Toyota
Ford Kuga
 Service Manual
Paint - General Information » Paint Repairs
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.

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.

    More about «Paint Repairs»:

    General information

    Pre-treatment of the surface

    Top coat application

    Repair stages for repair painting

    Polish

    Aids

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