The following passenger car series are currently produced at the Mercedes-Benz Sindelfingen plant:
Model 203 (C class as of MY 2001)
Model 210 (E class)
Model 215 (CL class)
Model 220 (S class as of MY 2000)
The following two illustrations show the corrosion protection measures in the Sindelfingen plant, starting with the pre-treatment of the body-in-white through to a finish painted and protected body. The temperatures specified relate to the target temperature of the bodies.
The first illustration shows the process sequence for the use of water-based paint, the second illustration shows the sequence for paints containing solvents.
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The following chapters or documents show how reliable corrosion protection is achieved for passenger cars produced in Sindelfingen through design measures, sequences of operations during
production, painting processes and the use of special materials.
The transport film is offered as special equipment to protect the painted surface from damage:
Material: PEPP
Processing method: Applied manually before assembly up to 1998
Applied with robot and manual assistance from 1999
Film thickness: approx. 50 - 70 μm
Function: Assembly and transport protection
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P98.00-0674-09
A Manually performed
1 Pre-cleaning
2 Cataphoretic immersion priming
3 Cataphor. immersion priming, 175° C, 15 min.
4 Body seam sealing
5 Underbody protection (UBS)
6 Underbody protection/body seam sealing drier, 155°C, 15 min.
13 Application of water-based paint (pneum.)
14 Intermediate drier, 60°C, 3 min.
15 Application of clear coat (ESTA, 2K)
16 Top coat drier, 130°C, 22 min.
17 Cavity protection (IGS)
18 Wax drier, 50°C, 6 min.
7 Grinding cataphoretic immersion priming (flaws only)
8 Inserting sound insulation mats
9 Function coating (ESTA)
10 Drier, 130 °C, 17 min.
11 Sanding (flaws only)
12 Application of water-based paint (ESTA)
P98.00-0675-09
Base paint containing solvents
A Manually performed
1 Pre-cleaning
2 Cataphoretic immersion priming
3 Cataphoretic immersion priming drier, 175°C, 15 min.
4 Body seam sealing
11 Sanding (flaws only)
12 Application of base paint (containing solvents)
13 Application of clear coat (ESTA, 1K)
14 Top coat drier, 130°C, 22 min.
15 Cavity protection (IGS)
16 Wax drier, 50°C, 6 min.
5 Underbody protection (UBS)
6 Underbody protection/body seam sealing drier, 155°C, 15 min.
7 Grinding cataphoretic immersion priming (flaws only)
8 Inserting sound insulation mats
9 Function coating (ESTA)
10 Drier, 130 °C, 17 min
P98.00-0676-06
Paint structure, layer thicknesses, solid water-based paint
1 Steel sheet
2 Zinc-phosphatizing approx. 2.5 g/m2
3 Electro-dipcoat primer
on horizontal surfaces 18 μm
on perpendicular surfaces 20 2 μm
4 Function coating 15 - 22 μm
4 Filler (up to 02/98)
on vertical surfaces 30 - 35 μm
on horizontal surfaces 35 - 45 μm
5 Base paint 20 5 μm
Metallic base paint
5 Base paint containing
solvents 13 2 μm
5 Diluted base paint 13 2 μm
Clear varnish
6 1K clear varnish (base paint
containing solvents)
on perpendicular surfaces 33 2 μm
on horizontal surfaces 43 2 μm
6 2K clear varnish (diluted base paint)
on perpendicular surfaces 33 2 μm
on horizontal surfaces 43 2 μm
Paintwork structure