding pad.
♦ Dimension -a- = 3 cm
Note
To dry the area, a soft sanding pad made of foam should be used.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
satelettronica
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Clean inner area with water-based silicone remover .

rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
op
– Mask off inner area for painting according to dimension -a-.
C py
t. rig
gh ht
yri by
♦ Dimension -a- = 3 - 4 mm op Vo
by c lksw
cted agen
Prote AG.

– Rub down cover from outside and at edges all around dry us‐
satelettronica
ing P600 - 800 sandpaper.
AG. Volkswagen AG d
agen
Note Volksw
oes
not
by gu
d ara
ise nte
♦ To dry the area, a soft sanding pad made
uthor
of foam should be eo
used. ss a ra
c
ce
e
♦ Ensure that the edges on the cover are sanded all around.
nl
pt
du
an
itte
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♦ Avoid sanding through.
erm
ab
ility
ot p
wit
If material is sanded through and a hole is formed, it should be
, is n
h re
filled with 2-pack elastic additive - LKF 696 009 A2- , white, primed
hole
and rubbed down, if necessary, with P 800 sandpaper.

spec
es, in part or in w
t to the co
Note
rrectness of i
Observe the handling instructions on the packaging and in the

technical bulletins ⇒ General information, commercial vehicle
l purpos
paintwork .
nform
ercia
Position of cover when painting and drying

m
at
om
ion
c
in t
r
Note
o
his
ate
do
priv
When painting and drying, the installation position of the cover

um
for
should be observed. Failure to do this may result in the cover

en
ng
t.
yi
being deformed.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Applying base coat

– Apply base coat according to specifications in ⇒ General in‐
formation, commercial vehicle paintwork .
Note
Ensure that paint is applied from the outside including the edge
area up to the masking tape or masked off area on the inside.
Mixing clear coat

– After base coat has dried, mix 2-pack HS clear coat with ap‐
prox. 10% 2-pack elastic additive - ALZ 011 001- .
satelettronica
AG. Volkswagen AG d
agen oes
lksw not
Apply clear coat d by Vo gu
ara
rise nte
– Apply 2-pack HS clear coat with 2-pack elastic uadditive
tho - ALZ eo
ra
011 001- . ss a c
ce
e
nl
pt
du
an
itte
y li
Note
erm
ab
ility
ot p
♦ If 2-pack elastic additive is used, the drying times are extended
wit
, is n
accordingly.
h re
hole
spec
♦ Observe the handling instructions on the packaging and in the
es, in part or in w
technical bulletins ⇒ General information, commercial vehicle
t to the co
paintwork .
rrectness of i
Position of cover after drying
l purpos
Note
nf
ercia
or
After drying, it is imperative for the cover to be in the installation

m
m
atio
position until it is installed.

om
n in
or c
thi
te
sd
a
7.4 Paint repair old front roof reinforcement

iv
o
r
rp
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o
m
f
en
ng
t.
yi Co
WARNING Cop py
t. rig
gh ht
pyri by
Observe the notes on occupational health and safety in the
co Vo
by lksw
cted agen
paintwork manual. Prote AG.


Preparation for paintwork structure
Note
♦ Before commencing work, the front roof reinforcement is to be

washed and cleaned thoroughly with warm water, including
the storage area.
♦ Residue from grit/salt, road dirt or other environmental influ‐
ences cannot be removed using silicone remover alone.
– Clean old part of front roof reinforcement using water-based

silicone remover .
satelettronica
– Rub down existing paintwork structure in area of bonding sur‐
face on old part of front roof reinforcement approx. according
to dimension -a- dry using P120 with an orbital sander and
dust extractor.
♦ Dimension -a- = approx. 5 cm
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
46
cted agen
Prote AG.
Rep. gr.00 - Technical data
Applying filler/surfacer
– Apply 2-pack pro basic filler to cut edges and sanded areas of
old part of front roof reinforcement.
Note
Refer to technical data sheet for 2-pack pro basic filler ⇒ General
paintwork information, commercial vehicles .
satelettronica
lkswage es n
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byV ua
d ran
ir se tee
tho
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ce
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un
pt
an
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itte
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ab
pe
ility
Filler drying
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
Note utho eo
ra
s a c
s
ce
♦ Forced drying is indispensable. le
un
pt
an
d
itte
♦ The time and parameters to be set depend on the IR radiator
y li
erm
ab
being used and should be gleaned from the technical data of
ility
ot p
the IR radiator.
wit
is n
h re
ole,
spec
t to the co
Sanding down base filler/surfacer
rrectne
– After drying 2-pack pro basic filler in area of bonding surface,
rub down lightly with P240 - 280 sandpaper.
ss o
cial p
f inform
Note
mer
atio
om
n
Avoid sanding through.
c
satelettronica
or
n thi
te
sd
iva
o
pr
cum
r
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en
ng
t.
yi Co
Cop py
t. rig
gh ht
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Additional paint repair instructions p by
co Vo
by lksw
cted agen
Prote AG.
Note
♦ When painting in the storage area of the pop-up roof on the

front roof reinforcement, the bonding surface for the cover
must first be masked off.
♦ Layering paint in the area of the bonding surface is not per‐
missible.

7.5 Painting of contrasting shade for front

roof reinforcement
Note
♦ The following description can also be applied in essence for

the »Cover«.
♦ The following painting procedure for contrasting shade applies
for pre-painted new parts and must be adhered to without fail.
♦ The area not to be painted with contrasting shade must be
spaciously masked to protect it against paint mist and soiling.
Masking area of contrasting shade
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
– Clean front roof reinforcement with water-based silicone re‐

for
en
g
mover .
n
t.
yi Co
Cop py
– Position and fix template -1- on front roof reinforcement.
t. rig
gh ht
pyri by
Vo
o
– Pull off lower backing step by step and uniformly apply tem‐
c by lksw
cted agen
plate -1- on front roof reinforcement.
Prote AG.

– Check template -1- for uniform seating on front roof reinforce‐

ment and correct if necessary.
– Pull protective film off template -1-.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
– Mask the area to be treated with commercially available con‐

h re
ole,
tour tape -1- exactly along the line determined by the template
spec
-2-.
t to the co
Dry-sanding area of contrasting shade

rrectne
Note
ss
♦ It is essential to ensure that the adhesive tape -2- is not applied on the contour tape -3-.
o
cial p
f in
♦ When applying the adhesive tape -2- make sure not to leave open any spaces.
form
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e nte
horis
eo Transporter 2016 ➤
ut
ss a Vehicle-specific paint
ra
c information - Edition 11.2018
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
op
satelettronica
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Mask off area for contrasting shade -1- with contour tape -3-,
commercially available covering material and adhesive tape
-2-.
– Manually dry-sand area for contrasting shade -1- with
P600-800 sandpaper or using emery cloth (red).
Note
– Thoroughly clean area for contrasting shade -1- with water-

based silicone remover .
Painting area of contrasting shade
Coating is performed with:

1 - Contrasting shade
❑ 2-pack HS top coat ,
»L-041«
❑ 2-pack clear coat
Note
♦ Observe further information on

2-pack HS top coat : ⇒ General
information, Paint for commer‐
cial vehicles; Rep. gr. 00 ; Orig‐
inal products; Top coats .
♦ Observe further information on
2-pack clear coat : ⇒ General in‐
formation, Paint for commercial
vehicles; Rep. gr. 00 ; Original
products; Clear coats .
♦ Before drying carefully tear off
contour tape to avoid a further
development of the masking
edges.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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o
m
f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

7.6 Paint repair in storage area of pop-up roof at front roof reinforcement
Storage area, pop-up roof, overview
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
satelettronica
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
o Vo
WARNING by c lksw
cted agen
Prote AG.
Please observe the notes on occupational health and safety in

the paintwork guide!
We refer to the usage of workplace - VAS 6673- with mobile
exhaust extraction system - VAS 6572/2- for chip removing
work on aluminium body parts!

Transporter 2016 ➤ n AG. Volkswagen AG do
lkswage es n
Vehicle-specific paint information - Edition 11.2018 d byV
o ot g
ua
ran
ir se tee
tho
u or
a ac
ss
Note
ce
le
un
pt
an
d
itte
♦ These repair instructions provide supplementary information
y li
rm
ab
to the familiar workshop manuals, in particular for the storage
pe
ility
area of the pop-up roof on the front roof reinforcement.
ot
wit
, is n
h re
♦ However, warranty claims or transfer of costs to the manufac‐
hole
spec
turer cannot be derived.
es, in part or in w
t to the co
♦ It is not necessary to remove the pop-up roof.
♦ Depending on the location and extent of damage, partial spot
or clever repair measures or complete coating of the entire
rrectness of i
system area might be possible.
l purpos
♦ If this damage is repaired when mounting the plastic roof spoil‐
er, this paintwork repair is to be done prior to mounting the
nform
ercia
spoiler.
m
a
com
ti
Possible damage to front roof reinforcement
on in
r
te o
thi
Corrosion damage to the front roof reinforcement often arises in
s
iva
the vicinity of edges.
do
r
rp
satelettronica
um
fo
♦ -1- Upper edge, transition/contact surface between front roof
en
ng
t.
yi
reinforcement and pop-up roof
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Sand the damaged spot with a coarse grit (P180-P230) and

an orbital sander with a 5 - 10 mm stroke.
– Sand transitions in the damaged area with a finer grit (P320)
and, if required, the same orbital sander.
– Apply 2-pack pro basic filler according to the processing guide‐

lines of the manufacturer beyond the sanding spots on the
existing paintwork structure.
Note
– Lightly sand 2-pack pro basic filler with P320 grain sandpaper
after drying.
Note

– Apply 2-pack HS performance surfacer in accordance with ⇒

General information, commercial vehicle paintwork .
. Volkswage n AG n AG d
wage oe
– After finish sanding (P800)y Vuniformly
olks cover the filler coated
s no
t gu
area with ready to useisbase
ed b paint (Minijet or spray can). ara
n r tee
ho
aut or
ac
ss
Note
ce
le
un
pt
an
d
itte
y li
Proceed with great care to avoid sanding through during finish
erm
ab
sanding.
ility
ot p
wit
is n
h re
– Extend the area of application of each subsequent coat
ole,
through a process of overlapping so that only a fade-out area
spec
remains.
t to the co
– Extend the fade out area and blend in, spraying with reduced
pressure.
rrectne
– Apply prepared clear coat to the repair spot (1 or 2 spray ap‐
plications with Minijet or spray can depending on surface
s
area).
s o
cial p
f i
– In case of a spot or clever repair measure, afterwards purely
nform
satelettronica
apply blender - LVE 013 100 - on the touch-up area within the
mer
atio
sanded surface.
om
n
c
i
or
n thi
te
sd
a
Note
iv
o
pr
cum
r
fo
en
ng
After drying with the IR radiator and a subsequent flash-off time

t.
yi Co
of one day at approx. 20 °C, a paint protection film must be applied Cop py
t. rig
for protecting the storage area of the pop-up roof. opyri
gh by
Vo
ht
c by lksw
cted agen
– Apply paint protection film for roof reinforcement at front ⇒ Prote AG.
General body repairs, California; Rep. gr. 75 ; Roof reinforce‐

ment; Renewing pain protection film for roof reinforcement at
front .
Before
After

7.7 Paint repair side arms - front roof reinforcement

Overview of corrosion damage
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
satelettronica
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
WARNING
co Vo
by lksw
cted agen
Prote AG.


lkswage es n
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Note ir se
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tee
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to the familiar workshop manuals, in particular for the powder-
nl
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coated body parts in the roof area (front roof reinforcement).
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ility
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es, in part or in w
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♦ Clean damaged area with water-based silicone remover be‐
rrectness of i
fore masking off.
l purpos
♦ Ensure that paint damage on the roof side member is kept as

minimal as possible.
nform
mercia
at
– Sand down damaged area by hand to below the edge with
om
ion
sandpaper (P180-P240).
c
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or
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ate
do
priv
cum
for
en
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t.
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Cop py
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Prote AG.
– Mask off damaged area again.

– Sand down damaged area by hand to below the edge with
abrasive fleece.
– Clean damaged area with water-based silicone remover .
– Take anti-corrosion measures with 2-pack pro basic filler up

to area below edge, applying with brush -1-.
Note

– Apply 2-pack pro basic filler beyond sanded areas onto exist‐
ing paintwork structure.
Note
– Lightly sand 2-pack pro basic filler by hand with P320 grain
sandpaper after drying.
AG. Volkswagen AG d
agen oes
lksw not
Note by
Vo gu
ara
ed
ris nte
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Proceed with great careautto avoid sanding through!
h
ra
c
ss
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un
pt
an
d
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rm
ab
pe
ility
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h re
hole
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– Then apply 2-pack HS performance surfacer in accordance
es, in part or in w
with ⇒ General information, commercial vehicle paintwork .

t to the co
– After drying and intermediate sanding of the 2-pack HS per‐
formance surfacer , coat the damaged area with base coat -
rrectness of i
RAL 9006- = white aluminium and afterwards with matt 2-pack

clear coat according to the ⇒ General information, commercial
l purpos
vehicle paintwork .
nform
ercia
Note
m
a
com
tion in
Proceed with great care to avoid sanding through during inter‐

r
te o
thi
mediate sanding.
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Sealing side arms

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op
– Once the paint has dried, clean both side arms across the C py
t. rig
whole length. gh ht
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by c lksw
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– Mask off side arms with masking tape and commercially avail‐
Prote AG.
able adhesive tape.

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tho
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– Lightly sand down exposed area with fine abrasive fleece.
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– Clean bonding surface with cleaning solution - D.291.091.A1- .
itte
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rrectness of i
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– Then apply 2-pack MS adhesive - D.172.500.M2- .
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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t.
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Cop py
t. rig
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pyri by
Vo
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by
cted agen
Prote AG.

– Smooth down 2-pack MS adhesive - D.172.500.M2- .

– Check joint is even and fill in any gaps with 2-pack MS adhe‐
sive - D.172.500.M2- if necessary.
AG. Volkswagen AG d
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nl
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– Carefully pull off masking tape.
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nf
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7.8 Painting instructions, roof reinforcement
rm
m
atio
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at front
o
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or c
thi
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General problems
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♦ In individual cases, the PUR cover may have a different shape
o
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when supplied in its primed state. This is evident by it having

t.
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no curve. Cop py
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♦ During the painting process, it can also become distorted. p by
co Vo
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♦ In both cases, stress-free installation on the front RCBR mod‐ Prote AG.
ule can no longer be assured.
Problems in delivered state
♦ In its delivered state, the shape of the cover does not match
the shape of the body.
♦ The unfinished cover has a more flat form in its delivered state
and is missing its curve.
Damage scenarios
Cover -1- blocks outer, front areas when fitted on old RCBR.

Cover -1- blocks outer, rear areas when fitted on old RCBR -2-.
Cause
♦ Storage problems in priming process encountered by supplier.
satelettronica
Testing cover
– Hold cover -1- in upright position against an even vertical sur‐
face -2-.
– Using depth gauge , measure cavity between surface -2- and
front edge of cover
olks-1-.
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Minimum dimension
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♦ Minimum
ss
au dimension -a- = 35.2 mm ra
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Measure if test is not passed

nl
pt
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In the event of a complaint, the cover is returned to the manufac‐

erm
ab
turer through the replacement part warranty.

ility
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Fill in form »Primed cover complaint« and send it to

h re
»nsc.technik@volkswagen.de« with the reference »RCBR cover

hole
spec
not OK«.
es, in part or in w
t to the co
Measure if test is passed

Paint cover if test was successful ⇒ page 42 .
rrectness of i
Problems during painting process

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Cause:
♦ The cover’s shape changes during painting due to tempera‐
nf
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ture and storage

orm
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atio
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Measures:
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♦ Paint cover -1- in situ

thi
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♦ Store cover -1- during drying phase in situ

o
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♦ Check cover after paintwork has dried ⇒ page 61

t.
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Cop py
♦ Cover may be installed if test is passed
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7.9 Paint repair rear roof reinforcement

nform
mercia
at
om
DANGER!
ion
c
in t
or
his
e
♦ The front roof reinforcement as well as the pop-up roof are

at
do
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made of aluminium alloy.

p
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♦ When processing and sanding aluminium surfaces, there

ng
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is a risk of explosion due to electrostatic discharge. Please Cop py
always observe the guidelines on “Working with explosive
ht. rig
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♦ For this reason, aluminium surfaces may only be pro‐
AG.
cessed with pneumatic tools, sanding media and extrac‐

tion units specially dedicated and approved for this
purpose.
♦ Separate workspaces for working with aluminium are not
only recommended for safety reasons but also improve
the processing results, as contact corrosion is prevented.
Contact corrosion occurs, if the same tools are used for
processing both steel and aluminium parts. The surface
underneath the paintwork starts to corrode resulting in re‐
work or even in customer complaints.
♦ All this, however, can be prevented in an efficient manner
by using a separate workspace with tools specially desig‐
nated for being used only within this workspace.

Vehicle-specific spaint
wage information - Edition
k es 11.2018 not
Vol gu
d by ara
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ris
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nl
pt
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spec
es, in part or in w
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rrectness of i
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Prote AG.
WARNING

Note

coated body parts in the roof area (rear roof reinforcement).

– If required, remove rear water drain grommet ⇒ General body

repairs, California; Rep. gr. 75 ; Roof reinforcement; Remov‐
ing and installing water drain grommet .
– Sand transitions in the damaged area with a finer grit (P120 -
P240) and, if required, the same orbital sander.
ing paintwork structure/powder coating.
Note
satelettronica
– Lightly sand 2-pack pro basic filler by hand with P320 grain
sandpaper after drying.
AG. Volkswagen AG d
agen oes
lksw not
Note d byV
o gu
ara
ise nte
or eo
h
s aut ra
c
s
ce
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nl
pt
du
an
itte
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ab
ility
ot p
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, is n
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spec

es, in part or in w
with ⇒ General information, commercial vehicle paintwork .

t to the co

rrectness of i

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vehicle paintwork .
nform
ercia
Note
m
at
om
ion
c

in t
or
mediate sanding.
his
ate
do
priv
cum
or
– If applicable, install rear water drain grommet after 2-pack

f
en
ng
t.
clear coat has dried ⇒ General body repairs, California; Rep.
yi Co
op py
gr. 75 ; Roof reinforcement; Removing and installing rear wa‐ . C rig
ht ht
ter drain grommet .
rig by
copy Vo
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Prote AG.

AG. Volkswagen AG d
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s aut
Vehicle-specific paint ra
c information - Edition 11.2018
s
ce
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un
pt
an
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8 Paintwork repairs, pop-up roof, Cali‐
itte
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rm
ab
pe fornia
ility
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⇒ “8.1 Damage scenarios”, page 65
h re
hole
spec
⇒ “8.2 Paint repairs under and outside roof frame seal”,
es, in part or in w
page 66
t to the co
⇒ “8.3 Paintwork repairs to inner corner reinforcement”,
page 73
rrectness of i
8.1 Damage scenarios
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nform
ercia
Note
m
a
com
ti
When detected at an early stage and if the customer has made a
on in
complaint, the affected parts can be repaired. A respective per‐
r
te o
thi
mission to repair must always be obtained.
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t.
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op
satelettronica
C py
t. rig
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pyri by
Vo
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Prote AG.
Corrosion damage to the pop-up roof also often arises in the vi‐
cinity of edges, starting beneath the circumferential seal of the
pop-up roof.
8. Paintwork repairs, pop-up roof, California 65

lkswage es n
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♦ -1- Edge area beneath circumferential seal d byV ua
ran
ir se tee
♦ -2- Rear edge area, above circumferential seal autho
or
ac
ss
8.2 Paint repairs under and outside roof
ce
e
nl
pt
du
frame seal
an
itte
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erm
ab
Overview of corrosion damage ⇒ page 66
ility
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Paint repairs to corrosion damage under roof frame seal
h re
hole
⇒ page 67
spec
es, in part or in w
Paint repairs to corrosion damage outside roof frame seal
t to the co
⇒ page 69
rrectness of i
WARNING l purpos
Please observe the notes on occupational health and safety in

the paintwork guide!
nform
ercia

m
at
om
ion
c
in t
or
satelettronica
his
e

at
do
riv

p
cum
for
en
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t.
yi Co
Cop py
t. rig
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yri
Note
p by
co Vo
by lksw
cted agen
Prote AG.
to the known workshop manuals in particular for the outer shell
of the pop-up roof.
♦ Depending on the location and extent of damage, different
spot or clever repair measures are possible and given priority.

satelettronica
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o ot g
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tho
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un
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is n
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spec
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rrectne
Paint repairs to corrosion damage under roof frame seal
ss o
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Note
form
mer
atio
m
♦ Corrosion on roof edge in the area of the plug-in flange of the

o
n
c
circumferential seal -1- is the most frequent scope of damage

i
or
n thi
on the pop-up roof and is not visible for the customer.

te
sd
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pr

um
r
fo
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ng
t.
♦ Before removing the seal, the position at which the masking
yi Co
op
tape is to be placed on the upper edge of the seal must be
C py
t. rig
gh
marked with a commercially available felt-tipped pen.
ht
pyri by
Vo
co lksw
by
cted
♦ It is recommended to cover the edge area with masking tape
agen
Prote AG.
so that sanding over the visible area is avoided.
♦ If the masking tape gets damaged by accidentally sanding
over it, new masking tape needs to be attached before apply‐
ing the 2-pack pro basic filler .

– Mark position of masking tape before removing the seal -1- at

upper edge using commercially available overhead pen.
– Pull off circumferential seal -1-.
– Clean sealing flange with water-based
en AG. V
olkswsilicone
agen AG remover .
wag does
olks not
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– Affix masking tape -1- along marking.
h re
ole,
spec
– Sand and smooth off minor corrosion damage covered by the
seal with grit (P180).
t to the co
– Remove masking tape -1-.
rrectne
satelettronica
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
– Affix new masking tape -2- at same marking.

te
sd
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o
r
– Affix commercially available adhesive tape -3- over masking

p
cum
r
fo
tape -2-.
en
ng
t.
yi Co
op
– Restore corrosion protection with 2-pack pro basic filler (brush
C py
t. rig
gh
application -1-).
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
– After applying 2-pack pro basic filler -1-, remove masking tape
and commercially available adhesive tape.
– Install roof frame seal ⇒ General body repairs, California; Rep.
gr. 75 ; Pop-up roof; Removing and installing roof frame seal .

Paint repairs to corrosion damage outside roof frame seal
Note
♦ Corrosion on roof edge in the area of the plug-in flange of the

circumferential seal is occasionally visible for the customer at
the roof areas.
♦ It is necessary to remove the pop-up roof.
♦ If major corrosion damage occurs on the pop-up roof, depend‐
ing on the extent of damage either a spot or clever repair
measure or circumferential painting is necessary in compli‐
ance with the subsequent work steps.
lkswage es n
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byV ua
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Corrosion damage tho to the seal edge often arises in the vicinity
tee of
or
the roof frame au seal. ac
ss
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♦ -1- seal edge of front roof frame seal, transition from roof frame
un
pt
seal to roof shell
an
d
itte
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erm
ab
satelettronica
ility
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rrectne
Paint repair with partial spot repair and clever repair
– Clean the surface you are going to work on thoroughly using
ss
a non-fluffing cloth and cleaning agent.

o
cial p
f inform
– Polish damaged spot and transition areas for removing the

mer
paint exposed to weathering using ROTEX R0 90 and grinding

atio
m
paste MPA 5000.

o
n
c
i
or
n thi
– Clean surface afterwards.

te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
– Sand the damaged spot using a suitable abrasive - initially cted agen
Prote AG.
coarsely (P120/P180), then fine (P280).
– Then clean the sanded area of sanding residues using a non-
fluffing cloth and cleaning agent.

Note
– Once 2-pack pro basic filler has dried, sand down area to be
filled with P400 sandpaper.
Note
– Use the fine grinding disk Platin S1000 and S2000 to sand the
spot to be filled in order to achieve a good paint adhesion and
an optimum transition from new paint to existing paint.
satelettronica
lkswage es n
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byV ua
d ran
ir se tee
tho
u or
a ac
ss ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
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spec
es, in part or in w
t to the co
rrectness of i
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nf
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orm
m
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or c
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


– After finish sanding (P800) uniformly cover the filler coated
area with ready to use base paint (Minijet or spray can).
Note
Proceed with great care to avoid sanding through during finish

sanding.
– Extend the area of application

swage of. Veach
n AG subsequent
olkswagen AG
does coat
through a processbyofVooverlapping so that only a fade-out
lk not
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– Extend thes aufade out area and blend in, spraying with reduced
ra
c
pressure.s
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un
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– Apply prepared clear coat to the repair spot (1 or 2 spray ap‐
an
d
itte
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plications with Minijet or spray can depending on surface
erm
ab
area).
ility
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– In case of a spot or clever repair measure, afterwards purely
h re
satelettronica
ole,
apply blender - LVE 013 100 - on the touch-up area within the
spec
sanded surface.
t to the co
Note
rrectne
♦ After drying according to the manufacturer's instructions and
a brief cooling phase, the spraying zone can be polished in ss
ROTEX mode (no heat generation, no hologram formation) for
o
cial p
achieving the final gloss level.

inform
mer
♦ Afterwards, clean the surface thoroughly using a non-fluffing

atio
m
cloth and cleaning agent.

o
n
c
i
or
♦ In compliance with the above work steps, a spot or clever re‐

thi
te
sd
a
pair measure can be performed.

iv
o
pr
cum
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fo
♦ If the pop-up roof shows several visible damaged spots, cir‐

en
ng
t.
cumferential painting of the roof edge area might be neces‐
yi Co
op
sary.
C py
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♦ Please observe the notes on the damage documentation
cop Vo
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when doing so.
cted agen
Prote AG.
Before

After
Circumferential painting of roof edge

– Sand the damaged spot with a coarse grain sandpaper (P180
- P320) and an orbital sander with a 5 - 10 mm stroke.
– Afterwards sand the transitions in the damaged area with a
fine grit (P240) and an orbital sander with a 5 - 10 mm stroke.
satelettronica
Note
Refer to technical data sheet for 2-pack pro basic filler ⇒ General wagen AG. Volkswagen AG doe
paintwork information, commercial vehicles . yV
olks s no
t gu
b ara
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oris
– Lightly sand 2-pack pro basic filler with P240-grain sandpaper
au
th e or
ac
after drying. ss ce
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nl
pt
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Note
erm
ab
ility
ot p

wit
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spec
es, in part or in w
t to the co

rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
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Vo
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by
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AG. Volkswagen AG d Transporter 2016 ➤
agen
olksw Vehicle-specific
oes
paint
not information - Edition 11.2018
yV gu
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– After drying and intermediate
ut
ho sanding of the 2-pack HS per‐ eo
formance surfacer coverss athe damaged area with top coat. ra
c
ce
e
nl
pt
du
an
itte
Note
y li
erm
ab
ility
Proceed with great care to avoid sanding through during inter‐ ot p
wit
, is n
mediate sanding.
h re
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t to the co
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l purpos
Note
nf
ercia
o
After furnace drying of the paint (according to the paint manufac‐
rm
m
turer's guidelines), dry the roof edge area all round with an IR
atio
m
radiator -1-.
o
n in
or c
thi
te
sd
a
– Install roof frame seal ⇒ General body repairs, California; Rep.

iv
satelettronica
o
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rp
cu
gr. 75 ; Pop-up roof; Removing and installing roof frame seal .
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
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Prote
8.3 Paintwork repairs to inner corner reinforcement
AG.
Overview of paint damage

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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au ra
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e
nl
pt
du
an
itte
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erm
ab
ility
ot p
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, is n
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spec
es, in part or in w
t to the co
WARNING
rrectness of i

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nform
ercia

m
at
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ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Paintwork repairs
Note

coated edge reinforcements on the pop-up roof.
♦ Depending on the location and extent of damage, different
spot or clever repair measures are possible and given priority.

satelettronica
ing paintwork structure/powder coating. AG. Volkswagen A
agen G do
es n
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y Vol ot g
ua
b
ed ran
Note oris tee
th or
s au ac
Refer to technical data sheet for 2-pack
s
pro basic filler ⇒ General
ce
e
nl

pt
du
an
itte
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erm
ab
– Manually sand 2-pack pro basic filler with P320-grain sand‐

ility
ot p
paper after drying.

wit
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spec
Note
es, in part or in w
t to the co

rrectness of i
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with ⇒ General paintwork information, commercial vehicles .
nf
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or

m
m
atio

om
n in

or c
vehicle paintwork .
thi
te
sd
iva
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Note
t.
yi Co
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mediate sanding.
o Vo
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Prote AG.

9 Contrasting colours
⇒ “9.1 Contrasting colours, Transporter Caravelle”, page 76
⇒ “9.2 Contrasting colours, Transporter Multivan”, page 78
⇒ “9.3 Contrasting colours, Transporter California”, page 84
9.1 Contrasting colours, Transporter Cara‐

velle
⇒ “9.1.1 Contrasting colours, Trendline”, page 76
⇒ “9.1.2 Contrasting colours, Comfortline/Highline”, page 77
9.1.1 Contrasting colours, Trendline
1 - Mirror cover
❑ Left and right
❑ Unpainted
❑ As an option: painted in
satelettronica
standard colour
2 - Door handles
❑ Unpainted
standard colour
3 - Bumper
❑ Front
❑ Unpainted
standard colour
4 - Bumper AG. Volkswagen AG d
agen oes
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❑ Rear d by V gu
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❑ Unpainted uthor eo
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❑ As an option: painted in ss c
standard colour
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9.1.2 Contrasting colours, Comfortline/Highline
1 - Entire vehicle
❑ Standard colour
2 - B-pillar trim
❑ Left and right
❑ Only for equipment ver‐
sion Highline
❑ Colour: L-041 black uni
+ 2 x clear coat and pol‐
ished
3 - Radiator grille
ished
4 - Mirrors
❑ Left and right
satelettronica
sion Highline
ished
AG. Volkswagen AG d
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9. Contrasting colours 77
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9.2 Contrasting colours, Transporter Multi‐
du
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⇒ “9.2.1 Contrasting colours, Freestyle”, page 78 ot p
wit
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hole
⇒ “9.2.2 Contrasting colours, Generation SIX”, page 79
spec
es, in part or in w
⇒ “9.2.3 Contrasting colours, Edition”, page 80
t to the co
⇒ “9.2.4 Contrasting colours, 70 Years of Bulli”, page 81
⇒ “9.2.5 Contrasting colours, PanAmericana”, page 82
rrectness of i
⇒ “9.2.6 Contrasting colours, Comfortline, Family”, page 83
l purpos
9.2.1 Contrasting colours, Freestyle
nf
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m
atio
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1 - Entire vehicle
o
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❑ Basic model Trendline
thi
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❑ Colour: L-A5F Sum‐

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2 - B-pillar trim
Co
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❑ Colour: L-041 black,
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3 - Rear lid handle

❑ Colour: L-A5F Sum‐
merblue

9.2.2 Contrasting colours, Generation SIX
1 - Entire vehicle
❑ Paintwork, top
❑ Basic model Trendline,
Comfortline, Highline
❑ Base coat colour: L-B9A
Candy white
❑ Base coat colour: L-
A7W Reflex Silver, only
in combination with sec‐
ondary colour L-R5T
Acapulco Blue
2 - Entire vehicle
❑ Paintwork, bottom
❑ Secondary colour: L- n AG. Volkswagen AG do
lkswage es n
H3T Cherry Red byV
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❑ Secondary colour: L- ir se tee
ho
R7H Indium Grey aut or
ac
satelettronica
ss
❑ Secondary colour: L-
ce
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nl
pt
H6Z Bamboo Garden
du
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Green
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T5U Starlight Blue
wit
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spec
H1X Mojave Beige
es, in part or in w
t to the co
R5T Acapulco Blue only
in combination with
base coat colour: L-
rrectness of i
A7W Reflex Silver
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3 - B-pillar trim
❑ Left and right
nform
ercia

m
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at
om
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c
in t
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+ 2 x clear coat and polished

his
ate
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4 - Radiator grille
p
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for
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❑ Colour: L-041 black uni + 2 x clear coat and polished

n
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9.2.3 Contrasting colours, Edition
du
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1 - Entire vehicle
wit
, is n
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❑ Basic model Comfort‐
hole
line
spec
es, in part or in w
t to the co
Paintwork:
❑ Solid paint colour: L-
B9A Candy White
rrectness of i
l purpos
H3T Cherry Red

❑ Metallic paint colour: L-
nform
ercia
H1X Mojave Beige

m
at
om
A7W Reflex Silver
ion
c
in t
r

o
his
te
R7H Indium Grey

a
do
priv
c
um
for
en
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H6Z Bamboo Garden

n
t.
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Green op
satelettronica
C py
t. rig
gh
ht
pyri by
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R5T Acapulco Blue
co lksw
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❑ Pearlescent paint col‐
AG.
our: L-0K1 Oryx White

2 - Roof
ished
3 - B-pillar trim
❑ Left and right
ished
4 - Mirror cover
❑ Left and right
❑ Top
❑ Colour: L-C9X Deep Black Pearlescent
5 - Radiator grille

9.2.4 Contrasting colours, 70 Years of Bulli
1 - Entire vehicle
❑ Paintwork, top wage
es n
lks
❑ Base coat colour:d by V L-B9A
o ot g
ua
Candy white
o
ir se
ran
te
h eo
ut ra
2 - Entire vehicle
ss
a c
ce
le
un
pt
an
d
itte
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erm
R1X Curcuma Yellow
ab
ility
Metallic
ot p
wit
is n
3 - B-pillar trim
h re
ole,
spec
❑ Left and right
t to the co
ished
rrectne
4 - Mirror cover
❑ Left and right
satelettronica
ss o
❑ Bottom
cial p
f in
❑ Chromed
form
mer
atio
5 - Radiator grille
om
n
c
❑ Colour: L-041 black uni i

or
n thi
e

t
sd
va
ished
i
o
pr
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9.2.5 Contrasting colours, PanAmericana
1 - Entire vehicle
❑ Standard colour
2 - Bumper
❑ Rear
❑ Structure finish
❑ Colour: L-MI1 Nucleus
Grey
3 - Bumper
❑ Front
❑ Structure finish in lower
front area
❑ Colour: L-MI1 Nucleus
Grey
satelettronica
AG. Volkswagen AG d
agen oes
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spec
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9.2.6 Contrasting colours, Comfortline, Family
1 - Entire vehicle
❑ Standard colour
2 - B-pillar trim
❑ Left and right AG. Volkswagen AG d
agen oes
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❑ Only for equipment ver‐ by Vol not
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d
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9.3 Contrasting colours, Transporter Cali‐

fornia
⇒ “9.3.1 Contrasting colours, Beach/Coast”, page 84 n AG. Volkswagen AG do
lkswage es n
⇒ “9.3.2 Contrasting colours, Ocean”, page 85 d byV
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⇒ “9.3.3 Contrasting colours, Edition”, page 86 utho
or
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ss
⇒ “9.3.4 Secondary colour finish Beach/Coast/Ocean”,
ce
le
page 87
un
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9.3.1 Contrasting colours, Beach/Coast
rm
ab
pe
ility
ot
wit
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1 - Entire vehicle
hole
spec
❑ Standard colour
es, in part or in w
t to the co
❑ Exclusive finish colour:
L-L1S Grape Yellow
rrectness of i
l purpos
satelettronica
nform
mercia
a
com
tion in
r
te o
thi
s
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cum
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9.3.2 Contrasting colours, Ocean
1 - Entire vehicle
❑ Standard colour
2 - Radiator grille
ished
AG. Volkswagen AG d
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ility
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rrectness of i
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at
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c
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or
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ate
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9.3.3 Contrasting colours, Edition
1 - Entire vehicle
Paintwork:
B9A Candy White
H3T Cherry Red
L1S Grape Yellow AG. Volkswagen AG d
(Beach only) agen oes
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❑ Metallic paint colour: L- ed b ara
nte
is
A7W Reflex Silver hor eo
aut ra
❑ Metallic paint colour: L- ss c
R7H Indium Grey
ce
le
un
pt
an
d
❑ Pearlescent paint col‐

itte
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our: L-0K1 Oryx White
erm
ab
ility
ot p
2 - Roof
wit
is n
satelettronica
h re
ole,
spec
ished
t to the co
3 - B-pillar trim
❑ Left and right
rrectne
s
ished
s o
cial p
f in
4 - Mirror cover
form
mer
❑ Left and right
atio
m
❑ Top
o
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c
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or
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❑ Colour: L-C9X Deep
te
sd
a
Black Pearlescent
iv
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5 - Radiator grille
en
ng
t.
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❑ Colour: L-041 black uni Cop py
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py
ished co Vo
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Prote AG.

9.3.4 Secondary colour finish Beach/Coast/Ocean
1 - Entire vehicle
❑ Paintwork, top
❑ Base coat colour: L-B9A
Candy white
❑ Base coat colour: L-
A7W Reflex Silver, only
in combination with sec‐
ondary colour L-R5T
Acapulco Blue
2 - Entire vehicle
H3T Cherry Red (Ocean
Red)
H1X Mojave Beige
satelettronica
H6Z Bamboo Garden
Green
T5U Starlight Bluewagen AG. Volkswagen AG doe
(Ocean Blue)y Volks s no
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❑ Secondary ori colour: L-
se nte
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ut
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d
R5T Acapulco Blue only

itte
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in combination with
erm
ab
ility
base coat colour: L-

ot p
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A7W Reflex Silver

is n
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ole,
3 - B-pillar trim
spec
❑ Left and right

t to the co

sion Ocean
rrectne

+ 2 x clear coat and polished
ss
4 - Radiator grille
o
cial p
f i
❑ Only for equipment version Ocean

nform
mer

atio
om
n
c
i
or
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te
sd
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o
pr
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r
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en
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Cop py
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Vo
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by
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Prote AG.

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Vehicle-specific paint information

Service Department. Technical Information

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Copyright © 2018 Volkswagen AG, Wolfsburg D4B8063E4C6

6.1 Cavity sealing, body - overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

6.2 Cavity sealing, doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

7.4 Paint repair old front roof reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

7.8 Painting instructions, roof reinforcement at front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

7.9 Paint repair rear roof reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

8.1 Damage scenarios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

⇒ “1.1 Sanding”, page 1

Avoid sanding through to substrate

1.2 Seam sealing

Fine seam sealing

20 mm wide and 2 mm high.

– Sealant in the marked areas must be smoothed following ap‐

Sealing the folded seam groove

2 Rep. gr.00 - Technical data

1.3 Cavity sealing

2 Areas exposed to stone chipping

♦ The marked areas are exposed to stone chipping.

4 Rep. gr.00 - Technical data

2. Areas exposed to stone chipping 5

3.1 Masking areas, front body

♦ The subsequent descriptions should be adapted accordingly

Masking areas, engine compartment

A - Threads free of surfacer

6 Rep. gr.00 - Technical data

A - Contact surfaces free of wagen AG. Volkswagen AG doe

3.2 Masking areas, rear body

Masking areas, underbody (panel van / Kombi)

A - Contact surfaces free of

Masking areas, underbody (double and single cabin)

8 Rep. gr.00 - Technical data

A - Contact surfaces free of

4.1 Seam seals, front body

♦ When performing repair work, the seam sealing should be re‐

Seam seals, engine compartment

- Coarse seam sealing

- Coarse seam sealing

12 Rep. gr.00 - Technical data

- Coarse seam sealing

❑ Sealant in the marked

areas must be smooth‐

areas must be brushed

When smoothing or brushing the sealant seam, ensure that the

4.2 Seam seals, centre body

♦ To avoid damage or faulty operation, brush seam seals

smooth near parts which must be attached.

as all other studs and contact surfaces for assembly must be

model and version.

14 Rep. gr.00 - Technical data

- Coarse seam sealing

4.2.2 Seam seals, middle body, B-pillar

- Fine seam sealing

When smoothing or brushing the sealant seam, ensure that the

Seam seals, right B-pillar

16 Rep. gr.00 - Technical data

areas must be smooth‐

4.2.3 Seam seals, middle body, sliding door area

- Fine seam sealing