N98.00-2167-09
1 Preparations
2 Cataphoretic immersion priming
3 Cataphoretic immersion priming drier, 180 °C, 30 min
4 E-coat sanding (defects)
5 Lower and inner seam sealant
6 Underfloor protection (UBS) 300 up to 500 μm)
13 Water-based paint (manual, pneumatic)
14 Top coat oven, 70 °C, 4 min
15 Clearcoat (manual and pneumatic, followed by drying at 130 °C,
for 30 min)
16 Repair surface defects
17 Cavity preservation (IGS)
18 Wax drier, ambient temperature
A Manual
7 Outer seam sealant
8 Apply textured paint on inside
9 Underfloor protection drier, 160 °C, 20 min
10 Filler application (water-borne, ESTA and manual)
11 Filler drier, 150 °C, 30 min
12 Grind filler (defects)
N98.00-2163-12
Finish structure, layer depths
1 Surface treated sheet steel
2 Cathodic immersion painting
Outside: 20 μm
Inside: 12 up to 15 μm
3 Water-borne filler 25 μm
4 water-based paint
Outside: 15 up to 25 μm
Inside: 15 up to 30 μm
5 2K clearcoat
Outside: 40 μm
Inside: 25 μm
6 Hollow cavity preservation
Entire paintwork structure:
Standard finish: 100 to 110 μm
Metallic finish: 100 μm
This chapter provides information on the plant and model-specific corrosion prevention measures for the Vario and Vaneo van model series.
The preceding graphics portray the corrosion prevention measure employed at the Ludwigsfelde plant, starting with cleaning the body-in-white and culminating in the assembly of the painted and protected body.
The paintwork structure produced during this process is shown on a sample door.
Cavities as well as seams, folds and the underfloor receive an additional corrosion protection through the application of wax and PVC.
The temperatures stated relate to the object temperatures of the bodies.
The following chapters and documents show how design measures, production flows, painting methods and the use of specific materials provide reliable corrosion protection for the Vaneo.