Ford Focus RS (2011 year). Instruction — part 133
• Puddle weld.
E85598
11. Luggage compartment bulkhead
connecting pieces
• Intermittent MIG weld.
E85586
G942256en
501-30-
36
Rear End Sheet Metal Repairs
501-30-
36
REMOVAL AND INSTALLATION
SECTION 501-36 Paint - General Information
PAGE
CONTENTS
SPECIFICATIONS
501-36-3
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
DESCRIPTION AND OPERATION
501-36-4
Description and Usage of Paint Literature. . . . . . . . . . . . . . . . . . ..
501-36-5
Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
501-36-5
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
501-36-5
Hazardous materials designations. . . . . . . . . . . . . . . . . . . . . .
501-36-7
Instructions on measures to be taken for personal protection. . . . . . . . . . .
501-36-7
Icons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
501-36-10
Health and Safety Precautions. . . . . . . . . . . . . . . . . . . . . . ...
501-36-10
General instructions for the paint shop and handling paint materials. . . . . . . . .
501-36-10
Personal protection. . . . . . . . . . . . . . . . . . . . . . . . . . . .
501-36-12
Environmental Regulations. . . . . . . . . . . . . . . . . . . . . . . . .
501-36-12
Waste disposal in the repair paint shop. . . . . . . . . . . . . . . . . . . ..
501-36-12
The new VOC (Volatile Organic Compounds) solvent regulation . . . . . . . . . ..
501-36-13
Factory Paint Application. . . . . . . . . . . . . . . . . . . . . . . . .
501-36-13
General fundamentals of paint technology. . . . . . . . . . . . . . . . . . .
501-36-13
Painting process and corrosion protection. . . . . . . . . . . . . . . . . . .
501-36-14
The structure of an original paint finish . . . . . . . . . . . . . . . . . . . ..
501-36-14
Colored fillers applied in production. . . . . . . . . . . . . . . . . . . . ...
501-36-15
Paintwork Defects and Damage. . . . . . . . . . . . . . . . . . . . . . .
501-36-15
Diagnosis and Damage Assessment. . . . . . . . . . . . . . . . . . . . ..
501-36-15
Paint damage guide. . . . . . . . . . . . . . . . . . . . . . . . . . .
501-36-15
Paint damage caused by environmental factors. . . . . . . . . . . . . . . .
501-36-19
Mechanical damage. . . . . . . . . . . . . . . . . . . . . . . . . . ...
501-36-19
Damage due to corrosion. . . . . . . . . . . . . . . . . . . . . . . . ...
501-36-19
Damage caused by faults in treatment. . . . . . . . . . . . . . . . . . . ...
501-36-29
Tools and Equipment for Paint Repairs. . . . . . . . . . . . . . . . . . . ..
501-36-29
General work equipment. . . . . . . . . . . . . . . . . . . . . . . . .
501-36-29
Filler and spray guns. . . . . . . . . . . . . . . . . . . . . . . . . . ..
501-36-31
Hand and machine sanding tools. . . . . . . . . . . . . . . . . . . . . ...
501-36-34
Polishing and finishing tools. . . . . . . . . . . . . . . . . . . . . . . ...
501-36-34
Infrared drying technology. . . . . . . . . . . . . . . . . . . . . . . . ..
501-36-34
Air dryers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
501-36-35
Paint mixing system. . . . . . . . . . . . . . . . . . . . . . . . . . .
501-36-35
Painting cabin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
501-36-36
Refinishing Materials. . . . . . . . . . . . . . . . . . . . . . . . . . ..
501-36-36
Stopper materials. . . . . . . . . . . . . . . . . . . . . . . . . . . ...
501-36-37
Primers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
501-36-38
HS primer filler and HS tinted filler. . . . . . . . . . . . . . . . . . . . . .
501-36-38
Paint. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
501-36-40
Additional Materials. . . . . . . . . . . . . . . . . . . . . . . . . . .
501-36-40
Adhesive sealants. . . . . . . . . . . . . . . . . . . . . . . . . . . ..
501-36-40
Underbody protection. . . . . . . . . . . . . . . . . . . . . . . . . . .
501-36-
Paint - General Information
501-36-
1
.
PAGE 1 OF 2
VEHICLE APPLICATION:
501-36-41
Paint additives . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
501-36-43
Additive materials. . . . . . . . . . . . . . . . . . . . . . . . . . . ...
501-36-44
Paint Repairs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
501-36-44
General information. . . . . . . . . . . . . . . . . . . . . . . . . . .
501-36-44
Pre-treatment of the surface . . . . . . . . . . . . . . . . . . . . . . . ..
501-36-46
Top coat application. . . . . . . . . . . . . . . . . . . . . . . . . . .
501-36-47
Repair stages for repair painting. . . . . . . . . . . . . . . . . . . . . .
501-36-48
Polish. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
501-36-49
Aids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
501-36-50
Painting Plastic Parts. . . . . . . . . . . . . . . . . . . . . . . . . . ..
501-36-50
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
501-36-50
Plastic groups. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
501-36-51
Painting new components. . . . . . . . . . . . . . . . . . . . . . . . ..
501-36-51
Unknown primer. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
501-36-52
Paint faults on plastic substrates. . . . . . . . . . . . . . . . . . . . . .
501-36-53
Spot Repairs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
501-36-53
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
501-36-54
Repair process. . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
501-36-55
Dirt inclusions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
501-36-57
Corrosion Prevention. . . . . . . . . . . . . . . . . . . . . . . . . . ..
501-36-57
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
501-36-57
Operations after painting. . . . . . . . . . . . . . . . . . . . . . . . .
501-36-57
Definition of the degree of rust. . . . . . . . . . . . . . . . . . . . . . ...
501-36-59
Color Identification and Chromatics. . . . . . . . . . . . . . . . . . . . .
501-36-59
Basic color theory. . . . . . . . . . . . . . . . . . . . . . . . . . . ...
501-36-60
Metallic and pearl pigments. . . . . . . . . . . . . . . . . . . . . . . .
501-36-61
Color codes and their determination on Ford vehicles . . . . . . . . . . . . . ..
501-36-64
Matching tinted filler to the color code . . . . . . . . . . . . . . . . . . . ...
501-36-65
Tips and Tricks. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
501-36-65
Comparing paint structures. . . . . . . . . . . . . . . . . . . . . . . .
501-36-65
Etching substrate. . . . . . . . . . . . . . . . . . . . . . . . . . . .
501-36-65
Masking the vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . .
501-36-67
Color shade problems. . . . . . . . . . . . . . . . . . . . . . . . . .
501-36-67
Isopropanol and water. . . . . . . . . . . . . . . . . . . . . . . . . .
501-36-67
Temperature reduction spray. . . . . . . . . . . . . . . . . . . . . . . ..
501-36-67
Paint plane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
501-36-67
Shading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
501-36-68
Sanding marks. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
501-36-68
Improving touch-up work. . . . . . . . . . . . . . . . . . . . . . . . .
501-36-
Paint - General Information
501-36-
2
.
PAGE 2 OF 2
Specification
Finis Code
Description
-
5 030 492
Underbody protection
WSK-M7C89-A
1 219 834
Anti-corrosion wax
-
5 030 081
Cavity wax
S-M3G4620-A
1 128 983
Profiled butyl seal
-
1 205 996
Weld primer
WSK-M4G245-B
1 136 479
Clinched flange protection
WSS-M4G364-A
1 205 817
Seam sealing compound
-
1 143 255
Body sealing compound
Because the supply of paint materials to the dealer workshops has been handed over to paint suppliers, the specifications for
these materials are not given in the table.
G468087en
501-36-
3
Paint - General Information
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3
SPECIFICATIONS
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:
• DuPont
• Glasurit
• PPG
• 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.
G468088en
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.
G468089en
501-36-
5
Paint - General Information
501-36-
5
DESCRIPTION AND OPERATION
Hazardous material symbols
Description
Item
Very poisonous, T+ (extremely toxic),
small quantities can be fatal.
1
Poisonous, T (toxic), causes serious
damage to health
2
Corrosive, C (corrosive), destroys living
tissue.
3
Harmful to health, Xn (noxious).
4
Irritant, Xi (irritant), can cause
inflammation.
5
Description
Item
Explosive
6
Highly flammable, F+ (extremely
flammable), already flammable at
temperatures below 0° C.
7
Flammable, F (flammable), forms a
flammable mixture with air.
8
Oxidizing, O (oxidizing), reacts with
combustible substances.
9
As well as the danger symbols, there is more
comprehensive manufacturer's information to be
G468089en
501-36-
6
Paint - General Information
501-36-
6
DESCRIPTION AND OPERATION
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
Description
Item
Breathing protection must be worn
1
Eye protection must be worn
2
Ear protection must be worn
3
Protective gloves must be worn
4
Protective footwear must be worn
5
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
Description
Item
Clean
1
Sand
2
Mix
Description
Item
2 component mixture
1
3 component mixture
2
G468089en
501-36-
7
Paint - General Information
501-36-
7
DESCRIPTION AND OPERATION
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