In the course of production the car body is completely galvanized. External elements of the body have an electrolytic zinc coating, since this type of coating is technologically advanced when applying a paint and varnish coating and is easily deformed. Internal and invisible elements of the body are cheaper hot-dip galvanized. To increase corrosion resistance, all hollow parts of the body are additionally filled with wax, and a protective coating is applied to the bottom. Bumpers and wheel arch lockers are made of plastic for strength and durability.
When disassembling and assembling, take care not to damage the seals and the anti-corrosion coating applied by the manufacturer.
Before starting work on the instrument panel, doors or any electrical devices, remove the ground wire from the battery. To do this, read the notes in the subsection Removing and installing the battery and subsection Entering the radio code.
Safety measures during body work
- When repairing the body, spot welding should be used. Only if it is impossible to bring electrodes to the place of welding, welding in an inert gas environment should be used. Since the body is completely galvanized, the following safety measures must be taken:
- When carrying out welding work or any other work involving the formation of sparks, be sure to disconnect the battery (positive and negative cables) and carefully insulate both terminals (–) And (+). When working near the battery, it must be removed.
Warning: Removing the battery erases data from the electronic memory units, in particular, the radio code. Without a code, the radio can only be switched on by its manufacturer or an AUDI workshop. So read the notes in the subsection Entering the radio code.
Warning: Welding galvanized sheets produces toxic zinc oxide. Therefore, it is necessary to ensure good ventilation of the workplace.
Warning: Increase the welding current by 10%, maximum 30%.
Warning: Use hard copper electrodes with high heat resistance (above + 400°С).
Warning: Clean the electrodes frequently and grind them down to a contact surface diameter of 4 mm.
Warning: Increase the pressure on the electrode.
Warning: Increase welding time. The time is correct if the welding points are placed without spatter.
Warning: Parts of the air conditioner filled with the working fluid must not be welded and soldered with both soft and hard solder. This also applies to situations where there is a risk of heating of air conditioner components when welding or soldering other structural components.
Additionally
Do not open the cooling circuit of the air conditioner, as refrigerant can cause frostbite if it comes into contact with the skin.
When applying a paint coating in a drying oven, the vehicle must not be heated to temperatures above + 80°C. Otherwise, the vehicle electronics may be damaged. In addition, the pressure in the air conditioner increases, which can lead to the destruction of the system.
The protective coating of the bottom of the car made of PVC is removed with a rotating steel brush or hot air with a temperature of up to +180°C using a spatula. When the PVC coating is heated to temperatures above 180°C, a chemical reaction occurs and hydrochloric acid is formed, which contributes to active corrosion, in addition, harmful vapors are formed.
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