501-36 Pintura – informações gerais

501-36-1 Paint - General Information 501-36-1 . SECTION 501-36 Paint - General Information VEHICLE APPLICATION: 2011.50 Ranger CONTENTS DESCRIPTION AND OPERATION Description and Usage of Paint Literature.......................................................................... Symbols.............................................................................................................................. General............................................................................................................................... Hazardous materials designations..................................................................................... Instructions on measures to be taken for personal protection............................................ Icons................................................................................................................................... Health and Safety Precautions........................................................................................... General instructions for the paint shop and handling paint materials................................. Personal protection............................................................................................................. Environmental Regulations................................................................................................. Waste disposal in the repair paint shop.............................................................................. The new VOC (Volatile Organic Compounds) solvent regulation ...................................... Factory Paint Application.................................................................................................... General fundamentals of paint technology......................................................................... Painting process and corrosion protection......................................................................... The structure of an original paint finish .............................................................................. Colored fillers applied in production................................................................................... Paintwork Defects and Damage......................................................................................... Diagnosis and Damage Assessment.................................................................................. Paint damage guide............................................................................................................ Paint damage caused by environmental factors................................................................ Mechanical damage........................................................................................................... Damage due to corrosion................................................................................................... Damage caused by faults in treatment............................................................................... Tools and Equipment for Paint Repairs.............................................................................. General work equipment.................................................................................................... Filler and spray guns.......................................................................................................... Hand and machine sanding tools....................................................................................... Polishing and finishing tools............................................................................................... Infrared drying technology.................................................................................................. Air dryers............................................................................................................................ Paint mixing system............................................................................................................ Painting cabin..................................................................................................................... Refinishing Materials.......................................................................................................... Stopper materials............................................................................................................... Primers............................................................................................................................... HS primer filler and HS tinted filler..................................................................................... Paint................................................................................................................................... Additional Materials............................................................................................................ Adhesive sealants.............................................................................................................. Underbody protection......................................................................................................... Paint additives ................................................................................................................... Additive materials............................................................................................................... Paint Repairs...................................................................................................................... PAGE 501-36-3 501-36-4 501-36-4 501-36-4 501-36-6 501-36-6 501-36-9 501-36-9 501-36-9 501-36-11 501-36-11 501-36-11 501-36-12 501-36-12 501-36-12 501-36-13 501-36-13 501-36-14 501-36-14 501-36-14 501-36-14 501-36-18 501-36-18 501-36-18 501-36-28 501-36-28 501-36-28 501-36-30 501-36-33 501-36-33 501-36-33 501-36-34 501-36-34 501-36-35 501-36-35 501-36-36 501-36-37 501-36-37 501-36-39 501-36-39 501-36-39 501-36-40 501-36-42 501-36-43

501-36-2 Paint - General Information 501-36-2 . General information............................................................................................................ Pre-treatment of the surface .............................................................................................. Top coat application............................................................................................................ Repair stages for repair painting........................................................................................ Polish.................................................................................................................................. Aids..................................................................................................................................... Painting Plastic Parts.......................................................................................................... General............................................................................................................................... Plastic groups..................................................................................................................... Painting new components.................................................................................................. Unknown primer................................................................................................................. Paint faults on plastic substrates........................................................................................ Spot Repairs....................................................................................................................... General............................................................................................................................... Repair process................................................................................................................... Dirt inclusions..................................................................................................................... Corrosion Prevention.......................................................................................................... General............................................................................................................................... Operations after painting.................................................................................................... Definition of the degree of rust........................................................................................... Color Identification and Chromatics.................................................................................... Basic color theory............................................................................................................... Metallic and pearl pigments................................................................................................ Color codes and their determination on Ford vehicles ...................................................... Matching tinted filler to the color code ............................................................................... Tips and Tricks.................................................................................................................... Comparing paint structures................................................................................................ Etching substrate................................................................................................................ Masking the vehicle............................................................................................................ Color shade problems........................................................................................................ Isopropanol and water........................................................................................................ Temperature reduction spray.............................................................................................. Paint plane.......................................................................................................................... Shading.............................................................................................................................. Sanding marks.................................................................................................................... Improving touch-up work.................................................................................................... 501-36-43 501-36-43 501-36-45 501-36-46 501-36-47 501-36-48 501-36-49 501-36-49 501-36-49 501-36-50 501-36-50 501-36-51 501-36-52 501-36-52 501-36-53 501-36-54 501-36-56 501-36-56 501-36-56 501-36-56 501-36-58 501-36-58 501-36-59 501-36-60 501-36-63 501-36-64 501-36-64 501-36-64 501-36-64 501-36-66 501-36-66 501-36-66 501-36-66 501-36-66 501-36-67 501-36-67

501-36-3 Paint - General Information 501-36-3 DESCRIPTION AND OPERATION Description and Usage of Paint Literature Vehicle paints are subject to severe demands caused by external influences. Moisture, air-borne deposits in the form of various chemicals and UV light constantly affect a paint surface. Furthermore, mechanical damage occurs through grit, stones and sand. Bird droppings, insect residues, pollen and tree sap also attack the paint surface. The present literature not only informs the specialist about current repair painting techniques, but also provides tips and instructions on modern and economical repair processes. High quality bodywork paints require the use of the most modern technologies and regular updating of the technician's knowledge of painting techniques, because of the constantly new developments in paint technology. Information about different materials is listed under Specification. Furthermore, information on the fundamental principles of repair painting and paint materials is provided in several chapters. The safety instructions indicate the possible health hazards and other sources of danger. There are also notes about tools and materials as well as on basic painting methods. In the model specific repair instructions, only the most important repair steps or special features are referred to. Detailed information on the generally applicable painting procedures is given in this paint manual. Direct supply of repair paints by Ford has been discontinued. There is however an agreement with many paint manufacturers, which ensures fast and problem-free supply to the dealer undertakings. Paint suppliers: ‡ 'X3RQW ‡ Glasurit ‡ 33* ‡ Sikkens ‡ Spies Hecker ‡ Standox When using painting materials, it should be taken into account that the manufacturers have exactly matched their products between each other. In order to avoid quality defects, difficulties in working and losses in corrosion protection, these may not be substituted with other products. NOTE: The Ford Service Organization organizes basic and more in-depth training on much of the content of this paint manual. As well as the practical part of the training, a further component is the Student Information document, which offers supplementary information in the form of a brochure. During all work it must always be ensured that personal safety and the operational capability of the vehicle are not threatened by the choice of methods, tools and components. The information given in the diagrams in the chapter "Paint Damage" is provided by the repair paint manufacturer.

501-36-4 Paint - General Information 501-36-4 DESCRIPTION AND OPERATION Symbols General Various symbols, signs, instructions and illustrations are used in this literature. Warnings and cautions have different meanings and require different ways of proceeding. Diagrammatic representations are provided with instructional signs for improved clarity. These are briefly explained below: WARNING: This caption is used when failure to follow instructions exactly or failure to follow them at all may result in a hazard to persons or in persons being injured. CAUTION: This caption is used when incorrectly following the test procedures or instructions or failure to follow them at all could lead to damage to the vehicle or components. NOTE: This caption is used when attention needs to be drawn to special or extra information. When reading this handbook, you will come across the points WARNING, CAUTION AND NOTE. These instructions are always given immediately before the corresponding job steps. Hazardous materials designations Many accidents occur because of ignorance. In the area of personal health protection, it is particularly important to clearly emphasize sources of danger and their effects on human organs. Only with knowledge of hazardous material designations can it be certain that the necessary precautions are taken when handling substances which are harmful to health. NOTE: Pay attention to the manufacturer's data on the containers and given in the Safety Data Sheet.

501-36-5 Paint - General Information 501-36-5 DESCRIPTION AND OPERATION Hazardous material symbols TO BE UPDATED LATER Item Description 1 Very poisonous, T+ (extremely toxic), small quantities can be fatal. 2 Poisonous, T (toxic), causes serious damage to health 3 Corrosive, C (corrosive), destroys living tissue. 4 Harmful to health, Xn (noxious). Item Description 5 Irritant, Xi (irritant), can cause inflammation. 6 Explosive 7 Highly flammable, F+ (extremely flammable), already flammable at temperatures below 0° C.

501-36-6 Paint - General Information 501-36-6 DESCRIPTION AND OPERATION Item Description 8 Flammable, F (flammable), forms a flammable mixture with air. Oxidizing, O (oxidizing), reacts with combustible substances. As well as the danger symbols, there is more comprehensive manufacturer's information to be found on the containers and in the Safety Data Sheets, and you must pay attention to this information. Instructions on measures to be taken for personal protection. As well as the information about sources of danger, there are mandatory instructions which draw your attention to the personal protection measures to be taken. Mandatory symbol TO BE UPDATED LATER Item Description 1 Breathing protection must be worn 2 Eye protection must be worn 3 Ear protection must be worn Item Description 4 Protective gloves must be worn 5 Protective footwear must be worn Icons So that the necessary information for optimal handling is clear, unambiguous and can be quickly understood, the leading paint manufacturers have agreed a standard symbolic language. Language independent representations in the form of icons provide handling instructions which are supplemented with quantity or time information. Pretreatment TO BE UPDATED LATER Item Description 1 Clean 2 Sand

501-36-7 Paint - General Information 501-36-7 DESCRIPTION AND OPERATION Mix TO BE UPDATED LATER Item Description 1 2 component mixture 2 3 component mixture 3 Use a measuring rod 4 Addition of hardener 5 Addition of additives Process TO BE UPDATED LATER Item Description 1 Flow-beaker spray gun 2 Suction-beaker spray gun 3 Spray passes 4 Filler 5 Coat 6 Underbody protection spray gun

501-36-8 Paint - General Information 501-36-8 DESCRIPTION AND OPERATION Dry TO BE UPDATED LATER Item Description 1 Ventilate 2 Drying time 3 Drying time with infra-red dryer Further processing TO BE UPDATED LATER Item Description 1 Hand abrade (wet) 2 Hand abrade (dry) 3 Eccentric sander (wet) Item Description 4 Eccentric sander (dry) 5 Oscillating sander (wet) 6 Oscillating sander (dry) Store TO BE UPDATED LATER Item Description 1 Protect from moisture 2 Store in a frost-free environment 3 Store in a cool place 4 Close the container Other TO BE UPDATED LATER Item Description 1 Stir by hand 2 Stir using a mixing machine 3 Polish 4 Roll

501-36- Paint - General Information 501-36- DESCRIPTION AND OPERATION Health and Safety Precautions General instructions for the paint shop and handling paint materials Hazardous areas in repair paint shops: ‡ Danger from fires, explosions and hot surfaces. ‡ Dangers to health and safety from the effects of harmful substances because of their absorption through the skin and/or inhalation. ‡ Dangers caused by electricity, compressed air, power tools and noise. WARNING: During painting work there is an increased danger of fire or explosion. Prevent any sparks being created. Fire, naked lights and smoking are forbidden. Measures: ‡ Wear protective footwear made from anti-static material. ‡ Only use tools made of wood, brass or copper to clean stands and extraction ducts. Do not use tools made of steel. Only fill or decant paint materials in a specially marked area. As well as these general instructions on the dangers in repair paint shops, all national and international regulations must be observed: ‡ Health and Safety at Work Act ‡ Ordinance on Hazardous Substances ‡ Technical Rules for Hazardous Substances ‡ Regulations for the Prevention of Industrial Accidents ‡ EU Directive on Hazardous Substances, 98/24/EU ‡ EU Directive on Noise, 2003/10/EU ‡ EU Directive on Volatile Organic Compounds (VOC), 1999/13/EU, 2001/81/EU, 2004/42/EU ‡ Safety instructions of equipment and tool manufacturers Personal protection Besides the body and limbs, several organs vital to life are in very particular danger. Because damage is mostly irreparable, special attention and comprehensive protection are necessary. WARNING: Solvents cause damage to the health through inhalation. Splashes in the eyes or on the skin can cause bodily harm. When working with solvents, always use suitable means of protection. E59518 Item Description 1 Protective hood with fresh air supply 2 Protective clothing 3 Protective gloves 4 Protective footwear Breathing protection During painting work and in the preparations for painting, gases, vapors, mists or dusts can appear in dangerous concentrations in the areas where fellow employees breath. For short periods of work or minimal concentrations of hazardous substances, breathing protection devices with a combination filter are suitable as breathing protection equipment.

501-36-10 Paint - General Information 501-36-10 DESCRIPTION AND OPERATION E59517 Item Description 1 Activated charcoal filter 2 Coarse filter For higher concentrations of harmful substances, breathing protection devices which are independent of the local atmosphere are suitable. In these types of isolation systems, a compressed air hose carries natural air from the compressor line into the protective mask. During supply, the air undergoes pressure reduction, water removal, fine filtration and usually warming to natural breath temperature. WARNING: Vapor or spray mist containing isocyanate as a paint base or hardener can cause toxic respiratory disease (conditions similar to asthma) leading to permanent damage, even when inhaled in the lowest concentrations. Filter masks with wadding, sponge or colloid filters and also paper masks are all unsuitable for working with coating materials because they do not stop solvent vapors. The instructions for use provided by the manufacturer must be observed when working with breathing protection equipment. Skin protection Spray painters who are subject to considerable exposure to coating materials must wear suitable protective work clothing (flame-proof and anti-static). NOTE: Also, when working with water based materials, comprehensive skin protection must be worn, because these materials are very easily absorbed through the skin. The protective clothing must be changed at the proper intervals. Items of clothing which are contaminated with coating materials can easily catch fire. When selecting protective clothing, it must be taken into account that cloth containing a high proportion of easily melted plastic thread considerably increases the degree of burns injury (melted plastic on the skin!). This must also be taken into account in the choice of underwear. For areas of skin which are not covered by protective clothing, suitable skin protection, skin cleaning and skin care agents must be used. Eye protection Working with portable hand sanding machines on which the tools move unguarded, at speed and with power is fundamentally dangerous. Goggles must be worn not only when sanding, but also when working with paints and their additives. These contain substances which are harmful to the eyes. Damage ranging from irritation of the cornea to incurable illnesses are possible. The protective goggles must be inert toward splashes of solvent, and fully enclose the areas at the side of the eyes on both sides. The best protection during spray painting is offered by full mask respirators or helmet respirators with a built-in visor. Ear protection Noise disturbance in repair paint shops caused by various sources is particularly high. Sanding and compressed air machines, paint cabin extractor fans (compressors) and extractor ducts in the work rooms are the causes of the high levels of noise. WARNING: Avoid damage to your hearing! Wear ear protection. Suitable ear protection is offered by ear plugs or ear defenders.

501-36-11 Paint - General Information 501-36-11 DESCRIPTION AND OPERATION Environmental Regulations Waste disposal in the repair paint shop More than ever before, since the introduction of EU directives, rigorous attention is paid to the avoidance of waste materials and to recycling in repair paint shops. In this respect, repair paint shops must take into account and comply with the following requirements: ‡ Separate waste according to its recycling and disposal methods. ‡ Produce evidence for the correct transport and disposal of waste. NOTE: The organization of disposal in the plant must comply with the requirements of the Waste Avoidance and Management Act: The avoidance and recycling of waste must always take priority. However, despite all measures which may be taken, waste cannot be completely avoided. NOTE: Waste which is not allowed in household rubbish, and which can no longer be utilized, must be disposed of as special waste. Paint residues containing solvent, application residues, sanding dust, waste containing peroxides, solvents, soiled cleaning cloths and paint slurry all count as special waste. Each of these must be collected in a separate, sealed and suitably labeled metal container and properly disposed of using a specialist company. Careful separation allows some waste to be usefully re-used. ‡ Empty metal containers can be sent for scrap instead of being disposed of as waste. ‡ Contaminated cleaning thinners can be separated by distillation. ‡ Packing material and masking paper can be added to the recycled paper collection. Residues which cannot be used must be correctly disposed of. All remaining waste must be treated as commercial waste and disposed of according to the local regulations. The new VOC (Volatile Organic Compounds) solvent regulation Keeping the air clean protects the environment and the population from the heath-damaging effects of air pollutants. In certain atmospheric conditions, volatile organic compounds contribute to summer smog. NOTE: For comprehensive information, please refer to the European VOC Directive, 1999/13/EU. Furthermore, the effective national regulations must be complied with. The European VOC (Volatile Organic Compounds) Directive has controlled the limits for such compounds since August 2001. It applies to production coating companies and those which undertake repair painting of private and commercial vehicles. Not least because of the VOC legislation, modern, low solvent and solvent-free lacquers and paints are finding greatly increased distribution across industry and the trade. Up to the year 2007, emissions from painting work will drop by at least 40%. At the same time, the paint manufacturers guarantee for example that they will produce a ready-to-spray product consisting of base paint + hardener + thinners, with a permitted VOC level. A company in business today can conform with the stipulated requirements by introducing water-based paints and using the other necessary products from the relevant paint manufacturers. For more detailed information, please refer to the EU VOC Directive.

501-36-12 Paint - General Information 501-36-12 DESCRIPTION AND OPERATION Factory Paint Application General fundamentals of paint technology Paint is a pigment-containing liquid which undergoes chemical and/or physical processes after it has been applied to a surface, so changing into a solid film covering. Repair paint consists of binder, pigments, filler and solvent. NOTE: Organic solvent is being replaced by solvent based on water. Constituents of paint ‡ Binder œ Mostly semi-fluid resins which bind together the other components of the paint when it dries. œ Makes the paint durable. œ Ensures good surface coverage. ‡ Pigments œ Fine, colored powders, which give color to the paint. œ Cover the components below (covering power). ‡ Additives œ Additives give the paint special properties. œ e.g. flow improver, softener, drying accelerator, thickener. ‡ Solvent œ Thins the paint and allows it to flow more freely. œ Evaporates during drying. Painting process and corrosion protection. In production, painting consists of individual steps which are optimally matched to each other. Bodywork consists almost entirely of steel panels which have been pre-coated with zinc. The zinc layer is between 5-10 µm thick and acts as the first corrosion protection layer of the steel panel. Production sequence: ‡ Clean and de-grease œ In the first step, the bare bodywork is initially dipped in a cleaning bath and cleaned with a degreasing solution. ‡ Phosphatising œ The cleaned bodywork is dipped in a bath containing various phosphate salt solutions. This creates a crystalline metal-phosphate layer which offers the optimal prepared surface and also corrosion protection. ‡ CDP base œ The cataphoretic dip paint (CDP) base acts as a further corrosion protection layer. œ In this process the bodywork is completely immersed in a bath consisting of a paint and electrolyte solution. œ By application of an electric voltage, an electric field is created. œ Positively charged paint particles settle on the negatively charged bodywork and form a protective layer up to 20 µm thick. œ Next the bodywork is placed in a dryer, where the CDP base is hardened at 180°C. ‡ Sealing, stone-chip protection œ Edges, seams and but joints are sealer with a sealing compound. œ Vulnerable areas are coated with stone-chip protection. ‡ Filler œ Filler protects the body panels from stone impacts. Furthermore, any unevenness of the metal surface is flattened out, in order to create the most homogenous and fault-free undersurface possible. œ Once the filler is dry, it serves as the base on which paint is applied. ‡ Top coat œ The top coat is applied as a single layer or two layers of paint. œ When working with two layer paint, in the first job step the initial colored base paint is applied. In the second job step, a clear lacquer is applied, giving the base paint shine and hardness.

501-36-13 Paint - General Information 501-36-13 DESCRIPTION AND OPERATION The structure of an original paint finish During construction of the original paint, a total surface thickness of between 120 and 130 µm is achieved. The thicknesses of the layers may vary however, because they are greater for horizontal surfaces than vertical ones. Paint layers TO BE UPDATED LATER Item Description 1 Steel panel 2 Phosphate layer 2.9 g/m×, corresponding to 2 µm. 3 Cathodic dip paint 30-35 µm 4 Filler 30-35 µm 5 Base paint 15-20 µm 6 Clear varnish 55 µm Colored fillers applied in production Filler which gives color is used in production. Its use makes the base paint and clear varnish unnecessary on certain vehicle interior surfaces (engine, doors). Not every exterior paint has its own matching filler. It is more that the tones of the filler are color compatible, i.e. they have similar intensity to the top coat. During repair painting the filler color tones must be used according to the manufacturer's instructions.

501-36-14 Paint - General Information 501-36-14 DESCRIPTION AND OPERATION Paintwork Defects and Damage Diagnosis and Damage Assessment Paint concerns, regardless of their causes, are part of the everyday work in the paint shop. Correct damage assessment and determination of the cause are preconditions for a professional resolution of a paint concern. Paint concerns can still occur through a variety of causes, despite improved paint materials and new spray methods. NOTE: A first appraisal of the paint damage should be done before cleaning. External factors such as rust, droppings, incorrect or insufficient paint care can then be more easily detected. Diagnosis is best done in daylight but not in direct sunlight. Exact evaluation can also be done under artificial light from special luminescent lamps. Paint damage guide The most important paint damage concerns which make a paint repair necessary are: ‡ Damage from biological paint contamination such as bird or insect droppings, tree resin and aphids. ‡ Chemical paint damage caused by industrial contaminants such as smoke, fuel, acids, oils. ‡ Mechanical damage caused by stone impact during operation, scratches in the car wash and parking. ‡ Damage caused by faults in treatment. Application defects such as paint runs or orange peel. ‡ Dirt inclusions in the paint layer, e.g. caused by dust in top coat or textile lint. ‡ Damage due to corrosion. Before repair of such paint concerns, exact diagnosis must be performed to determine the cause exactly. On the spot diagnoses using simple aids and processes are often enough. Diagnosis without disturbing the paint is done by: ‡ Optical inspection without visual aids, under suitable light conditions from a suitable angle and correct distance. ‡ Optical inspection with the help of a magnifying glass. ‡ pH paper. ‡ Measurement of the thickness using FE / NFE coating thickness meters for ferrous (FE) and non-ferrous metals and non-magnetic steel (NFE) - magnetic process on steel panels, eddy current process on non-metals. A test method where the traces of testing can be easily removed again is the finger nail test. With suitable experience the existing hardness of the paint can be determined. Test methods where the paint is partially destroyed are: ‡ Pencil hardness test. ‡ Adhesion test using adhesive tape. ‡ Lattice cut test process to check the strength of adhesion. Under certain circumstances these test methods are not enough for a certain diagnosis. In this case, paint diagnosis under laboratory conditions must be performed. Measuring and testing equipment for painted surfaces Coating thickness measuring devices Magnifying glass pH paper (together with water) Suitable photographic equipment with macro lens Shine measuring equipment Paint damage caused by environmental factors ‡ Bee droppings ‡ Bird droppings ‡ Insects ‡ Tree resin and sap ‡ Aphid secretions ‡ Tar spots ‡ Cement, plaster and slaked lime ‡ Rust film/deposits from industrial fallout ‡ Battery acid ‡ Brake fluid

501-36-15 Paint - General Information 501-36-15 DESCRIPTION AND OPERATION In all the cases of paint damage described below, if the damage is irreversible a new paint finish must be applied. Paint damage cause by bee droppings Bee droppings can be recognized on a paint surface through its yellow or brown color and sausage or drop-like shape with a diameter of 3-4 mm. Cause/damage pattern: ‡ In combination with heat and high air humidity, bee droppings leave discolorations and cause paint decomposition. ‡ The paint can be destroyed down to the filler. TO BE UPDATED LATER Repair of damage: ‡ If the damage is light, perform a polishing repair. Paint damage caused by bird droppings Bird dropping damage appears most often as matt, etched topcoat areas of various sizes. If left on the vehicle for a long time, crack formation and etching down to the filler will occur. Cause/damage pattern: ‡ Bird droppings are particularly harmful in combination with heat and moisture. The urea (white part) has a very high salt content and is very aggressive. ‡ The intensity of the damage varies depending on the type, quantity, contact time and extent. ‡ Cracks, etching, marks up to dissolution of the top coat are the results. TO BE UPDATED LATER Repair of damage: ‡ If the damage is light, perform a polishing repair. Paint damage caused by insects At insect impact locations on the hood, roof and bumper, small etched or etched through paint marks with partially visible spots of filler. Cause/damage pattern: ‡ The top coat layer is destroyed in a short time by surface swelling and etching. ‡ Colliding insects stick to the paint surface. In combination with moisture and heat, because of the resulting acids the insect bodies sink into the paint top coat. ‡ The corrosion is G, C, U or O shaped and is only a few millimeters thick. TO BE UPDATED LATER Repair of damage: ‡ Wash the vehicle, treat the affected area with insect remover. Clean the paint surface several times. ‡ Protect with hard wax.

501-36-16 Paint - General Information 501-36-16 DESCRIPTION AND OPERATION Paint damage caused by tree resin or sap Small yellow-brown marks or drops on the horizontal parts of the vehicle. The drops melt in sunlight. Resin damage only occurs in the warm summer months. Cause/damage pattern: ‡ Because of their chemical composition, tree resins combine with or adhere very well to paint top coats and cause them to swell. The higher the temperature, the more intensive is the chemical bonding between the resin and the paint topcoat surface. TO BE UPDATED LATER Repair of damage: ‡ Soak several times using a cloth saturated with a petrol & paraffin mixture. NOTE: After successful cleaning the top coat must be preserved. ‡ Swellings can be removed by warming. Paint damage from aphid secretions Small, round, matt marks about 1 mm diameter and etching with small islands down to the filler. Fresh aphid excrement looks like small drops of honey. Cause/damage pattern: ‡ Aphids produce a mixture of starch, leaf acid and sugar from sap in leaves. Under the effects of warming and moisture this can turn into alcohol. ‡ The round shape of the damage and the island of intact paint are typical. TO BE UPDATED LATER Repair of damage: ‡ Remove the excrement as soon as possible. ‡ Small single matt locations without etching can be repaired using a polishing repair. Paint damage caused by tar spots Yellow or dark marks. Cause/damage pattern: ‡ Firmly stuck spots of tar which lead to discoloration of the surface. In some cases penetration through the clear lacquer into the top coat. TO BE UPDATED LATER Repair of damage: ‡ Clean the paint surface with tar remover and polish. Paint damage caused by cement, plaster and slaked lime Damage appears as whitish matt marks on the top coat. Cause/damage pattern: ‡ Corrosive alkaline compounds interacting with moisture.

501-36-17 Paint - General Information 501-36-17 DESCRIPTION AND OPERATION TO BE UPDATED LATER Repair of damage: ‡ Wash immediately if the contamination is fresh. ‡ If the contamination has dried on, dissolve and neutralise it with vinegar, then thoroughly wash off with water and rinse. ‡ Rectify mild damage using a polishing repair. Rust film/deposits from industrial fallout Small round marks, about 1 mm in size, in all shades from black, grey, blue to reddish, on the horizontal surfaces of the vehicle. Cause/damage pattern: ‡ Deposits from oil fired systems and industrial plant, especially at high humidities and inversion weather conditions, cause damage to the paint top coat. ‡ As the activity time increases so called rust halos form. They spread as long as the deposits corrode. ‡ Industrial fallout containing iron will no longer be removable after a few days! TO BE UPDATED LATER Repair of damage: ‡ Remove the dust using an industrial fallout remover and thoroughly wash. ‡ Polish the paint surface. NOTE: Never try to remove the particles of industrial fallout by polishing or rubbing! ‡ Use cleaning dough. Damage caused by battery acid. Splashes of battery acid caused by carelessly topping up the battery. WARNING: Batteries contain sulphuric acid. When working near the battery, or where there is battery acid on the vehicle body, protect the skin and eyes from contact with the acid. If battery acid contacts the skin or enters the eyes, flush the affected area immediately with water (flush for at least 15 minutes) and call a doctor without delay. If acid is swallowed, call a doctor immediately. Failure to follow these instructions may result in personal injury. NOTE: High temperatures accelerate the attack on the top coat. At 50°C the top coat layer breaks down after about 15 minutes! Cause/damage pattern: ‡ Etching of the paint layer to decomposition of the paint finish. TO BE UPDATED LATER Repair of damage: ‡ Flush the acid splashes with plenty of water and neutralize with car washing liquid. ‡ If the contact time of the acid was short, perform a polishing repair. Paint damage caused by brake fluid. Careless handling of brake fluid. The glycols contained in the fluid cause swellings.

501-36-18 Paint - General Information 501-36-18 DESCRIPTION AND OPERATION Cause/damage pattern: ‡ The temperature and contact time are critical. Splashes lead to loss of shine and lightening of color. TO BE UPDATED LATER Repair of damage: ‡ Flush immediately with plenty of water. ‡ The swellings can often be made to recede completely by treatment with the radiant heater or in the paint drying oven at max. 60°C for about 1 hour. Mechanical damage Stone impact damage or mechanical damage Mechanical damage caused by impact of stones or other hard objects and extending down to the metal panel lead very quickly to corrosion and rusting under the paint on the adjoining surface. Cause/damage pattern: ‡ Paint damage caused from the outside, down to filler, primer or metal panel. TO BE UPDATED LATER Repair of damage: ‡ Sand or blast out. ‡ Use anti-corrosion primer. ‡ Apply top coat. Damage due to corrosion Blistering/rusting below Air or water filled blister-shaped raised areas in the paint film. Cause/damage pattern: ‡ Overpainting corroded steel panel. ‡ Condensation in the spray air. ‡ Sanding water not dried out or salt crystal residues. ‡ Road chippings and road winter grit containing salt. E59486 Repair of damage: ‡ Sand the affected area of damage or the body component and re-create the paint finish. ‡ More severe and larger areas of rusting below must be repaired using the corresponding repair painting, Repair Level III or IV. Damage caused by faults in treatment ‡ Craters ‡ Paint boils ‡ Adhesion defects ‡ Adhesion defects - clear lacquer ‡ Sanding scores ‡ Formation of stripes ‡ Peeling/blistering on plastic parts ‡ Blistering on polyester material ‡ Peroxide marks in metallic paints

501-36-19 Paint - General Information 501-36-19 DESCRIPTION AND OPERATION ‡ Crack formation ‡ Shrinking back/zone edge marks ‡ Blistering ‡ Etching ‡ Paint wrinkles/puckering ‡ Cloud formation ‡ Spots/metallics ‡ Metamerism/color deviations ‡ Washing out ‡ Loss of gloss ‡ Covering ability/areas of thin paint ‡ Flow problems/orange peel ‡ Dirt embedded in metallic base paint ‡ Dirt embedded in top coat ‡ Water marks ‡ Paint runs ‡ Swirl marks Craters Crater-like single or extensively occurring depressions with raised edges, in top coat or the intermediate layers. Cause/damage pattern: ‡ Substrate not adequately cleaned with silicone remover. ‡ Spray air contaminated by oil residues and water accumulations. ‡ Filter ceiling not adequate for requirements. ‡ Use of polishes, cleaning agents or sprays (e.g. interior sprays) containing silicone. ‡ Oil, wax, grease, silicone containing residues. ‡ Working clothes contaminated by materials containing silicone. TO BE UPDATED LATER Repair of damage: ‡ Sand paint surface, clean with silicone remover and apply one thin spray pass. Let it begin to dry well, then apply several thin and dry sprayed passes. Paint boils Small, hard, closed or burst blisters in the paint top coat. They appear locally in groups or spread individually across the whole surface. Sanding opens up a larger cavity, under which the primer can often be seen. Cause/damage pattern: ‡ Paint applied in layers which were too thick. ‡ Specified flash-off and drying times between coats were not adhered to. ‡ Specified working viscosity and spray pressure were not adhered to. ‡ Use of unsuitable hardener and thinner materials. (Solvent combinations in paint system not optimally matched). ‡ Poor booth conditions. TO BE UPDATED LATER Repair of damage: ‡ Single boil blisters can be removed using polishing. ‡ After thorough drying, sand the top coat at the affected areas, clean with silicone remover and re-paint. Fill any fine pores still present with 2-component acrylic filler. ‡ On larger areas of damaged topcoat, sand completely away and apply new paint finish. Adhesion defects Whole coating detached from substrate or individual layers one from another. Sometimes

501-36-20 Paint - General Information 501-36-20 DESCRIPTION AND OPERATION adhesion defects can only be noticed after an external influence such as stone impact. Cause/damage pattern: ‡ Substrate not adequately prepared (rust, grease, moisture, sanding, cleaning). ‡ Unsuitable material used. ‡ Drying times, flash-off times too short. ‡ Base paint not sprayed wet-in-wet, instead the intermediate drying times were too long. ‡ Failure to intermediate sand. ‡ Condensation formed because of temperature fluctuations. ‡ Unprofessional preparation (especially on plastics). ‡ Overheated CDP/intermediate filler. TO BE UPDATED LATER Repair of damage: ‡ Sand out the damage and recreate the paint finish. Create the paint finish strictly in accordance with the general technical information. Adhesion defects in clear lacquer. Clear lacquer detched from base paint. Cause/damage pattern: ‡ Base paint layer too thick. ‡ Intermediate and final flash-off times of base paint too long. ‡ Incorrect mixture ratio clear lacquer/hardner. TO BE UPDATED LATER Repair of damage: ‡ Refinish sanding and recreate the paint finish. Sanding scores Single or wide area clusters of scoring or sanding marks, often with raised edges. Noticeable on metallic paints as light-dark stripes. Cause/damage pattern: ‡ Stopper sanded too coarsely. ‡ Filler sanded too coarsely. ‡ Filler not thoroughly dried bfore sanding. ‡ Old paint sanded too coarsely. ‡ Soft elastic substrates, e.g. TPA base, treated with thinners which was too aggressive and therefore etched. ‡ Top coat applied too thinly. TO BE UPDATED LATER Repair of damage: ‡ If the damage pattern is minimal, after the top coat has dried fine sand the paint surface and refurbish by polishing. ‡ If the damage is great or on metallic paints, sand the paint surface or substrates and if necessary remove them, then cover the bare metal and re-paint.

501-36-21 Paint - General Information 501-36-21 DESCRIPTION AND OPERATION Formation of stripes Differing, stripe shaped color/effect formations in dark/light areas of a metallic paint finish. Cause/damage pattern: ‡ Spray gun (nozzle) not perfect. ‡ Incorrect spray pressure. ‡ Thinners not suitable. ‡ Incorrect spray viscosity. ‡ Flash-off time too short. ‡ Unsuitable working temperature. TO BE UPDATED LATER Repair of damage: ‡ Apply base paint evenly. ‡ Repair spray gun. ‡ After clear lacquer has thoroughly dried, sand surface and paint again. Peeling/blistering on plastic parts Paint adhesion insufficient between top coat and filler and/or primer layer. It often happens that the whole of the paint finish detaches from the plastic. Cause/damage pattern: ‡ Plastic item not cleaned sufficiently, not or inadequately tempered. ‡ Unsuitable cleaning agent used. ‡ Unsuitable materials used. ‡ Moisture. ‡ Paint finish underbaked or overbaked. ‡ Poor or lack of intermediate sanding. TO BE UPDATED LATER Repair of damage: ‡ Sand away faulty paint coats and re-apply paint finish. ‡ In extreme cases use a new part. Blistering on polyester material Color shade differences or marks in paintwork subsequently applied to previously unpainted plastic material. Cause/damage pattern: ‡ Plastic material is not suitable for painting. ‡ Incorrect bonding agent. ‡ Paint used not solvent resistant. Repair of damage: ‡ Repaint using suitable materials. ‡ Install unpainted new part (after consulting customer). Peroxide marks in metallic paints After longer period of drying, abnormal marks where the color shade varies. Cause/damage pattern: ‡ Too much hardener added to polyester stopper (over 3% can cause this damage pattern). ‡ Polyester stopper not well enough mixed.

501-36-22 Paint - General Information 501-36-22 DESCRIPTION AND OPERATION TO BE UPDATED LATER Repair of damage: ‡ Sand, fill with polyester or epoxide filler and re-paint. Crack formation Cracks of different lengths and depths running in all directions. Cause/damage pattern: ‡ Layers too thick. ‡ Painted several times. ‡ Temperature fluctuations. ‡ Mechanical effects e.g. distortions. ‡ Substrate not thoroughly hardened. ‡ Old paint not completely dried out. ‡ No or insufficient hardener added. ‡ 2-component materials used on nitro or TPA. TO BE UPDATED LATER Repair of damage: ‡ Sand away layers until sound substrate is reached and create new paint finish (prime, fill, apply topcoat). Shrinking back/zone edge marks Lifting or dropping in of edge zones (edges which accentuate themselves in the top coat), flow problems and loss of shine in top coat. Cause/damage pattern: ‡ Old paintwork not rubbed down to a seamless transition. ‡ Stopper and filler on a viscoplastic base primer. ‡ Filler sanded and overpainted when not thoroughly hard. ‡ Previous materials overworked too early, substrate not sufficiently hardened. ‡ Primer applied in layers which were too thick, and not dried for long enough. ‡ Sanding paper too coarse. ‡ Top coat thinned too much. TO BE UPDATED LATER Repair of damage: ‡ After hardening off the top coat, fine sand the surface and polish up, apply filler if necessary and paint once more. Blistering Small, spot-like, air-filled or water-filled blister shaped high-spots in the paint construction. Their dimensions can range from pin-head to pin-point size in a closed paint film. Arrangement and accumulation very variable. In the advanced stages, circular flaking of the paint from the substrate. These are neither boils nor corrosion. Cause/damage pattern: ‡ Moisture absorption by substrate. ‡ Insufficient drying of the substrate after wet sanding (especially on polyester material). ‡ Humidity too high before painting; condensation formation because of temperature fluctuations. ‡ Pores/sink holes in substrate not sanded out.

501-36-23 Paint - General Information 501-36-23 DESCRIPTION AND OPERATION ‡ Polyester material not covered. ‡ Sweat from hands. ‡ Salts and minerals in sanding water. ‡ Spray air contaminated. TO BE UPDATED LATER Repair of damage: ‡ Sand away damage, matt sand remainder of surface, clean with silicone remover, fill and re-paint. Etching The base paint is etched by the clear lacquer. This causes the aluminum pigments to change their alignments. The color of the etched base paint seems more grey than that of normal base paint. Result is that the surface structure of the clear lacquer becomes increasingly more matt. Cause/damage pattern: ‡ Base painted too wet. ‡ No intermediate flash-off time. ‡ Layers too thick. TO BE UPDATED LATER Repair of damage: ‡ Sand and re-paint. Paint wrinkles/puckering Lifting/puckering of the paint surface. Cause/damage pattern: ‡ First paint not hardened through or can be etched. ‡ Areas of clear lacquer which were sanded through to base paint have not been not isolated with filler, or with unsuitable filler. ‡ Unsuitable substrate (e.g. spray can painting with TPA or nitro). ‡ Use of unsuitable primer, paint and thinner materials. ‡ Paint systems not matched to each other. ‡ In wet-in-wet process, specified flash-off times not adhered to. ‡ Synthetic resin top coat (alkyd resin) worked over too soon. TO BE UPDATED LATER Repair of damage: ‡ After thorough drying, completely remove the top coat together with the attacked substrate at the affected areas and re-create a new paint finish. ‡ Before applying top coat, rub down the complete surface. Cloud formation Differing, blotchy color/effect formations in dark/light areas of a metallic paint finish. Cause/damage pattern: ‡ Spray gun, spray nozzle, spray pressure not perfect. ‡ Varying spray viscosity, spraying method, flash-off times, spray booth temperature. ‡ Thinners not suitable.

501-36-24 Paint - General Information 501-36-24 DESCRIPTION AND OPERATION TO BE UPDATED LATER Repair of damage: ‡ Droplet method before clear lacquer application. ‡ After clear lacquer has thoroughly dried, sand surface and re-paint. Spots Points rising up from the paint film. Cause/damage pattern: ‡ Metallic base paint sprayed too dry, so that the metal particles could not incorporate into the paint. The clear lacquer could not cover these vertical standing particles because the spray air was too hot or the booth temperature was too high. TO BE UPDATED LATER Repair of damage: ‡ After the paint surface has dried, lightly sand it with grade P800 sanding paper, clean with silicone remover and re-apply clear lacquer. Metamerism/color deviations Noticeable when identical color shades undergo a change of hue as the light source changes (daylight/artificial light). Different pigment composition between original and repair paint. Cause/damage pattern: ‡ Use of paints with pigmentation which was not compatible with the standard, e.g. a green can be formulated from yellow and blue, or directly from green. ‡ Use of an unsuitable mixed or ready made paint to re-tone. TO BE UPDATED LATER Repair of damage: ‡ Repaint using the correct paint. Washing out On paint which has been newly applied but not yet dried, the interaction of surface tension and very different specific gravities of the different pigments can lead to swirl-like turbulence which results in separation of the pigments. Cause/damage pattern: ‡ Layer too thick, paint not stirred enough. TO BE UPDATED LATER Repair of damage: ‡ Sand and re-paint. Loss of gloss Milky, dreary tarnishing of the paint with more or less even loss of gloss.

501-36-25 Paint - General Information 501-36-25 DESCRIPTION AND OPERATION Cause/damage pattern: ‡ Cold with low air humidity. ‡ Heat with high air humidity. ‡ Substrate can be etched. ‡ Hardener fault or wrong hardener used. ‡ Paint thinned too much. ‡ Proportion of pigment too high because of poor stirring. ‡ Not optimum drying. TO BE UPDATED LATER Repair of damage: ‡ After drying, remove the matt effect by polishing. If unsuccessful, rub down complete area and paint again. Covering ability/areas of thin paint Different color shades in the surface. The minimum layer thickness is not achieved here. The effects range from local minor shade variations through mottled spray zones to completely missing top coat. Cause/damage pattern: ‡ No correct, uniform substrate (effect paint). ‡ On three-layer systems, wrong filler. ‡ Insufficient top coat application. TO BE UPDATED LATER Repair of damage: ‡ Sand surface and recreate the paint finish. Flow problems/orange peel Surface structure bumpy, grained. The surface is similar to the peel of an orange. Cause/damage pattern: ‡ Paint viscosity too high. ‡ Use of fast evaporating, highly volatile thinners. ‡ Booth temperature too high. ‡ Spray gun distance too great, too little material applied. ‡ Nozzle too large. ‡ Incorrect spray pressure. TO BE UPDATED LATER Repair of damage: ‡ Small surfaces: fine sand and polish. ‡ Sand out the surface and recreate the paint finish. Dirt embedded in metallic base paint. Inclusions of contamination in metallic base paint, of different sizes and shapes (grains or lint). Cause/damage pattern: ‡ Dust was not properly removed from the surface to be painted. ‡ Paint material not sieved. ‡ Function of the painting facilities not optimum. ‡ Filter contaminated. ‡ Wearing unsuitable clothing. Repair of damage: ‡ Sand and repaint.

501-36-26 Paint - General Information 501-36-26 DESCRIPTION AND OPERATION Dirt embedded in top coat Inclusions of contamination in top coat or under paint layers, of different sizes and shapes (grains or lint). Optical adverse effect. Cause/damage pattern: ‡ Dust was not properly removed from the surface to be painted. ‡ Paint material not sieved. ‡ Function of the painting facilities not optimum. ‡ Filter contaminated. ‡ Wearing unsuitable clothing. TO BE UPDATED LATER Repair of damage: ‡ Single inclusions: after thorough hardening, sand out using 1200 - 1500 grade paper and repolish using a suitable silicone-free sanding or painting paste. ‡ Large area contamination: sand and repaint. Water marks Ring shaped marks appearing on the paint surface. Cause/damage pattern: ‡ Evaporation of water droplets on freshly painted and not yet fully hardened paint finishes (mostly only found on horizontal surfaces). ‡ Layer too thick. ‡ Drying time too short. ‡ Hardening faults or hardener no longer useable. ‡ Use of unsuitable thinners. TO BE UPDATED LATER Repair of damage: ‡ Rub down only slight marks with sanding paper grade P1000 - P1200 and then polish. ‡ For heavy marking, sand the surface matt, clean with silicone remover and repaint. Paint runs Wave-like paint run tracks in top coat or in an intermediate layer on vertical surfaces. Mostly in the area of swage lines, seams or openings (there they are paint runs, otherwise curtains). Cause/damage pattern: ‡ Uneven paint application. ‡ The specified viscosity was not complied with. ‡ Use of unsuitable thinner materials. ‡ Air, material or room temperature too low. ‡ Layers too thick. ‡ Spray gun (nozzle) not perfect. TO BE UPDATED LATER Repair of damage: ‡ After thorough drying, sand unevenness flat, if necessary leave to dry afterwards. ‡ Small areas of damage can be equalised using the paint plane, then sand, polish or repaint.

501-36-27 Paint - General Information 501-36-27 DESCRIPTION AND OPERATION Swirl marks Three dimensional appearance in the paint surface in the form of smears or blotches. This effect is intensified in direct sunlight. Cause/damage pattern: ‡ Polishing using polishing machine on paint which has not yet hardened throughout. ‡ Polishing intervals too long or none at all. ‡ Pressure too high while polishing. ‡ Incorrect polishing material or polishing tool. TO BE UPDATED LATER Repair of damage: ‡ Allow the paint to harden completely and then polish. ‡ If the damage is irreversible, rub down and apply new clear lacquer.

501-36-28 Paint - General Information 501-36-28 DESCRIPTION AND OPERATION Tools and Equipment for Paint Repairs General work equipment In the repair paint shop there is a range of painting tools which make the work of the painter easier and improve the quality of the repair paintwork. Among these are small tools which are used for the following work: ‡ Measuring beakers to measure and mix various paint materials. ‡ Measuring rods with which the required combination amounts of paint and primer filler are gauged and mixed. ‡ Viscosity measuring beaker with a calibrated opening of 4mm, used to set the correct paint viscosity. ‡ Paint filter/paint sieve for filtering foreign bodies out of mixed paint or primer. Care must be taken that the correct filter is used for each paint. ‡ Color sample plates onto which the mixed paint is applied, and the shade is then compared to that of the vehicle. Other aids which should help the painter to find the correct shade are color sample cards and color panels, which are offered by many paint manufacturers. ‡ Dust bonding cloths which are impregnated with a tacky resin and which pick up dust particles particularly well. A surface to be painted must be cleaned with a dust binding cloth immediately before paint is applied. ‡ Compressed air guns are used to remove sanding residues and to dry sanded surfaces. Filler and spray guns NOTE: Regular maintenance, cleaning after use and careful handling of all individual parts of the spray gun are essential for a high-quality paint finish. The spray gun is the most important implement in the paint shop. Application of paint using the spray gun can produce a layer with absolutely constant thickness and a smooth paint surface. Principle of operation TO BE UPDATED LATER Item Description 1 Air supply 2 Paint supply 3 Nozzle needle Because of the construction design and with the aid of compressed air, a spray-ready paint mixture is dragged out of the container to the nozzle by the venturi effect, and is applied to the surface being worked. When the trigger of the spray gun is pressed to the first pressure point, only the compressed air passage opens. If the trigger is pressed further, the nozzle needle displaces and the air stream drags paint with it at high speed. This produces a spray mist consisting of micro-droplets of paint.

501-36-29 Paint - General Information 501-36-29 DESCRIPTION AND OPERATION Types of spray gun TO BE UPDATED LATER Item Description 1 Suction-beaker spray gun 2 Flow-beaker spray gun In the flow-beaker spray gun, the paint container is mounted above the spray gun. On the suction-beaker spray gun, it is below. Furthermore, spray guns are categorized by their air pressure requirement into high and low pressure guns. High pressure guns have the disadvantage that they exhibit high consumption of energy and materials. The spray pressure they require is between 1 - 6 bar. Because of the high air pressure and the large amount of air needed, the result is a powerful paint mist formation (paint transfer rate approx. 35%). Current practice is mainly to work with reduced mist spray systems (RP and HVLP systems). Reduced pressure (RP) guns are optimized high pressure guns which have an input pressure at the gun of approx. 2.5 bar and an atomization pressure at the air cap of 1 - 2 bar. In practice this spray technology is preferred for spraying clear lacquer because of the finer atomization. Low pressure guns have the advantage that they exhibit minimal paint mist formation and because of this the paint transfer rate rises to approx. 65%. The spray pressure required in this case is between 1 - 5 bar. Nozzle sizes from 1 - 2.2 mm can be used. HVLP spray guns TO BE UPDATED LATER Item Description 1 Quantity control 2 Working pressure control 3 Spray pattern control The high volume low pressure (HVLP) spray gun is a high performance spray gun which forms a soft, fine and homogenous spray pattern. The atomization pressure at the air cap is 0.7 bar when the input pressure at the gun is 2.0 bar. The low atomization pressure of 0.7 bar together with greatly reduced spray mist provide high material ejection. The low nozzle internal pressure minimizes rebound of the paint droplets from the object and thus the proportion of overspray. This spray technology has a very high application efficiency. By matching the size of the nozzle, the HVLP spray gun can be used for all repair painting materials. HVLP spray guns are often used in practice for the application of water based paints. Mini spray guns are often used for small, localized touching-up work. Use of HVLP spray technology and nozzle sizes of 0.3 - 1.2 mm permits very fine

501-36-30 Paint - General Information 501-36-30 DESCRIPTION AND OPERATION work, so that the area of the repair can be kept as small as possible. In order to ensure that a spray gun operates efficiently for a long time, careful cleaning is absolutely vital after use. NOTE: During cleaning you must distinguish between water based and solvent based materials. Cleaning by hand: ‡ Empty the paint beaker immediately after use. ‡ Flush the gun with cleaner. ‡ Clean it inside and outside with a brush. ‡ Dismantle the gun to clean it thoroughly. ‡ Clean the air cap using a suitable brush. ‡ Use nozzle cleaning needles to clean bores and nozzles. A spray gun washing machine is recommended if the painting work is highly intensive. New types of paint processing systems are replacing the conventional mixing beaker, filter and spray gun flow beaker. This reduces the amount of solvent required for cleaning and the amount of routine waste which remains. Paint preparation system (PPS) TO BE UPDATED LATER Item Description 1 Beaker 2 Color bag With this system, which is suitable for both suction and flow beaker spray guns, only one beaker is required for mixing and painting. A bag is inserted in the beaker, in which paint can be mixed, processed and stored after use or completely disposed of. The small quantity of paint remaining in the gun is removed using a minimum quantity of solvent from the pipette bottle. The amount of cleaner used is reduced because only the spray gun needs to be cleaned. Hand and machine sanding tools Sanding is used to prepare a surface for application of a paint layer, enabling it to adhere well. Sanding materials have a great influence on the quality of a repair paint finish. The correct sanding medium must therefore be chosen for every material.

501-36-31 Paint - General Information 501-36-31 DESCRIPTION AND OPERATION During sanding, material is mechanically removed from a surface. In the paint shop, carborundum or silicon carbide abrasive on a substrate of paper or cloth are the most common sanding materials used. Carborundum is a very hard mineral consisting mostly of aluminum oxide. During use carborundum becomes blunt and wears away. Application Working area Body work, corrosion Equalizing paint system damage transition Stopper Rough sand Fine sand Spray stopper Rough sand Fine sand Filler sanding work Filler fine sand Top coat Old paint Touch-up paint surfaces Paint damage Sanding out faults Soft Pads are recommended for manual refinishing of contours, curves and difficult to reach areas. On a Soft Pad the abrasive is found on a coarse structured fleece. Because of this, it is very flexible, does not kink and does not slip in the hand. This enables a fine and even finish to be achieved. Silicon carbide has a very high degree of hardness, but is more brittle than carborundum. When silicon carbide is used, the mineral grains break. New long and pointed profiles are formed. Use of the correct sanding paper depends on the application, the substrates and the tools used. The following table can be used as a guideline, but the recommendations of the supplier of the auxiliary materials and additive materials must be followed. Grade Sanding system to P150 Orbital sander, dry Hand sanding, dry P80 - P150 Orbital sander, dry P240 - P320 Orbital sander, dry Hand sanding, dry P120 - P180 Orbital sander, dry P240 - P320 Orbital sander, dry Hand sanding, dry P400 - P500 Orbital sander, dry P800 - P1200 Hand sand, wet P400 - P500 Orbital sand, dry P800 - P1200 Hand sand, wet P1000 - P2000 Hand sand, wet P2000 - P3000 Hand sand, wet Item Description 1 Extraction bores 2 Connection for extraction equipment Notes on working with sanding tools:

501-36-32 Paint - General Information 501-36-32 DESCRIPTION AND OPERATION ‡ Tools with a rigid backing pad do not adjust to fit the surface. They are used for flat surfaces. ‡ Tools with a flexible backing pad are used for fine sanding of a surface because they adjust to the shape of the surface. ‡ Build up an even working pressure over the sanding surface. ‡ Keep the sanding paper tight on the tool (use self-gripping systems). ‡ Align the extraction holes in the sanding paper with the holes in the tool. ‡ Guide the tool flat over the surface to be worked. Do not tilt it. Hand sanding can be carried out dry but also wet. Wet and dry paper with particle size P 80 to P 1200 is used for this in the paint field. Ways of sanding Sanding tools are driven either by electricity or compressed air. TO BE UPDATED LATER Item Description 1 Sanding machine 2 Polishing machine 3 Orbital sander The disadvantage of electrically driven machines is that their own weight is high compared with pneumatic systems. They also become warm during work. They do not however need any special operating equipment for their energy supply. Sanding machines are categorized by their type of sanding movement. Rotational sanders On these machines the sanding paper turns. ‡ Advantage: œ Ideal for heavy sanding work. œ Fast and aggressive sanding possible. ‡ Disadvantage: œ Large amount of heat developed. œ Difficulty sanding flat surfaces. ‡ Application: œ Removal of old paint layers. œ Preparation of panel for stopper. œ Removal of rust. Oscillating sander On these machines the sanding paper oscillates. The backing pad is rectangular. ‡ Advantage: œ Large sanding surface. œ Ideal for large and flat surfaces. ‡ Disadvantage: œ Hardly useable on rounded surfaces. œ Flexible backing pad not possible. œ Vibrations because of the poor support of the backing pad. ‡ Application: œ Sanding of polyester stopper. œ Sanding processes on flat surfaces. Orbital sander On these machines the sanding paper turns and oscillates. ‡ Advantage: œ Easy to handle and good sanding power. œ Minimal heat development. ‡ Disadvantage: œ Not suitable for sanding stopper on flat surfaces. œ Smooth guidance important, otherwise sanding marks will occur. ‡ Application: œ Sanding of paint layers. œ Well suited for final preparation of a primer. NOTE: Comply with the manufacturer's recommendations when setting the orbital sander.

501-36-33 Paint - General Information 501-36-33 DESCRIPTION AND OPERATION On the orbital sander, stroke settings of approx. 3 mm for fine sanding work and approx. 5 - 7 mm for coarse sanding work have been established. Polishing and finishing tools The term polishing in the context of paint repairs means the elimination of paint flaws and high shine polishing of neighboring parts. During polishing the fine sanded surface is returned to a high shine using a special abrasive polish. Before the actual polishing, all flaws in the paint surface must be removed and the following working procedures must be adhered to: ‡ Thoroughly clean the vehicle. ‡ Remove spray mist from all surfaces. ‡ Sand out and polish particle inclusions. ‡ Sand down paint runs and polish them out. ‡ Examine the exactness of the color match in daylight. ‡ Remove masking edges. ‡ Remove sanding water, sanding dust and polish residues. After the polishing process the results must be tested using a special test spray. Infrared drying technology The drying process in a painting/drying cabin occurs through heat conductance (convection). When an infrared dryer is used, the drying process is through heat radiation. TO BE UPDATED LATER The infrared rays penetrate the air and the paint layer without warming them. Because the infrared rays are reflected from the steel panel, the paint coat is warmed from the inside outwards. Advantages of infrared drying: ‡ The drying process occurs from the inside to the outside. ‡ The drying time is shorter than for warm air systems. ‡ Because the infrared dryer consists of several cassettes which can be switched on independently, the drying area can be optimally controlled. Independent of the manufacturer's instructions, pay attention to the following: ‡ Flash-off time of the paint before switching on the infrared dryer. ‡ Distance between the infrared dryer and the surface. ‡ Duration of the irradiation. The most common use of the infrared dryer is to dry stopper and primers. The wait time between the job steps is shortened without having to use the painting/drying cabin. The painting/drying cabin can then be used exclusively for application and drying of topcoat. There are two types of infrared dryer: ‡ Infrared dryer with short wavelength radiation. ‡ Infrared dryer with medium wavelength radiation. As an indication, the following drying times are listed for some materials (at 80 cm distance): NOTE: Observe the material manufacturer's and supplier's specifications. ‡ Polyester stopper 2 minutes. ‡ Spray stopper 2 to 7 minutes. ‡ Water based primer-filler 7 to 9 minutes. ‡ Primer 3 to 8 minutes. ‡ Top coat 7 to 10 minutes. $LU GU\HUV The air dryer is suitable in places where drying needs to be done, but without great outlay (painting/drying cabin or infrared dryer).

501-36-34 Paint - General Information 501-36-34 DESCRIPTION AND OPERATION TO BE UPDATED LATER NOTE: Air from the compressor is often too cold for effective drying. Air dryers use the venturi effect to blow the warm ambient air over the paint surface in a gentle air flow. Paint mixing system Because of the many different color variants, it is now seldom possible to store all color shades as ready-made mixtures. For this reason, vehicle manufacturers make the mixture proportions of their paints available as color codes. The required color shade can be obtained from the paint mixing system using this color code. All the color components are combined according to their proportions by weight using a precise computer scales to produce a finished color shade. Painting cabin The air requirement in a painting cabin is large. The outside air which is drawn in must be passed through filtering and warming equipment. This particularly applies during colder times of the year and especially for combined types of building where the painting cabin is also used as a drying cabin. It is primarily used to keep the air free of dust. At the same time, explosive solvent-air mixture concentrations are prevented NOTE: Vacuum will lead to contamination of the newly applied paint. The outside air flows through door gaps, wall joints and other openings and as it does so, brings dust deposits with it. The air supply quantity depends on the size of the painting space and the quantity of extracted air. Enough air must be supplied to cause positive pressure in the painting space. An air extraction : air supply ratio of about 1 : 1.05 is sufficient. The filters should have a dust-removal grade of not less than 99.8% and must always be kept clean. It is especially important that the air supply does not cause strong air currents in the painting cabin. If not, the following problems could occur: ‡ Paint contamination cause by paint mist, which persists in air eddies and gradually falls on the fresh paintwork. ‡ Flow problems in the paint because of the high speed of the air, causing the paint to thicken very quickly on the surface. ‡ Loss of gloss and wrinkle formation because the surface dries too fast. ‡ Painter disturbance while working. In modern paint cabins the air supply is provided from the complete surface of the ceiling. The air speed should be 0.3 m/sec (measured in the unrestricted cross-section of the spray cabin). At the same time, the air in the cabin should change about 350 times per hour. Air extraction is best achieved through extraction channels in the floor of the painting cabin. NOTE: Refer to the manufacturer's specifications for the operating instructions, safety instructions and notes on the maintenance of a paint cabin. Smooth walls in the paint cabin should prevent dust deposits. Regular cleaning is necessary however. Special easily washed adhesive-bonding paint can be applied to the walls to protect the cabin from paint mist.

501-36-35 Paint - General Information 501-36-35 DESCRIPTION AND OPERATION Refinishing Materials The manufacturer's instructions must always be followed when dealing with all materials! The information given in the following text is data which is independent of the manufacturer, and it should only be used as an indication. Stopper materials ‡ 1-component nitro-combination stopper ‡ 2-component polyester stopper ‡ 2-component plastic stopper Use suitable primer to protect from corrosion areas which have been sanded bare before applying stopper. 1-component nitro-combination stopper Nitro-combination stopper has mostly been superseded by 2-component polyester stopper. Fast drying fine stopper for the smoothing of irregularities. The working properties of 1-component nitro-combination stopper can be improved by the addition of nitro thinners. Drying time increases with thickness of the layer. Application 1-component nitro- combination stopper Layer thickness Max. 80 µm Drying time up to 2 hours at 20°C Sand P240 - P400 2-component polyester general stopper CAUTIONS: Do not exceed the quantity of hardener specified by the manufacturer, excess peroxide can cause staining of the paint top coat. Mix the stopper base and the hardener well to avoid a marble-like effect. Check that the manufacturer permits use on the substrate to which it will be applied. 2-component polyester stopper is available in coarse and fine grades. The coarse stopper can be used for very uneven areas and surfaces and fine stopper or spray stopper should be applied afterwards. Application 2-component polyester coarse stopper Use Rough equalization of unevenness Hardener quantity approx. 3 - 5% Working time approx. 4 - 6 minutes Drying 20°C approx. 12 minutes Short wavelength infrared approx. 4 minutes Medium wavelength infrared approx. 5 - 10 minutes Sanding tool Eccentric, sanding disk by hand Grade P80 - P150 Application 2-component polyester fine stopper Use Equalization of uneven- ness Hardener quantity approx. 3 - 5% Working time approx. 4 - 6 minutes Drying 20°C approx. 12 minutes Short wavelength infrared approx. 4 minutes Medium wavelength infrared approx. 5 - 10 minutes Sanding tool Eccentric, sanding disk by hand Grade P80 - P240 Application 2-component polyester glass fiber stopper Use Equalization of uneven- ness; blending in of vehicle extensions; repair of GRP components Hardener quantity approx. 3 - 5%

501-36-36 Paint - General Information 501-36-36 DESCRIPTION AND OPERATION Application 2-component polyester glass fiber stopper Working time approx. 4 - 6 minutes Drying 20°C approx. 12 minutes Short wavelength infrared approx. 4 minutes Medium wavelength infrared approx. 5 - 10 minutes Sanding tool Eccentric, sanding disk by hand Grade P80 - P150 2-component polyester fine stopper should always be applied after 2-component polyester glass fiber stopper. Application 2-component polyester spray stopper Use Equalization of uneven- ness Hardener quantity approx. 3 - 5% Working time approx. 25 - 30 minutes Layer thickness 200 µm or 4 - 8 spray passes Drying 20°C approx. 3 hours Short wavelength infrared approx. 10 minutes Medium wavelength infrared approx. 15 - 20 minutes Sanding tool Eccentric, sanding disk by hand Grade P80 - P150; fine sand - P280 Application 2-component plastic stopper for flexible thermoplastic Use Equalization of scratches or unevenness Hardener quantity approx. 3 - 5% Working time approx. 25 - 30 minutes Drying 20°C approx. 15 - 30 minutes Application 2-component plastic stopper for flexible thermoplastic 60°C approx. 15 min (Short wavelength infrared approx. 8 minutes)* (Medium wavelength infrared approx. 8-10 minutes)* Sanding tool Eccentric, sanding disk by hand Grade P80 - P150; fine sand - P280 Infrared drying may adversely affect adhesion, therefore check the manufacturer's instructions. Plastic stopper has a very great tendency to shrink back, so that the edge of the stopper repair becomes visible. Plastic stoppers are flexible and universally applicable on all types of plastic (except for pure PE and PP, these are plastics which cannot be painted). The manufacturer's instructions must be very exactly followed in order that no adhesion problems occur. A special plastic etch primer is specified for some materials. Primers Application 1-component primer Use Isolation of bare sanded areas. Spray gun HVLP 1.3 mm Spray pressure 2.0 bar Drying 20°C approx. 15 - 20 minutes 60°C approx. 10 min Coat application Wet on wet, no interme- diate sanding Application 2-component primer Use Corrosion protection and bonding agent (steel sheet, zinc coated steel sheet, aluminum)

501-36-37 Paint - General Information 501-36-37 DESCRIPTION AND OPERATION Application 2-component primer Spray gun HVLP 1.3 mm Spray pressure 2.0 bar Drying 20°C approx. 15 - 20 minutes 60°C approx. 10 min Coat application Wet on wet, no interme- diate sanding HS primer filler and HS tinted filler Note: ‡ Primer filler is available as 1-component and 2-component water based and solvent based forms. ‡ 1-component products are only suitable for isolation of sanded through bare areas and new painting. ‡ Water based products are also used for the skinning of thermoplastics and substrates which are sensitive to solvents. ‡ Tinted fillers can be individually matched to the top coat color and therefore find uses in effect paints and paints with poor covering power. ‡ Use dry sand or wet sand filler according to application in order to avoid unnecessary sanding work. ‡ On critical substrates the use of epoxy resin base filler is recommended in order to avoid adhesion problems. Application HS primer filler and HS tinted filler Use Equalization of uneven- ness, edge zones, sanding scores Spray gun HVLP 1.6 - 1.9 mm Spray pressure 2.0 bar Layer thickness 50 - 70 µm to 150 µm possible Drying 20°C approx. 2.5 hours (60°C approx. 25 min)* (Short wavelength infrared approx. 8 minutes)* Application HS primer filler and HS tinted filler (Medium wavelength infrared approx. 10-15 minutes)* Coat application Wet on wet, no interme- diate sanding In order to avoid boiling out, drying should be performed slowly. Paint The base and the clear lacquer must be matched to one another. Application Water based paint Use Two layer metallic effect paint and Uni-paint finishes Spray viscosity At 20°C 18 - 20 s Spray gun HVLP 1.2 - 1.3 mm Spray pressure 2.0 bar Layer thickness 15 - 20 µm Drying 20°C approx. 2.5 hours 60°C approx. 25 min Short wavelength infrared approx. 8 minutes Medium wavelength infrared approx. 10 - 15 minutes Coat application Wet on wet Ventilation time approx. 5 minutes The base paint must be dried matt before the clear lacquer is applied. Application 2-component HS clear lacquer Use Gloss providing protective coat for base coat substrate Spray viscosity At 20°C 18 - 20 s Spray gun HVLP 1.2 - 1.3 mm Spray pressure 2.0 bar Layer thickness 50 - 70 µm

501-36-38 Paint - General Information 501-36-38 DESCRIPTION AND OPERATION Application 2-component HS clear lacquer Drying 20°C approx. 10 hours 60°C approx. 30 min Short wavelength infrared approx. 8 minutes Medium wavelength infrared approx. 10 - 15 minutes Application 2K HS Uni top coat Use Color and gloss providing paint layer Spray viscosity At 20°C 20 - 22 s Spray gun HVLP 1.2 - 1.3 mm Spray pressure 2.0 bar - 3.0 bar Layer thickness 50 - 70 µm Drying 20°C approx. 8 hours 60°C approx. 30 min Short wavelength infrared approx. 8 minutes Medium wavelength infrared approx. 10 -15 minutes

501-36-39 Paint - General Information 501-36-39 DESCRIPTION AND OPERATION Additional Materials The manufacturer's instructions must always be followed when dealing with any materials! The information given in the following text is data which is independent of the manufacturer, and it should only used as an indication. Adhesive sealants Adhesive sealants are permanently elastic, long-lived, can be painted and accept filler. Application: Sealing of visible and normal seams. Can be over-painted with 2-component paint, primer and fillers after having dried throughout. Contamination can be removed using cleaner and thinner. 1-component PUR adhesive sealant Note: ‡ Hardens using oxygen from the air. For that reason, it must only be stripped after it has completely dried through. 2-component MS polymer adhesive sealant 2-component MS polymer adhesive sealant is free of isocyanate, solvent and silicones and can be spot-welded. MS polymer adhesive sealant Can be over painted with water-based paints. Suitable for spraying and brushing to obtain a composition true to the original. MS polymer adhesive sealant is free of isocyanate, solvent and silicones and can be spot-welded. Underbody protection Underbody protection products are immune to abrasion, permanently elastic, adhere well and are suitable for a true to original texture. Underbody protection based on solvent Application: ‡ Underbody protection for visible areas. Properties: ‡ Can be over-painted, also with 2-component paint. ‡ Can be colored with a proportion of up to 40% paint. Note: ‡ Contamination can be removed using cleaner and thinner. Water based underbody protection Can be over-painted with water based paint. Can be colored with water based paint. Contamination can be removed using water. Application Water based underbody protection Use Underbody protection for visible areas Spray viscosity ready to use Spray gun Suction beaker HVLP gun 3 - 4 mm Spray pressure 4 - 6 bar Layer thickness 500 - 1000 µm Drying approx. 6 hours at 20°C approx. 45 - 60 minutes at 60°C Short wavelength infrared approx. 8 minutes Medium wavelength infrared approx. 10 - 15 minutes Application Water based underbody protection Use Isolation primer for peroxide marks, bloomed old paintwork and thermo- plastics.

501-36-40 Paint - General Information 501-36-40 DESCRIPTION AND OPERATION Application Water based underbody protection Spray viscosity Thin as necessary with distilled water Spray gun HVLP gun 1.9 mm Spray pressure 2.0 - 3.0 bar Layer thickness 40 - 50 µm Drying approx. 2 hours at 20°C approx. 30 minutes at 60°C Short wavelength infrared approx. 8 minutes Medium wavelength infrared approx. 10 - 15 minutes Paint additives Application Sanding test color Use To test sanding results Spray gun HVLP 1.7 - 1.9 mm Spray pressure 2.0 bar Layer thickness Spray drifted Application Fixer additive Use Converts solid top coat into two layer solid; multi- color painting Spray viscosity 18 - 20 secs at 20°C Spray gun HVLP 1.2 - 1.3 mm Spray pressure 2.0 - 3.0 bar Layer thickness max. 30 µm Coat application Wet on wet Ventilation time approx. 15 - 30 minutes Maintain maximum layer thickness without fail. Must always next be overpainted with clear lacquer. Application Drying accelerator Use Accelerates drying with only minimal reduction in working life Working life approx. 5 hours at 20°C Application Drying accelerator Spray gun HVLP 1.2 - 1.3 mm Spray pressure 2.0 bar Layer thickness 50 - 70 µm Drying approx. 6 hours at 20°C approx. 25 minutes at 60°C Short wavelength infrared approx. 8 minutes Medium wavelength infrared approx. 10 - 15 minutes Cannot be used in all paints, read the manufacturer's instructions. Particularly suitable for partial painting. Application Elastifier additive in primer material Use Elastifies the complete paint structure on plastics. Addition Up to 25% Spray gun HVLP 1.7 - 1.9 mm Spray pressure 2.0 - 3.0 bar Layer thickness 50 µm Drying approx. 4 hours at 20°C approx. 40 minutes at 60°C Short wavelength infrared approx. 8 minutes Medium wavelength infrared approx. 10 - 15 minutes Application Elastifier additive in top coat Use Elastifies the complete paint structure on plastics. Addition Up to 25% Spray gun HVLP 1.7 - 1.9 mm Spray pressure 2.0 - 3.0 bar Layer thickness 50 - 60 µm

501-36-41 Paint - General Information 501-36-41 DESCRIPTION AND OPERATION Application Elastifier additive in top coat Drying approx. 16 hours at 20°C approx. 45 minutes at 60°C Short wavelength infrared approx. 8 minutes Medium wavelength infrared approx. 10 - 15 minutes Application Matting additive in solid paint Use Elastifies the complete paint structure on plastics. Semi-gloss addition Up to 25% in the paint without hardener and thinner Silk gloss addition Up to 35% in the paint without hardener and thinner Silk matt addition Up to 45% in the paint without hardener and thinner Spray gun HVLP 1.2 - 1.3 mm Spray pressure 2.0 - 3.0 bar Layer thickness 50 - 70 µm Drying approx. 8 hours at 20°C approx. 30 minutes at 60°C Short wavelength infrared approx. 8 minutes Medium wavelength infrared approx. 10 - 15 minutes CAUTION: Do not dry using infrared. Application Matting additive in clear lacquer Use Elastifies the complete paint structure on plastics. Application Matting additive in clear lacquer Semi-gloss addition Up to 25% in the paint without hardener and thinner Silk gloss addition Up to 35% in the paint without hardener and thinner Silk matt addition Up to 45% in the paint without hardener and thinner Spray gun HVLP 1.2 - 1.3 mm Spray pressure 2.0 - 3.0 bar Layer thickness 50 - 70 µm Drying approx. 8 hours at 20°C approx. 30 minutes at 60°C Note: ‡ When mixing, first put in the matting additive, then the hardener and thinners. ‡ Stir immediately after adding the matting additive. ‡ Do not store after addition of the matting additive, storage will change the degree of gloss. ‡ Also suitable for use on plastics without addition of elastifier additive. Application Matting paste Use Matts, elasticizes and gives structure to solid paint and clear lacquer during painting of bumpers or hard plastic. Addition 1:1 or 2:1 depending on manufacturer in solid paint without hardener or thinners. Spray gun HVLP 1.2 - 1.3 mm Spray pressure 2.0 - 3.0 bar Layer thickness 50 - 70 µm Drying approx. 6 - 10 hours at 20°C approx. 30 minutes at 60°C

501-36-42 Paint - General Information 501-36-42 DESCRIPTION AND OPERATION Application Matting paste Short wavelength infrared approx. 8 minutes Medium wavelength infrared approx. 10 - 15 minutes Note: ‡ The paint must not be filtered. Application Anti-silicone additive Use Prevents silicone craters Addition 2% to maximum 5% Note: ‡ Only add away from the paint cabin and immediately remove contaminated cloths. ‡ If anti-silicone additive is used in the first coat, then it must be used in the following coats, and in at least the same proportions. Additive materials Variety of adhesive tapes For profile, fine and large area masking work. Properties: ‡ Withstands heat. ‡ Withstands water-based paint. ‡ Accepts paint. ‡ Easily removed without leaving adhesive residues. Masking film. For masking of large areas on vehicles. Properties: ‡ Accepts 2-component and water-based paints. ‡ Withstands heat. ‡ Withstands water spray and condensation. ‡ Withstands solvent. ‡ Easily cut. ‡ Environmentally friendly and can be recycled. Polishing materials. Polishing means microfine sanding. For this reason, polishes must only contain abrasives, and no silicones. During polishing repair, a good shine is achieved through the step-by-step use of polishes, starting with a highly abrasive polish and ending with a polish having very slight abrasive action. Polishes are available in graduations from coarse to fine. Abrasives Please refer to the "Tools" chapter for information on abrasives.

501-36-43 Paint - General Information 501-36-43 DESCRIPTION AND OPERATION Paint Repairs General information There is a great difference between painting in production and repair painting. In production, only the bodyshell is painted, it has no trim, upholstery or assemblies. Because of this, other paints, tools and processing techniques can be used. In contrast to that used in production, paint used in the workshop must dry at low temperatures. Plastics and the vehicle electronics must not be subjected to temperatures greater than 70°C. The painting process in the case of repair work consists of two phases: ‡ Pre-treatment of the surface for corrosion protection and the smoothing of irregularities. ‡ Top coat application. The precondition for a professional paint finish on a vehicle is the permanently maintained cleanliness of work spaces, tools and equipment, Original materials must be worked according to the manufacturer's instructions, so that no problems arise in the processing nor during drying. The room temperature must be 20 - 25°C and the humidity must be low. Temperatures which are too low or too high can lead to porosity, poor flow and boiling. High humidity leads to paint damage such as tarnishing of the paint film (matt film), adhesion problems and craters. Pre-treatment of the surface Perfect preparation of the subsurface is the precondition for a brilliant paintwork result. Faults in the preliminary stages delay completion and cause unnecessary extra work. The working steps described here demonstrate how important it is to follow these instructions step by step. NOTE: Thorough cleaning of the vehicle and especially of the area being repaired is particularly important because of the danger of contamination of the paint. Clean the area of the damage TO BE UPDATED LATER Clean the damaged surface thoroughly, to allow the extent of the damage to be seen. Use silicone remover to produce a grease-free surface. NOTE: The treated surface must be rubbed with a clean dry cloth before the solvent evaporates, otherwise there will be no cleaning effect. Effective de-greasing is important not only before the application of paint, but also before all sanding stages, for two reasons: ‡ During sanding of grease contaminated surfaces, globules may form with the sanding dust. Sanding marks will occur and the sanding medium quickly becomes unuseable. ‡ Oil and grease are embedded by the action of the abrasive particles, and are then very difficult to remove. Establish the area of damage and the repair stages. In doing so, establish how much disassembly work must be undertaken. Perform a color test at this stage. Mask off the area of the repair ready for preparatory work. Sand out the damage location TO BE UPDATED LATER

501-36-44 Paint - General Information 501-36-44 DESCRIPTION AND OPERATION When sanding, produce smooth transitions from the painted area to the bare metal. Use an eccentric sander and P80 or P120 abrasive sheets. Finish off sanding with P150 or P180. The remaining adhering sanding dust must be completely removed. Cleaning, de-greasing TO BE UPDATED LATER Use silicone remover to thoroughly clean the surface in order to remove grease residues, sweat from the hands and other contamination. NOTE: Use a solvent test to establish whether the old paint can be etched. Apply 2-component thinners to the damaged area using a clean cloth and rub lightly for about 1 minute. If the subsurfaces can be etched away, special pre-treatment is necessary. See "Tips and Tricks" Apply primer filler TO BE UPDATED LATER Before applying stopper, apply primer to the sanded and bare surface. Allow the primer to dry and then lightly sand by hand using P220 - P400 dry. NOTE: Most stopper can be applied directly to bare metal. But application of a primer filler provides better corrosion protection. NOTE: Avoid sanding through to the bare metal. Points which are sanded through must be retreated with primer filler. Stopper application TO BE UPDATED LATER Pre-sand the hardened stopper using an eccentric sander and P80 dry, then final-sand using P120 - P140 dry. Clean the sanded surface using silicone remover. Apply 2-component stopper to the filled surface. The stopper compound must only be applied thinly. NOTE: Use of a testing powder is recommended so that the sanding process can be more easily checked. Apply filler TO BE UPDATED LATER Filler can now be applied to the dried repair area. Choose the correctly toned filler according to the manufacturer's instructions. NOTE: Alternatively, filler with the correct tone can be mixed with the aid of colour matching cards.

501-36-45 Paint - General Information 501-36-45 DESCRIPTION AND OPERATION Sand the filler. TO BE UPDATED LATER The working area is expanded by applying new masking. This makes it possible to even out the transition from the damage area to the vehicle paintwork. NOTE: The primer filler must be carefully sanded. Faults in the primer filler layer will be visible in the top coat. The sanding process consists of two stages. Coarse sanding levels out the surface of the filler primer. Fine sanding ensures the necessary surface structure which allows the top coat to adhere well and cover sanding marks. Sand the filler using the eccentric sander and P400 - P500 used dry. Clean the sanded filler finished surface using silicone remover. The painted area is matted using a fine matting sponge, and then thoroughly cleaned. Surface ready for paint TO BE UPDATED LATER The surface which has been repaired and then prepared according to the manufacturer's instructions is now ready for basic paint application. Top coat application It is important for a good paint result that the recommended process data is adhered to, i.e. mixture proportions, layer thickness, viscosity, drying time etc. First of all the work area is carefully masked ready for paint application. The correct adhesive materials and techniques must be used so that no hard transitions and edges are created during painting. NOTE: The chapter "Tips and Tricks" gives in-depth information on masking work. Thoroughly check the surface once more and rub-off with a dust-bonding cloth. NOTE: Once more check the paint material and that the spray gun is correctly adjusted before applying the paint. Paint application TO BE UPDATED LATER The base paint is applied in two or three steps. First of all only the repair area is painted with the first paint application. Flash off TO BE UPDATED LATER Allow the paint application to flash off until the surface has a matt appearance. So that the transition to the original paint is optimally created, the next paint application is applied to a wider area. After the base paint has dried for the specified time, the clear lacquer is applied. Next the transitions to the original paintwork are treated with fade-out

501-36-46 Paint - General Information 501-36-46 DESCRIPTION AND OPERATION remover. This removes the spray mist and forms an ideal paint surface. Repair stages for repair painting The required time and material data is divided into four painting levels for calculations concerning repair painting. Proceed according to these divisions for every calculation. Level 1 - Painting of new components On new components, all inner surfaces, seams and edges which will no longer be seen after assembly must be primed and pre-painted. NOTE: The cathodic dip primer must not be sanded away. Cleaning with silicone remover or light sanding of the primer is all that is required. Job steps: ‡ Wash off, prime and pre-paint inner surfaces, seams and edges which cannot be reached at all or only partly after the component is installed. ‡ Sand new component with P280 - P320 or a fine sanding pad. ‡ Clean subsurface with silicone remover. ‡ Carry out masking work (when painting an installed component). ‡ Apply one spray run of filler, dry. ‡ Sand the filler. P1200 wet or P500 dry. ‡ Clean filler application with silicone remover. Then the prepared surface can be painted with solid or 2-component paint. If the new part has mild transport damage, this must be rectified beforehand. To do so, add the following steps: ‡ Grind out the scratch. ‡ Finely sand the surrounding surfaces. ‡ Use a steel cleaning agent to thoroughly clean and then rub dry. ‡ Apply corrosion protection primer to the bare areas. Level II - Top surface painting (color tone matching) Complete bodywork surfaces which are to be painted without the need to apply stopper belong to this group. In addition, surfaces with faults in the top coat surface which cannot be removed by polishing. The following faults are included: ‡ Loss of gloss. ‡ Sanding scores. ‡ Heavy paint runs. ‡ Large dust and dirt inclusions. The scope of the work is as follows: ‡ Sand the surface. ‡ Sand out paint damage and faults. ‡ Treatment of small areas which have been sanded through. ‡ Masking work (when painting an installed component). ‡ Apply top coat according to the painting process (one or several coat process). ‡ Dry the top coat and perform finishing work. Level III - Repair painting with stopper applied to up to 50% of the surface. If in addition to painting, work with stopper application must be performed, then the repair levels III or IV must be used. In repair level III, apart from painting the complete bodywork surface, partial stopper work is carried out on up to 50% of the surface to be painted. The necessary primer and filler work are also included. The following damage must be rectified in this level: ‡ Slight panel unevenness. ‡ Damage due to corrosion. ‡ Dented body surfaces. ‡ Weld locations. ‡ Deep scores or scratches. The scope of the work is as follows: ‡ Fine sand pre-treated bodywork surfaces (e.g. lead-loaded areas). ‡ Sand out existing damage. ‡ Perform all necessary masking operations on the vehicle. ‡ Apply primer. ‡ Partial stopper application on up to 50% of the surface to be painted (two to a maximum of three stopper applications). ‡ Fill the repair area. ‡ Apply stone chip protection (when present in production). ‡ Apply top coat according to the painting process (one or several coat process). ‡ Dry the top coat and perform finishing work.

501-36-47 Paint - General Information 501-36-47 DESCRIPTION AND OPERATION Level IV - Repair painting with stopper applied to more than 50% of the surface. In repair level IV, apart from painting the complete bodywork surface, partial stopper work is carried out on more than 50% of the surface to be painted. The necessary primer and filler work are also included. The following damage must be rectified in this level: ‡ Damage due to hail. ‡ More extensive stone chip damage. ‡ Extensively dented body panels. ‡ Sectional repairs with large weld seams. ‡ Surfaces with severe corrosion damage. The scope of the work is different to level III because of the partial application of stopper to more than 50% of the area to be painted. In addition, more extensive sanding work is usually required. Polish In order to achieve faultless quality, it is sometimes necessary afterwards to polish a newly painted surface. Even after the most careful painting, it sometimes happens that dirt inclusions and paint runs occur in work with top coat or clear lacquer. Before polishing, such paint faults must be removed with the sanding cylinder ("Finiball") and hand sanding or eccentric sander in a wet sanding process. Sanding cylinder TO BE UPDATED LATER The special sanding compound -1- (sanding bloom) for the sanding cylinder is self-adhering and available in grades from P1000 to P2500. ‡ P1000 - P1500 for pre-sanding of runs and large imperfections in the paint. ‡ P1500 - P3000 for subsequent sanding of runs and sanding out of dust inclusions. A small eccentric sander can be used for more extensive working areas. When doing so, first of all put the eccentric sander in place and then switch it on, so that the danger of sanding through on edge is reduced. Finally polish the sanded area to a high gloss with suitable polish. To this end the various manufacturers recommend materials and process techniques which are specially suited to their products. NOTE: The polishing is to be done in the same way as that used to remove swirl marks. Polish TO BE UPDATED LATER NOTE: Before using the nap sponge for the first time and after any long pauses in working, dampen the nap sponge with polish. Job steps: ‡ Clean and degrease the area to be polished using silicone remover. ‡ Apply the polish to the polishing disc and spread it. ‡ Place the polishing machine down flat on the area to be polished and before switching it on, gently distribute the polish over the underlying surface. ‡ Polish out the location for 10 - 15 seconds with the edge, working with a criss-cross motion. ‡ Subsequently polish the location for about 10 seconds with the machine laid down flat. ‡ Wash off and clean the polished location using the professional polishing cloth and then clean the polished surface. ‡ It is absolutely vital to carry out a visual check after finishing the polishing procedure. If any swirl marks are not completely removed by the first polishing procedure, then process must be repeated.

501-36-48 Paint - General Information 501-36-48 DESCRIPTION AND OPERATION Aids Cleaning putty Cleaning putty allows deposits on the paint surface to be removed easily and gently. The following paint faults can be removed using cleaning putty: ‡ Metal deposits and iron dust. ‡ Paint or color mist. ‡ Tree resin and tar. ‡ Insect residues. The surface to be worked must be thoroughly cleaned before the cleaning putty can be applied. Then the surface is sprayed with soapy water. Now the cleaning putty can be slid over the surface until all unevenness is removed.

501-36-49 Paint - General Information 501-36-49 DESCRIPTION AND OPERATION Painting Plastic Parts General Although these days plastics can be produced in all colors and with a matt or gloss surface, painting is often necessary. NOTE: Manufacturer's limitations concerning the feasibility of painting certain components must always be observed. Reasons in favor of applying paint to plastic are: ‡ Individual coloring, matching the body paint. ‡ More gloss and color brilliance through painting. ‡ Removal of production imperfections. ‡ Protection from atmospheric exposure. Nowadays painting plastic presents no problems because the materials are known and matched to the paint. In order that the painter can use the correct painting materials, the type of plastic must first be correctly determined. To allow this, plastics are marked on the rear in accordance with the recommendations of the Association of Vehicle Manufacturers. Once the type of plastic is determined it is an easy matter to assign special paint recommendations, matched to that particular plastic. Unmarked plastics require knowledge of materials so that a correct choice of paint materials can be made and the component can be reliably painted. Plastic groups Thermoplastics When warmed these undergo a reversible transformation into a plastic deformable state and once cooled they maintain their shape. They consist of string-like (linear) or only slightly branched molecular chains. Thermosets Thermosets are hard and have the form of a close-meshed network in all directions. They do not undergo plastic deformation, are especially resistant to chemicals, are difficult to swell and are insoluble. At normal temperatures they are hard to brittle. At first the material does not undergo any change when heated, but when it reaches a critical point, the thermoset is totally destroyed. Elastomers Elastomers are characterized by high elasticity over a wide temperature range. They have properties like rubber or a sponge and after compression or distension they return to their original state. Types of plastic The plastics used in the automotive area: ‡ ABS - Acrylonitrile butadiene styrene (polymer) ‡ PA - Polyamide ‡ PC - Polycarbonate ‡ PE - Polyethylene ‡ PP - Polypropylene ‡ PP/EPDM - Polypropylene/ethylene propylene diene copolymer ‡ PC/PBT - Polycarbonate/Polybutylene terephthalate ‡ PBT/PC - Polybutylene terephthalate/Polycarbonate ‡ PUR - Polyurethane ‡ GRP - Glass reinforced plastic NOTE: PE and PP are plastics which cannot be painted, or can only be painted using special techniques. As well as the pure plastics, so-called 'blends' are also used. This means combinations of different plastics. If we were dealing with metals they would be called alloys. Plastic identification Normally the identifier is marked on the plastic components used in vehicle construction. One method to determine the plastic group is the sanding test. In this a place is chosen which will not be visible later, and the finger belt sander is used to sand the plastic. The plastic group can be determined using the pattern left by the sanding and the dust: ‡ Thermosets produce a white dust. ‡ Thermoplastics smear and do not produce dust. The plastic group can be determined by a sound test:

501-36-50 Paint - General Information 501-36-50 DESCRIPTION AND OPERATION ‡ Degree of hardness - the higher-pitched the sound, the harder the plastic. ‡ Elasticity - the more muffled the sound, the higher the elasticity of the plastic. Cleaning plastic Plastic components are manufactured using complicated moulds and presses or other highly engineered tools, mostly using an injection moulding process or reactive injection moulding process. In order to be able to remove the component from a particular tool, a separating agent is used, which in some cases adheres very strongly to the plastic. This separating agent on the plastic components must be completely removed before any surface coating is applied. Warm storage (tempering) before actual cleaning brings the following advantages: ‡ The separating agent sweats out of the plastic. ‡ Tensions in the plastic are released. ‡ Air inclusions can be recognized and removed. Intensively clean the item several times using a pad and fresh cleaning agent. NOTE: A single wipe, even with cleaning agent, is not usually sufficient in most cases. Clean textured components with the aid of a soft brush. After cleaning, it is absolutely vital that cleaning agent absorbed by the plastic should be expelled by tempering again. If the ventilation is good and the room temperature is about 20°C the solvent can be evaporated away by overnight storage. Painting new components It is absolutely vital that the substrate of an unpainted new component is free of separating agent. Paint can only be applied directly to very few plastics. The plastic must first be identified exactly and then worked with a repair system which is matched to the type of plastic. In most cases a plastic etch primer must be applied as adhesion base to all plastics which can be painted. NOTE: Plastics have a tendency to become electrostatically charged. This can easily cause contamination during painting. Special antistatic cleaning cloths prevent electrostatic charging. Work process for thermoplastics: ‡ Thoroughly clean the surface. ‡ Temper the plastic. ‡ Afterwards clean with antistatic cleaner or antistatic cloths. ‡ Apply the bonding agent. ‡ Apply elastic filler. After it has dried, sand and clean. ‡ Apply one coat Uni-paint with elasticizer additive. For two layer painting the elasticizer additive is in the clear lacquer. NOTE: Follow the paint manufacturer's guidelines during all work. Work process for thermosets: ‡ As a rule, thermosets can be handled in the same way as normal body components. Work process for PUR soft foam: ‡ The work process is the same as for thermoplastic. ‡ Instead of using bonding agent, a filler wash is applied to close the pores of the PUR soft foam. The primer which has been applied to a primed new component can vary greatly. If no manufacturer's data is available, the composition and suitability for further working must be tested. Painted components with an already ascertained and intact paint coat present no problems for possible repainting. After sanding and careful cleaning with plastic cleaner or thinners, painting can be done directly. Unknown primer When dealing with unknown substrates it is important to carry out an adhesion test on the existing paint before any repainting is attempted. First of all a mechanical test must be carried out, for instance using a lattice cut and tear-off band. If the adhesion of the old paint is not acceptable, it must be mechanically removed and new paint finish applied. If the adhesion is acceptable, then an etch test is performed using 2-component thinners. If no etching can be detected in this test, application of the the paint finish can be started directly. Otherwise the old paint must be removed and a new paint finish created. With the help of universal or special plastic primers and with only a few materials complementary to those previously present anyway, the painter can now apply a long-lasting paint finish to all popular vehicle attachments made of plastic.

501-36-51 Paint - General Information 501-36-51 DESCRIPTION AND OPERATION Paint faults on plastic substrates NOTE: Paint faults are fully described in the chapter Paint Defects and Damage. The most common paint faults which can occur when painting plastic components and the methods of repair are briefly described. Discoloration Cause/damage pattern: ‡ Plastic material is not suitable for painting. ‡ Incorrect bonding agent. ‡ Paint used not solvent resistant. Repair of damage: ‡ Repaint using suitable materials. ‡ Install a new unpainted component. Softening Cause/damage pattern: ‡ Substrate not carefully cleaned. ‡ Air humidity too high or working temperature too low. ‡ Drying time incorrect (too short). ‡ Materials for substrate not correctly matched to each other or not mixed correctly. Repair of damage: ‡ Dry out, sand, re-isolate and paint. ‡ Sand away faulty paint coats and re-apply paint finish. Paint damage caused by detachment, poor adhesion Cause/damage pattern: ‡ Insufficient paint adhesion between top coat and filler. The whole of the paint finish detaches from the plastic. ‡ Plastic not cleaned sufficiently, not or inadequately tempered. ‡ Unsuitable cleaning agent or materials used. ‡ Poor or lack of intermediate sanding. ‡ Paint finish underbaked or overbaked. Repair of damage: ‡ Sand away faulty paint coats and re-apply paint finish. Paint damage caused by blisters, craters, sink holes Cause/damage pattern: ‡ Painting on PUR plastic which was not painted in production. ‡ Surface of the plastic material too porous. ‡ Flash-off time not adhered to. ‡ Drying temperature too high. ‡ Moisture in plastic material. ‡ Layers too thick. Repair of damage: ‡ Clean the damaged area, sand, re-isolate and paint. ‡ Remove the paint layers and re-paint. Crack formation Cause/damage pattern: ‡ Overexpansion of painted PUR plastic components. ‡ Use of unsuitable paint materials. ‡ Paint materials not suited to each other or incorrect mixture ratio. Repair of damage: ‡ It is not possible to repair overexpanded PUR plastic components. ‡ On other plastics, sand away damaged layers, isolate and repaint.

501-36-52 Paint - General Information 501-36-52 DESCRIPTION AND OPERATION Spot Repairs General In general, partial surface painting at a point is called a spot repair. Using this technique, minor paint damage can be resolved economically and to time. Advantage of this method Because this application remains confined to the area of the damage, it is often unnecessary to remove components or color match against neighboring components. The material used is very much reduced because only a part of the repair area is coated. Practical application areas Only occasionally can satisfactory results be achieved in the centre of larger surfaces and/or on difficult colors. In addition, unprofessional TO BE UPDATED LATER Because of their locations, the violet colored areas are the most suitable for spot repair painting. The turquoise areas are only marginally suitable and application may cause tear-off edges to appear in clear lacquer. Only certain application areas are recommended. NOTE: The final decision on whether to spot repair or paint the component must be made by an expert. Application areas: ‡ 2-layer paint. ‡ Depending on the damage zone, paint damage up to a diameter of 3.5 cm or a length of 10 cm. ‡ Scratches. ‡ Clear lacquer application up to an area of DIN A4 max. ‡ Smaller areas which are optically broken up by other components such as trim strip, tail lights, swage lines and edges. ‡ Boundary zones and edge areas of larger components. The best application areas have proven to be optical break lines such as corners, narrow surfaces, fenders and wheel arches. the rest of the areas are not suitable for spot repairs.

501-36-53 Paint - General Information 501-36-53 DESCRIPTION AND OPERATION Repair process Perfect preparation of the subsurface is the precondition for a brilliant paintwork result. Faults in the preliminary stages delay completion and cause unnecessary extra work. The working steps described here demonstrate how important it is to follow these instructions step by step. Illustration of damage TO BE UPDATED LATER A typical case for spot repair is a small stone chip on the fender. Cleaning TO BE UPDATED LATER First of all the component is thoroughly cleaned using silicone remover and refurbished using abrading and polishing paste. This re-creates the original degree of shine and ensures exact color matching on the touch-up surface. Sand out TO BE UPDATED LATER Sand out the damaged location using P180 - P320. Only small sanding blocks and small sanding machines must be used, so that the area of the repair remains as small as possible. Sanding is completed by rubbing down the surrounding surface with a fine sanding pad or P1000 paper. Remove sanding residues and clean the repair area with silicone remover. The peripheral zone must then be masked for application of the filler. NOTE: The size of the repair area must be kept as small as possible (maximum size DIN A4). Filling TO BE UPDATED LATER The filler layer is applied in stages. First of all, filler is only applied to the location which has been sanded away. After a wait time for flashing off, the second coat is applied so that it spreads over onto the existing paintwork. The filler must be dried according to the instructions of the material supplier.

501-36-54 Paint - General Information 501-36-54 DESCRIPTION AND OPERATION Rubbing down TO BE UPDATED LATER The repair location is now rubbed down with P400 - P500 and the bordering surface with P2000 - P4000. Remove sanding residues and clean the repair area with silicone remover. Paint TO BE UPDATED LATER Before painting, clean the area for the final time using a dust-bonding cloth. Then apply the basic paint in thin layers using a spray gun until enough coverage is achieved. After drying, apply clear lacquer in 1 or 2 coats (depending on product). In doing so, spray so that only the newly applied basic paint is completely covered. Finally a touch-up thinners is sprayed over the edge of the clear lacquer to dissolve the clear lacquer spray mist. Dry TO BE UPDATED LATER Now dry the clear lacquer according to the manufacturer's instructions using an infrared gun. Polish TO BE UPDATED LATER Polish the component using a polisher and polish and check the polished area for any swirl marks which may be present. Polish away any swirl marks which are present. Dirt inclusions Sand out TO BE UPDATED LATER Minor damage can be removed with a small sanding machine or preferably with an eccentric sander with P1500 - P2000. Very fine spray mist

501-36-55 Paint - General Information 501-36-55 DESCRIPTION AND OPERATION can be removed using P2000 - P4000 paper and a larger eccentric sander.

501-36-56 Paint - General Information 501-36-56 DESCRIPTION AND OPERATION Corrosion Prevention General Although corrosion protection measures and painting processes in production have reached a very high technical standard and will be continuously developed further, in the long term corrosion on a vehicle cannot be totally avoided. Further demands are therefore made of the paint specialist besides his knowledge of normal repainting of vehicles which have been repaired after an accident, in addition specialist knowledge is required for assessing and rectifying damage due to corrosion. During repair painting, take care over the maintenance and re-creation of the corrosion protection applied in production, in view of the long-term warranty on Ford vehicles. Only those repair materials which are approved by Ford may be used for body repair work and repair painting. For detailed information on corrosion protection measures during body repairs, please refer to chapter 501-25. Furthermore, information on corrosion protection measures is repeated in individual chapters of the paint manual. In particular, pay attention that the layer thicknesses specified in production are maintained. The complete system of solid one-layer on galvanized steel panels must equal at least 90 µm and the total system of two-layer on galvanized steel panels must equal at least 105 µm. It is important that sealing operations, as far as they are necessary, should be undertaken after the application of the paint to specification, in order to ensure the best corrosion protection. All components which form hollow cavities such as pillars, rails, side components etc. must be provided with a coating of cavity protection wax. Causes of corrosion Corrosion of steel is an electrochemical process during which the steel combines with oxygen. The following factors lead to corrosion: ‡ Acidic compounds contained in the air, such as carbonic acid and sulphur dioxide, combined with oxygen from the air and/or water. Salts such as sodium chloride used as road salt accelerate the corrosion process. ‡ Mechanical damage such as stone chips and scratches which penetrate through to the steel panel. ‡ Lack of care by the vehicle owner of the painted and corrosion proofed surfaces or areas on the vehicle. ‡ Unfavorable weather or environmental conditions, as may occur in areas with high humidity, high salt content in the air or serious air pollution due to aggressive gases and dusts. In the case of mechanical damage, formation of rust can often be seen, beginning to spread into the painted surface from a point (stone chip) or from a line (scratch). If these faults are not professionally rectified in good time, the result is rusting through from the outside to the inside. Rusting penetration from the inside to the outside occurs when for instance the cavity protection was inadequate. Operations after painting NOTE: The manufacturer's instructions must be followed when working with the various corrosion protection materials. ‡ After painting, treat all cavities in the repair area with cavity protection wax. In doing so, pay particular attention to the weld seams. In dead-end applications with a panel insert, the cavity protection wax must be applied so that it also reaches the area of the panel insert. ‡ Seals which were applied in production and not over painted must be reapplied. Seals protect vulnerable parts of the bodywork, keep moisture away, reduce wind and road noise and dampen vibrations. ‡ Apply transparent wax. Definition of the degree of rust In workshop practice, in order to be able to carry out a consistent and objective evaluation of the scope of the damage, a degree of rust on the scale of 1 to 5 is determined by the DIN 53 210 standard. The main criterion here is the extent to which rust exists under the paint structure. It is determined in millimeters (mm).

501-36-57 Paint - General Information 501-36-57 DESCRIPTION AND OPERATION Underlying rust grade: R1 < 1 mm Corrosion starting with up to 1 mm of rust underlying (in the form of a spot or a line). The damage can be rectified by cleaning the defective location and mechanically removing the underlying rust. For a small extent, apply a primer using a brush and allow it to dry. Touch-up the location with a paint pen or provide a new paint coating. Underlying rust grade R2 < 1 - 2 mm Advanced corrosion with up to 2 mm underlying rust. Rectifying the damage: ‡ Clean the defective location. ‡ Remove the underlying rust mechanically down to the paintwork carrier. ‡ Apply 1-component filler and then 2-component "Vario" filler. ‡ Provide the damage location with new paint coat on visible outer surfaces. Only locally touch-up areas which are not optically conspicuous. Underlying rust grade R3 < 2 - 4 mm More advanced corrosion with up to 4 mm underlying rust. The damage must be rectified in the same way as for R2. A permanent cure of this type of damage pattern is still just possible Underlying rust grade R4 < 4 - 5 mm Notably advanced corrosion with up to 5 mm underlying rust. The damage must be rectified in the same way as for R2. If it is found that for whole areas this is only possible with a great deal of work, or is not possible at all, then a new component must be used. Underlying rust grade R5 > 5 mm Extreme corrosion, with more than 5mm underlying rust (panels, flanges or load-bearing components partially rusted or rusted through). Such damage can no longer be repaired because in many cases the constructional strength of the component can no longer be produced. The risk in making a repair is too great. Install a new component and paint it.

501-36-58 Paint - General Information 501-36-58 DESCRIPTION AND OPERATION Color Identification and Chromatics Basic color theory In order to achieve optically perfect painting results it is vital to understand the physical principles of the origin of color impression. Color Color itself is a sensory perception. This perception arises through the combined effect of the following components: ‡ Light (sunlight or artificial light irradiates the object). ‡ Surface of the object (reflection from the object of certain constituent parts of the light). ‡ Eye (perception of the reflections from the object). TO BE UPDATED LATER Because the sensory impression of color is produced by all three of these components, it is dependent on the type, quality and function of the individual components. Practical examples make this clear: ‡ If a particular article is subjected to artificial light, then it gives a different impression of color to that which it gives in sunlight. ‡ An object with uniform color but different surface textures appears to have different colors (grained or ungrained dashboard). ‡ A person with perception disorder (colorblindness) cannot recognize certain colors or distinguish between them e.g. red-green weakness). In turn the type of color is determined by the light absorption ability of an object. Light shines with all color components (spectral colors) onto an object, certain components of the light are absorbed (taken in) and other components are reflected (sent on). The components which are reflected produce the specific color impression. TO BE UPDATED LATER The colors as we see them are the result of a combination of reflected colors from the spectrum. Physically speaking, these are electromagnetic waves with different wavelengths (and frequencies). The healthy human eye can recognize wavelengths between 0.36 µm (violet) and 0.78 µm (red). If all the perceptible wavelengths of the spectrum impinge on the human eye at the same time, the impression of white light is produced. Additive and subtractive color mixing TO BE UPDATED LATER Additive color mixing is the combination of light from different sources to give white. Different intensities of the additive primary colors red, green and blue allow millions of different colors to be represented (RGB colors). Additive color mixing is always therefore used when light should enter the eye directly (without reflection off an object). Such as in the case of computer monitors or overhead beamers.

501-36-59 Paint - General Information 501-36-59 DESCRIPTION AND OPERATION TO BE UPDATED LATER Subtractive color mixing means mixing the primary colors cyan, magenta and yellow to form a desired color (CMY colors). Subtractive color mixing is used when light should enter the eye of an observer after reflection from an object. Such as happens with painting or in printing. Oswald color circle TO BE UPDATED LATER The Oswald color circle is based on subtractive color mixing, and enables the behavior of paints when they are mixed together to be represented. Colors lying opposite each other are complementary colors and should not be mixed together as this will produce a dull (i.e. grey) shade. If green is added to red, the red becomes greyer, not greener. Color shades which are side by side are partner colors and produce a mixed color shade. For instance, mixing red and blue produces a pure violet. In addition, black and/or white may be necessary to produce a particular color shade. ‡ White makes the color shade lighter. ‡ Black makes the color shade darker. ‡ With black and white the color shade becomes more dreary or greyer. Metamerism Metamerism is the name of the effect which occurs when two colors appear identical in a particular light (e.g. artificial light), but the colors appear different under another light source (e.g. daylight). The cause is the fact that the human brain, aided by the eyes, does not evaluate the wavelength, instead it evaluates the spectral intensity of the reflected light. It is for this reason that color matching in practice must only ever be performed in daylight, or under special artificial light which is based on daylight. Metallic and pearl pigments Colored paints achieve their color effect by the addition of pigments. Pigments are colored, solid, very fine organic and inorganic particles which are insoluble in the binding material. Metallic pigments Aluminum platelets are added as pigment to form metallic paint.

501-36-60 Paint - General Information 501-36-60 DESCRIPTION AND OPERATION TO BE UPDATED LATER Depending on the size and shape of the aluminum platelets, different metallic effects can be achieved: ‡ Cornflake aluminum (1) causes very strong dispersion because of rough edges, low brilliance, very low flop and produces grey-silver shades. ‡ Dollar aluminum (2) causes hardly any dispersion because of the smooth surface, high brilliance, produces very light, almost white silver shades. With metallic paints however, only a light-dark light reflection effect occurs. Colored metallic paints are produced by the extra addition of color pigments to the metallic paint. Pearl pigments TO BE UPDATED LATER The basis of pearl pigments is formed by mica, which is metallized with a silver or gold layer. Depending on the angles of light and observation, the mica platelets reflect different proportions of light. Because of this, the color of the paint appears to the observer to change. Pearl pigments produce a colored and light-dark reflected light effect. Color codes and their determination on Ford vehicles It is necessary to determine the correct color shade of the original paintwork in order to perform a professional and perfect paint repair. The original paint color shade can be found by: ‡ Inspection of the vehicle type plate with the color code stamped on it. œ Later design œ Earlier design ‡ Color shade catalog or color shade system of the manufacturer. ‡ The bare bodyshell plate with color designation. Type plate Type plate - location on Ford vehicles: ‡ Right-hand B-pillar - door rebate ‡ Left-hand B-pillar - door rebate ‡ Hood lock panel ‡ Left-hand vertical edge of inner front wing ‡ Right-hand vertical edge of inner front wing ‡ Right-hand engine compartment side member ‡ Left-hand bulkhead ‡ Right-hand bulkhead

501-36-61 Paint - General Information 501-36-61 DESCRIPTION AND OPERATION ‡ Luggage compartment interior ‡ Inner rear panel - luggage compartment TO BE UPDATED LATER The type plate gives the color code in the last row. TO BE UPDATED LATER On the newer type plates, the color code is given in the left-hand column, at the penultimate position. TO BE UPDATED LATER Color shade catalog or color shade system of the repair paint manufacturer. The repair paint manufacturers offer a variety of possible systems for the determining the production color shade of motor vehicles. There are electronic systems, color card systems and manuals for the determination of color shades.

501-36-62 Paint - General Information 501-36-62 DESCRIPTION AND OPERATION Most repair paint manufacturers use the following systems: ‡ A tabular system based on the following parameters: œ Color code œ Make œ Model œ Build year œ Color or color name œ Ancillary codes ‡ A system with color cards based on the following parameters: œ Make œ Color shade œ Build year TO BE UPDATED LATER Because of the many parameters used, in a tabular system the color shade can also be determined by the lack of a parameter. When using the color cards, emphasis is placed on matching of the original color shade with the color shade samples. For this reason this method is very helpful when the other parameters are not available. Comparison of the results of both methods increases the certainty of using the correct original color shade and its formulation. Additional certainty can be achieved during color shade determination by making a color sample plate. Here it is however important to apply the complete paint structure with base paint and clear lacquer onto a sample plate (1) in order to carry out a color shade and color coverage test. TO BE UPDATED LATER The color shade comparison is done by comparing the vehicle paintwork with the sample plate (1). The color coverage test is possible by using the black test stripe (2): If the test stripe (2) is still visible after test painting of the sample plate (1), the coverage is not good enough. By using this determination of the original color shade, the formulation and information on any very slight fine adjustments which may be necessary can be established. Bare bodyshell plate The bare bodyshell plate is located: ‡ On the hood lock panel. ‡ Near the type plate. The color name is stamped on in the last row. TO BE UPDATED LATER

501-36-63 Paint - General Information 501-36-63 DESCRIPTION AND OPERATION Matching tinted filler to the color code NOTE: Color samples must always be made from the same materials as the subsequent repair painting. Perform color shade matching in the fully hardened state, in natural light or under suitable artificial light. Various tinted fillers are used during factory painting. In order to achieve the exact color shade of the factory applied paint, attention should be paid that the correctly matched fillers are used. TO BE UPDATED LATER The repair paint manufacturers offer suitable precolored primers. The use of filler color cards allows the matching color shade to be determined.

501-36-64 Paint - General Information 501-36-64 DESCRIPTION AND OPERATION Tips and Tricks Comparing paint structures It may happen that an area remains visible, especially when the area of the repair is small. The reason for this is the structural variation in the paint surface at the repair location compared with the original paint finish. The original paint finish has a slight orange peel effect while the repair areas is extremely smooth. This effect can be reduced by fine sanding using P3000 of the area around the repair location and then polishing. Etching substrate If the substrate can be etched during the solvent test, suitable preparation must be done. Job steps: NOTE: Follow the manufacturer specific instructions. ‡ Sand the damaged area extensively using an eccentric sander and P80 or P120 abrasive sheets. Finish off sanding with P150 or P180. ‡ Remove the sanding dust and clean the area of the damage using silicone remover. ‡ Apply polyester stopper to the bare panel and to the damaged area. ‡ Sand the dried polyester stopper to an even surface using P80 - P150. Finish sanding using P180 - P240. If required apply more stopper, again only on the bare panel. ‡ Wet sand the residual old paint finish using P600 - P800. Transitions with P400 - P600. Clean with silicone remover. ‡ Prime bare metal areas with acid primer. ‡ After the acid primer has been left exposed to the air for the correct evaporation time, apply 2-component primer filler in thin layers over the complete repair area, leaving enough air exposure time in between coats. ‡ After the filler has dried, sand wet with P800 or sand dry with P400. Sanded through areas must be covered again with 2-component Nonstop filler primer. Another possible method of preventing etching of the substrate is to use waterbased primer and filler materials. Masking the vehicle Masking and covering work are among the most important preparations required to achieve a high quality paint finish. Paint application onto neighboring components, paint mist and sharp paint transitions are quality faults. For this reason it is extremely important to take special care and to use suitable masking materials. NOTE: When water based paints are used, all materials must be stable towards water. Plan the masking work: ‡ Determine the sequence of masking work. Sometimes after masking film has been applied, it is difficult or impossible to reach certain areas. ‡ Prepare the masking material. ‡ Start with small difficult areas. Pay special attention to the areas of profiled seals, edges, openings and paint transitions. Masking tape Masking tape is available in various widths for special application areas. In practice however, a wide tape has proved best for almost all areas, also taking into account the time required for masking work. NOTE: Use of differing masking materials is often much more time-consuming. Advantages ‡ Good coverage. Narrower tapes must often be applied in several layers. ‡ More resistant to tearing. ‡ Wide tapes can be applied deep into joints and therefore protect from paint mist and contamination. ‡ Removal is often easier. Masking film Transparent plastic film has become accepted as a practical method to mask large areas of a whole vehicle. It can quickly and easily be applied to the vehicle from the roll.

501-36-65 Paint - General Information 501-36-65 DESCRIPTION AND OPERATION NOTE: Only mask the vehicle when it is dry. Moisture under the film can lead to matt paint in the drying process. Using masking film ‡ Clean the vehicle before masking it. ‡ Pull the film over the vehicle. Because of the static charge, the film lies on the vehicle like a second skin. ‡ Cut out the repair area using the film knife and then mask it. Other ways of masking a vehicle are: ‡ Masking using masking paper. ‡ Painting cloth (mostly used during filling work). Profiled seals If it is not possible to remove a profiled seal, then it must be masked in such a way that no edges can form due to paint accumulation. To do this, the seal is lifted slightly and masked. The following techniques are possible: TO BE UPDATED LATER Item Description 1 Masking tape with plastic strips 2 Sealing lip 3 Sandpaper with masking tape ‡ Laying a string or cord under the seal. Suitable for soft and elastic seal lips. ‡ Special masking tape with plastic strips for hard seal lips. ‡ Instead of using plastic strips, fine sandpaper cut into strips can be inserted and secured using normal masking tape. ‡ If the seal can be easily displaced, normal masking tape can also be used. Edges/openings Smooth paint transitions can be produced by positioning adhesive tapes. NOTE: Pull the adhesive tapes away immediately after the paint has been applied and check the paint transitions. TO BE UPDATED LATER Item Description 1 Vehicle edge 2 Adhesive surface 3 Masking paper Possible variations ‡ At edges apply one strip of masking tape half on the area not to be painted and mask using a second strip. ‡ On surfaces, two masking strips can be attached, each affixed by half their adhesive surface. The adhesive strip which arises is then applied with one half on the edge of the area to be painted. The other half is aligned and fixed in addition in the curves. ‡ Affix masking paper on one side over the area to be painted. Double back the masking paper and secure it. ‡ Affix round profiled foam at the edge of the area to be painted using masking tape. Foam strips are suitable for affixing to openings such as door gaps.

501-36-66 Paint - General Information 501-36-66 DESCRIPTION AND OPERATION TO BE UPDATED LATER NOTE: Choose a suitable profile diameter. A profile which is too thick will protrude from the opening, one which is too thin will leave a gap. Clean the door opening well and affix the matching shape. Color shade problems If a vehicle color shade is taken from a vehicle on a hot summer day and the mixed color applied, this may cause color shade problems. Some colors change so much at higher temperatures that it can lead to an incorrect result. Red color shades are particularly prone to this shade behavior. This means that color determination should always be done on the bodywork when it is at about the same temperature as the later working temperature will be. The best temperature of the item is between 15° and 25° C. Isopropanol and water Painted surfaces are very easily cleaned using a mixture of 70% water and 30% isopropanol (can be obtained through a laboratory supplies specialist or a pharmacist). Temperature reduction spray If finishing work must be performed on touched-up surfaces and newly painted plastic parts, problems may arise. The paint and the transitions are not yet fully hardened. NOTE: When working with the polishing machine, make certain that each operating run lasts no longer than about 5 - 10 seconds, in order to prevent the paint becoming warm. Even so, in order to be able to polish over transitions, temperature reduction spray must be applied to the surface. The transition area is then alternately sprayed and polished until a perfect transition surface is achieved. Paint faults on soft plastic components where elasticizer additive has been used in painting must be wet sanded using grade P2000 - P2500 paper. In doing this the sanding location and the surroundings are sprayed with temperature reduction spray and the paint faults sanded out by hand. Afterwards the location is polished as described above. Paint plane Dirt inclusions and paint runs can be removed with the sanding cylinder ("Finiball") and hand sanding or eccentric sander in a wet sanding process. Another practical tool for removal of paint faults which lie proud of the surface is the paint plane. NOTE: Guide the tool carefully with the minimum of force. It must not tilt, otherwise more serious damage may easily be caused. TO BE UPDATED LATER This tool allows paint faults to be carefully removed in shavings. Afterwards the surface must be polished using suitable materials. Shading Even when all the rules, steps and corresponding instructions have been followed concerning possible shades, it may happen that the mixed color shade does not exactly match the vehicle color. In these cases, shading must be done. Because there is no fixed formula for this, experience and a trained eye are important. Some rules must be followed for shading. NOTE: Self-made color sample plates of the current colors are very helpful for determining the

501-36-67 Paint - General Information 501-36-67 DESCRIPTION AND OPERATION color shade. Refer to the chapter Color Determination and Color Theory. ‡ When shading, if possible only use the paint mixture that is also allotted in the color shade formula. ‡ Observe the rules concerning contrary colors (complementary colors) and partner colors according to the Oswald color circle. ‡ Complementary colors are not recommended during shading because they mutually inhibit and lead to muddy mixtures. Sanding marks In certain circumstances, the recommended sanding methods up to now are no longer suitable for light metallic color shades. Wet sanding with grade P1200 paper or a grey sanding pad can cause sanding scratches which can become very visible under certain lights. In order to achieve an excellent paint result on difficult color shades, follow these working rules: ‡ Sand filler as before, rub down area to be painted with 3M ultra fine matting sponge and 3M matting gel. ‡ Sand filler as before, rub down area to be painted with soaked 3M wet sand paper P1500 - P2000. ‡ Sand filler as before, rub down area to be painted with 3M 260 L P1000 eccentric (Interface Pad). Improving touch-up work During application of special effect base paints, the effect particles align themselves exactly parallel to the surface in the paint layer while it is still liquid. This means a particular thickness of the paint layer is required. Because during painting the layer thickness in the transition zones reduces from normal to zero, the effect particles can no longer align themselves. This leads to lighter, darker or cloudy zones. If 1-component clear lacquer is sprayed before the base coat, this effect is prevented. An optically perfect transition will result.