Page 1 Service Body Repairs Passat 2011 ➤ Passat Variant 2011 ➤ Edition 04.2011 Service Department. Technical Information...
Page 2 In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed. All rights reserved. No reproduction without prior agreement from publisher. Copyright © 2011 Volkswagen AG, Wolfsburg D3E80312527...
Page 3: Table Of Contents
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Contents 00 - Technical data ........... .
Page 4 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Tools ..............
Page 5 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Renewing A-pillar reinforcement - part section ........192 10.1...
Page 6 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Renewing tail light mounting ..........284 Tools .
Page 7: Technical Data
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 00 – Technical data Vehicle identification data Vehicle identification number The vehicle identification number -1- is located in the area of the lower left-hand side of the windscreen (driver's perspective).
Page 8 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 ♦ The vehicle identification number -arrow A- is located on the wing mounting on the right in the luggage compartment (driv‐ er's perspective). ♦ The vehicle identification number -arrow B- is located on the sill panel seat mounting in the vicinity of the front door on the right side of the vehicle.
Page 9: Safety Instructions
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Safety instructions WARNING Before beginning any cutting, alignment or dent removal, refer to safety notes in the binder General information, body repairs and general body repairs. Safety notes ⇒ General Information; Body Repairs, General Body Repairs ;...
Page 10: Moulded Foam Elements
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Moulded foam elements On this vehicle, various bodywork cavities are fitted with moulded foam elements. The moulded foam elements reduce the amount of driving noise that is transmitted into the interior.
Page 11 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 As these temperatures cannot be achieved under normal work‐ shop conditions, proceed as follows: Remove foam material remains on vehicle. – Apply corrosion protection measures according to guidelines in ⇒...
Page 12: Galvanized Body Parts, High/Higher-Strength And Hot-Formed Body Panels
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Galvanized body parts, high/higher- strength and hot-formed body panels Working on galvanized body panels ⇒ General Information; Body Repairs, General Body Repairs ; Steel panel repairs; galvanized body parts .
Page 13 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 4. Galvanized body parts, high/higher-strength and hot-formed body panels...
Page 14 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Rep. gr.00 - Technical data...
Page 15: Laser Welding
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Laser welding On this vehicle, the roof and parts of the body are laser welded. With laser welding, a high-energy beam of light is directed over the seam to be welded by optical lenses or optical fibre.
Page 16: Body Panel Gaps/Shut Lines
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Body panel gaps/shut lines Note Use setting gauge -3371- to set or check shut lines. Body - front a - 2.5 mm ± 0.5 mm b - – 2.6 mm ± 0.8 mm c - 2.8 mm ±...
Page 17: Body - Centre
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Body - centre a - 2.0 mm ± 1.0mm b - 0.6 mm ± 0.5 mm c - 0.0 mm + 1.0 mm d - 4.2 mm ± 1.5 mm e - 0.0 mm + 1.0 mm...
Page 18: Body - Rear
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Body - rear a - 2.5 mm ± 0.5 mm b - – 3.2 mm ± 0.5 mm c - 5.5 mm ± 0.5 mm d - 3.5 mm ± 0.5 mm e - –...
Page 19: Body - Rear (Variant)
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Body - rear (Variant) a - 5.0 mm ± 0.5 mm b - – 0.8 mm – 1.0 mm + 0.5 c - 5.0 mm ± 0.5 mm d - 3.5 mm ±...
Page 20: Body Dimensions
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Body dimensions Note Dimensions only given for checking purposes. The alignment ♦ bracket set is the final authority. Bolts, screws, plugs, trim and attached components must be ♦...
Page 21 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 a - 920 mm ± 2.0 mm b - 1,479 mm ± 2.0 mm 7. Body dimensions...
Page 22: Body - Centre
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Body - centre a - 1,445 mm ± 2.0 mm Rep. gr.00 - Technical data...
Page 23 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 a - 1,480 mm ± 2.0 mm 7. Body dimensions...
Page 24 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 a - 1,472 mm ± 2.0 mm Rep. gr.00 - Technical data...
Page 25 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 a - 882 mm ± 2.0 mm b - 896 mm ± 2.0 mm 7. Body dimensions...
Page 26 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 a - 970 mm ± 2.0 mm b - 741 mm ± 2.0 mm Rep. gr.00 - Technical data...
Page 27: Body - Centre (Variant)
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Body - centre (Variant) a - 972 mm ± 2.0 mm b - 740 mm ± 2.0 mm 7. Body dimensions...
Page 28: Body - Rear
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Body - rear a - 528 mm ± 2.0 mm b - 1,125 mm ± 2.0 mm Rep. gr.00 - Technical data...
Page 29: Body - Rear (Variant)
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Body - rear (Variant) a - 857 mm ± 2.0 mm b - 938 mm ± 2.0 mm c - 1,198 mm ± 2.0 mm 7. Body dimensions...
Page 30: Floor Group - Front
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Floor group - front a - 430 mm ± 2.0 mm b - 874 mm ± 2.0 mm c - 678 mm ± 2.0 mm d - 1,152 mm ± 2.0 mm...
Page 31: Floor Group - Centre
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Floor group - centre Note Dimension -a- is measured on floor at the left and right B-pillar. a - 1,486 mm ± 2.0 mm 7. Body dimensions...
Page 32: Floor Group - Rear
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Floor group - rear a - 1,000 mm ± 2.0 mm b - 1,085 mm ± 2.0 mm c - 987 mm ± 2.0 mm Rep. gr.00 - Technical data...
Page 33: Tools
The use of different types and different thicknesses of steel ♦ requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 34: Alignment Bracket Set
Special tools and workshop equipment required ♦ Alignment bracket set Passat 2011 -VAS6325/3- ♦ Basic alignment bracket set -V.A.G 1610/- Set up of complete alignment bracket set for Passat 2011 - VAS6325/3- . Detailed information on setting up the alignment bracket set can be found with the equipment.
Page 35: Portal Gauge
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Portal gauge Note Alignment tasks may only be performed using Volkswagen AG approved alignment bracket sets or measurement and alignment systems . 10.1 Overview Special tools and workshop equipment required ♦...
Page 36 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Detailed information on setting up the portal gauge supplement for Passat 2006 -VAS 5007/22- set can be found with the equip‐ ment. 10.1.2 Rear door aperture Set up for portal gauge -VAS 5007- with portal gauge supplement for Passat 2006 -VAS 5007/22- , rear door aperture.
Page 37: Body - Front
The use of different types and different thicknesses of steel ♦ requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 38: Removing
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Removing – Separate original joint. Rep. gr.50 - Body - front...
Page 39 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Separate original joint. 1. Renewing left console...
Page 40: Installing
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Remove remaining material. Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 31 1.3.1 Preparing new part New part ♦ Left engine console –...
Page 41 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 1.3.2 Welding in – Adapt new part with vehicle positioned on alignment bracket set and fix in place. – Weld in console, SG plug weld seam and RP spot weld seam.
Page 42: Renewing Right Console
The use of different types and different thicknesses of steel ♦ requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 43: Removing
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Removing – Separate original joint. 2. Renewing right console...
Page 44: Installing
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Remove remaining material. Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 36 2.3.1 Welding in New part ♦ Right engine bracket –...
Page 45 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Weld in console, RP spot weld seam. 2. Renewing right console...
Page 46: Renewing Retaining Bracket For Subframe
The use of different types and different thicknesses of steel ♦ requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 47: Removing
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Removing – Separate original joint. 3. Renewing retaining bracket for subframe...
Page 48: Installing
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Remove remaining material. Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 40 3.3.1 Preparing new part New part ♦ Retaining bracket for subframe (parts designation: subframe retaining bracket) Rep.
Page 49 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Drill holes for SG plug weld seam (8 mm ∅). 3.3.2 Welding in – Adapt new part with vehicle positioned on alignment bracket set and fix in place.
Page 50: Renewing Bumper Bracket
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 RO: 50 65 55 50 Renewing bumper bracket WARNING Observe safety notes! Safety notes ⇒ General Information; Body Repairs, General Body Repairs ; Safety notes 1 - Bumper bracket...
Page 51: Tools
The use of different types and different thicknesses of steel ♦ requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 52: Installing
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Remove remaining material. Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 45 4.3.1 Welding in New part ♦ Front bumper bracket –...
Page 53 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Weld in bumper bracket, SG continuous weld seam. 4. Renewing bumper bracket...
Page 54: Renewing Upper Wheel Housing Longitudinal Member
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 RO: 50 72 55 00 Renewing upper wheel housing lon‐ gitudinal member Comprises: upper outer longitudinal member and upper inner longitudinal member Note If the upper longitudinal member for wheel housing is re‐...
Page 55: Tools
The use of different types and different thicknesses of steel ♦ requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 56: Removing
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Removing – Separate original joint at upper outer longitudinal member -1-. Rep. gr.50 - Body - front...
Page 57 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Separate original joint at upper inner longitudinal member -1-. 5. Renewing upper wheel housing longitudinal member...
Page 58: Installing
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Remove remaining material. Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 49 5.3.1 Preparing new part New part ♦ Upper inner longitudinal member ♦...
Page 59 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Drill 8 mm ∅ holes in upper outer longitudinal member for SG plug weld seam. 5.3.2 Welding in Note New part must be welded in within 90 minutes or adhesion of ad‐...
Page 60 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Weld in upper inner longitudinal member -1-, RP spot weld seam and SG staggered continuous weld seam. – Apply 2K body adhesive -D 180 KD3 A2- to areas bonded in the factory.
Page 61 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Adapt upper outer longitudinal member to fit with upper inner longitudinal member and check fit with adjacent parts. – Weld in upper outer longitudinal member, SG plug weld seam and RP spot weld seam.
Page 62: Renewing Front Wheel Housing
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 RO: 50 74 55 50 Renewing front wheel housing Includes: suspension strut mounting WARNING Observe safety notes! Safety notes ⇒ General Information; Body Repairs, General Body Repairs ; Safety notes •...
Page 63: Body Repairs - Edition 04.2011
♦ The use of different types and different thicknesses of steel requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 64 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Separate remainder of joint to plenum chamber -1-. Rep. gr.50 - Body - front...
Page 65: Installing
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Remove remaining material. Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 57 6.3.1 Preparing new parts ♦ Wheel housing ♦ Suspension strut mounting ♦...
Page 66 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Drill holes for SG plug weld seam (8 mm ∅). Note Drill a double row of holes in area -1-. ♦ Distance between holes: approx. 30 mm.
Page 67 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 6.3.2 Welding in – Adapt new part with assistance of alignment bracket fixtures -item 13-, -item 15-, -item 16- and -item 17- from alignment bracket set and to adjacent parts and fix in place.
Page 68 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Weld suspension strut mounting to suspension strut mounting reinforcement, SG plug weld seam. – Drill holes -1- (10 mm ∅) for mounting suspension strut. Ad‐ ditionally secure suspension strut mounting and suspension strut mounting reinforcement to alignment bracket fixture -2- using bolts.
Page 69 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Weld wheel housing and suspension strut mounting reinforce‐ ment, SG plug weld seam. 6. Renewing front wheel housing...
Page 70 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Recreate joint between suspension strut mounting and ple‐ num chamber; SG plug weld seam. – Recreate original joint between suspension strut mounting and suspension strut mounting reinforcement, RP spot weld seam.
Page 71 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Enlarge hole in suspension strut mounting reinforcement to dimension -a-. Dimension -a- = 34 mm Note Item 17 of alignment bracket set can be used to check dimension -a- ⇒...
Page 72: Repairing Threads For Securing Subframe (Suspension Subframe)
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 RO: 50 79 49 90 Repairing threads for securing sub‐ frame (suspension subframe) WARNING Observe safety notes! Safety notes ⇒ General Information; Body Repairs, General Body Repairs ; Safety notes...
Page 73: Tools
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Tools Special tools and workshop equipment required ♦ M12x1.5 thread repair set -VAS 6058- ♦ Drill -VAS 6267- Contents of thread repair kit 1 - Twist drill 12.5 mm ∅...
Page 74: Repairing Threads
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Repairing threads 7.3.1 Drilling thread – Drill out thread using twist drill. Note The drill must be held by an assistant using an additional hand ♦ support when drilling.
Page 75 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 7.3.2 Cutting thread – Cut thread with thread-cutting tap – Clean threaded sleeve (with compressed air). 7.3.3 Inserting thread insert – Screw thread insert -3- onto fitting spindle until the fitting pin -2- contacts the fitting lug -1- on the fitting spindle.
Page 76 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Screw thread insert into the threaded plate until the top of the thread insert is flush with the outer edge of the threaded plate (visual check).
Page 77: Renewing Front Longitudinal Member
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 RO: 50 79 55 00 Renewing front longitudinal member Includes: bumper mounting WARNING Observe safety notes! Safety notes ⇒ General Information; Body Repairs, General Body Repairs ; Safety notes...
Page 78: Tools
The use of different types and different thicknesses of steel ♦ requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 79 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Make parting cut on longitudinal member as shown. Dimension -a- = 55 mm 8. Renewing front longitudinal member...
Page 80 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Make parting cut on longitudinal member cover plate as shown. Dimension -a- = 55 mm Rep. gr.50 - Body - front...
Page 81: Installing
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Remove remaining material. Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 72 8.3.1 Preparing new part New part ♦ Longitudinal member assembly...
Page 82 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Transfer parting cuts to new part and cut out. – Drill holes for SG plug weld seam (8 mm ∅). 8.3.2 Welding in – Adapt new part with vehicle positioned on alignment bracket set and fix in place.
Page 83 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Check fit with adjacent parts. – Butt weld parting cut of longitudinal member all around (SG continuous weld seam). – Butt weld cover plate parting cut, SG continuous weld seam.
Page 84 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 8.3.3 Shortening new longitudinal member with cover plate Note The longitudinal member -2- with cover plate -1- (parts designation: longitudinal member) is too long at the front -shaded area- and must be shortened when adapting and welding in the bumper bracket.
Page 85 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Assemble alignment bracket mounting for front longitudinal member -RW 1- with spacer -RW 3- as shown and hold against longitudinal member from below. – Transfer dimensions (plus an additional 2mm) -a- to longitu‐...
Page 86 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Fix front bumper bracket -1- in position in front of longitudinal member -2- with aid of -RW 1- and -RW 3-. Note There must be a gap of 1-2 mm between longitudinal member -2- with cover plate -3- and bumper bracket -1-.
Page 87 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Weld in bumper bracket, SG continuous weld seam. 8. Renewing front longitudinal member...
Page 88: Renewing Front Longitudinal Member - Part Section
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 RO: 50 79 55 02 Renewing front longitudinal member - part section Includes: bumper bracket and longitudinal member reinforcement WARNING Observe safety notes! Safety notes ⇒ General Information; Body Repairs, General Body Repairs ;...
Page 89: Tools
The use of different types and different thicknesses of steel ♦ requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 90 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Position parting cuts -1 and 3- on longitudinal member ac‐ cording to degree of damage and cut out. Caution The parting cut for the longitudinal member is permitted only in the area shown.
Page 91 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Position parting cut -3- on longitudinal member -1- and longi‐ tudinal member -2- congruently and cut out. – Take note of laser weld seam -4-. 9. Renewing front longitudinal member - part section...
Page 92: Installing
Body Repairs - Edition 04.2011 – Remove residual material and remainder of longitudinal mem‐ ber reinforcement -1-. Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 83 9.3.1 Preparing new part New part ♦ Longitudinal member ♦...
Page 93 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Transfer parting cut to longitudinal member and longitudinal member cover plate and cut out. 9.3.2 Welding in – Adapt new part with vehicle positioned on alignment bracket set and fix in place.
Page 94 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Check fit with adjacent parts. – Weld in longitudinal member parting cut (all round), SG con‐ tinuous weld seam. Rep. gr.50 - Body - front...
Page 95 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Weld in longitudinal member reinforcement, RP spot weld seam. 9. Renewing front longitudinal member - part section...
Page 96 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Weld in cover plate, RP spot weld seam. Note Distance between weld points -a- approx. 35-40 mm – Weld in cover plate parting cut, SG continuous weld seam.
Page 97: Body - Centre
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 51 – Body - centre RO: 51 03 55 00 Renewing roof WARNING Observe safety notes! Safety notes ⇒ General Information; Body Repairs, General Body Repairs ; Safety notes...
Page 98: Tools
The use of different types and different thicknesses of steel ♦ requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 99 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 ♦ Setting gauge -3371- ♦ Tensioning strap -T10038- ♦ Suction lifter -V.A.G 1344- 1. Renewing roof...
Page 100: Removing
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Removing Note Apply textile adhesive tape on left and right roof members parallel to laser solder seams. This reduces ♦ danger of damage and contamination during repairs.
Page 101 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Note Roof side member -1- must not be damaged when removing residual remains of roof -2-. ♦ Use flap or felt discs only, do not use cutting disks or rough grinding disks.
Page 102: Installing
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 92 1.3.1 Preparing new part New part ♦ Roof ♦ 1K assembly adhesive -D 190 MKD A3- (3 cartridges) ♦...
Page 103 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Lightly sand down bonding areas on left and right of roof. This ensures that the 2K body adhesive -D 180 KD3 A2- bonds well with bonding areas.
Page 104 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 1.3.2 Adjusting roof depth Note The securing belts -1- prevent the roof lifting off the roof frame or shifting during the adhesion process. ♦ Securing belts must not be tightened too tightly in order to avoid damage.
Page 105 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 1.3.3 Bonding roof – Remove roof. – Apply corrosion protection measures according to guidelines in ⇒ Paint workshop manual: Corrosion and corrosion pro‐ tection, attached and welded parts, materials .
Page 106 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Apply 1K assembly adhesive -D 190 MKD A3- to roof cross member in area of the factory-fitted bonds using compressed air gun -V.A.G 1761/1- . Rep. gr.51 - Body - centre...
Page 107 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – In area of roof side member, apply 1K assembly adhesive -D 190 MKD A3- -1- using pneumatic cartridge gun - V.A.G 1761/1- . ♦ Dimension -a- = approx. 12 mm ♦...
Page 108 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Apply 1K assembly adhesive -D 190 MKD A3- on inner side of roof parallel to left and right roof flange with pneumatic car‐ tridge gun -V.A.G 1761/1- .
Page 109 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Cut first step of static mixer -D- off to achieve corresponding bead cross-section. – Carefully operate double cartridge gun -VAS 5237- without static mixer until adhesive is discharged uniformly from both chambers of cartridge connector.
Page 110 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Coat roof flanges with 2K body adhesive -D 180 KD3 A2- . – Immediately position and align roof. – Secure roof at front and rear window apertures using vice-grip pliers and also secure centre of roof using securing belts ⇒...
Page 111 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 1.3.4 Welding in – Weld roof in front and rear window apertures, RP spot weld seam. 1. Renewing roof...
Page 112 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Apply adhesive sealant -AKD 476 KD5 05- to seam between roof and roof side member to fully seal bonded seam -1-. – After painting, preserve roof cavities -arrow- with corrosion- preventive wax -AKR 321 M15 4- .
Page 113: Renewing Roof - Vehicles With Sliding/Tilting Sunroof
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 RO: 51 03 55 03 Renewing roof - vehicles with sliding/ tilting sunroof WARNING Observe safety notes! Safety notes ⇒ General Information; Body Repairs, General Body Repairs ; Safety notes...
Page 114: Tools
The use of different types and different thicknesses of steel ♦ requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 115 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 ♦ Setting gauge -3371- ♦ Tensioning strap -T10038- ♦ Suction lifter -V.A.G 1344- 2. Renewing roof - vehicles with sliding/tilting sunroof...
Page 116: Removing
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Removing Note Apply textile adhesive tape on left and right roof members parallel to laser solder seams. This reduces ♦ danger of damage and contamination during repairs.
Page 117 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Release bonded joints -1 and 3- from reinforcing frame -2-. – Separate original joint to inner side panel on left and right. Note Roof side member -1- must not be damaged when removing residual remains of roof -2-.
Page 118: Installing
– Remove all adhesive residues from left and right roof side members. – Touch up paint damage in accordance with Paint Workshop Manual. Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 108 2.3.1 Preparing new part New part ♦ Roof ♦...
Page 119 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 ♦ 2K body adhesive -D 180 KD3 A2- (2 cartridge sets) ♦ Adhesive sealant -AKD 476 KD5 05- ♦ Cavity sealant -AKR 321 M15 4- ♦ Felt -533 867 910 B-...
Page 120 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Check roof fit with windscreen and rear window. 2.3.2 Adjusting roof depth Note The securing belts -1- prevent the roof lifting off the roof frame or shifting during the adhesion process.
Page 121 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – If necessary for compensation purposes, place pieces of felt -533 867 910 B- on roof frame. 2.3.3 Bonding roof – Remove roof. – Apply corrosion protection measures according to guidelines in ⇒...
Page 122 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Apply 1K assembly adhesive -D 190 MKD A3- to roof cross member and to contact surfaces of reinforcing frame in area of the factory-fitted bonds using pneumatic cartridge gun - V.A.G 1761/1- .
Page 123 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – In area of roof side member, apply 1K assembly adhesive -D 190 MKD A3- -1- using pneumatic cartridge gun - V.A.G 1761/1- . ♦ Dimension -a- = approx. 12 mm ♦...
Page 124 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Apply 1K assembly adhesive -D 190 MKD A3- on inner side of roof parallel to left and right roof flange with pneumatic car‐ tridge gun -V.A.G 1761/1- .
Page 125 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Cut first step of static mixer -D- off to achieve corresponding bead cross-section. – Carefully operate double cartridge gun -VAS 5237- without static mixer until adhesive is discharged uniformly from both chambers of cartridge connector.
Page 126 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Coat roof flanges with 2K body adhesive -D 180 KD3 A2- . – Immediately position and align roof. – Secure roof at front and rear window apertures using vice-grip pliers and also secure centre of roof using securing belts ⇒...
Page 127 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 2.3.4 Welding in – Weld roof in front and rear window apertures, RP spot weld seam. 2. Renewing roof - vehicles with sliding/tilting sunroof...
Page 128 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Weld reinforcing frame to inside of side panel, SG staggered continuous weld seam. Rep. gr.51 - Body - centre...
Page 129 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Apply adhesive sealant -AKD 476 KD5 05- to seam between roof and roof side member to fully seal bonded seam -1-. – After painting, preserve roof cavities -arrow- with corrosion- preventive wax -AKR 321 M15 4- .
Page 130: Renewing Roof (Variant)
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 RO: 51 03 55 10 Renewing roof (Variant) WARNING Observe safety notes! Safety notes ⇒ General Information; Body Repairs, General Body Repairs ; Safety notes 1 - Roof...
Page 131: Tools
The use of different types and different thicknesses of steel ♦ requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 132 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 ♦ Setting gauge -3371- ♦ Tensioning strap -T10038- ♦ Suction lifter -V.A.G 1344- Rep. gr.51 - Body - centre...
Page 133: Removing
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Removing Note Apply textile adhesive tape on left and right roof members parallel to laser solder seams. This reduces ♦ danger of damage and contamination during repairs.
Page 134 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Note Roof side member -1- must not be damaged when removing residual remains of roof -2-. ♦ Use flap or felt discs only, do not use cutting disks or rough grinding disks.
Page 135: Installing
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 125 3.3.1 Preparing new part New part ♦ Roof ♦ 1K assembly adhesive -D 190 MKD A3- (3 cartridges) ♦...
Page 136 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Drill 6 mm ∅ holes for SG plug weld seam at transition to tail‐ gate aperture. – Lightly sand down bonding areas -1- on left and right of roof.
Page 137 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 3.3.2 Adjusting roof depth Note The securing belts -1- prevent the roof lifting off the roof frame or shifting during the adhesion process. ♦ Securing belts must not be tightened too tightly in order to avoid damage.
Page 138 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 3.3.3 Bonding roof – Remove roof. – Apply corrosion protection measures according to guidelines in ⇒ Paint workshop manual: Corrosion and corrosion pro‐ tection, attached and welded parts, materials .
Page 139 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Apply 1K assembly adhesive -D 190 MKD A3- to roof cross member in area of the factory-fitted bonds using compressed air gun -V.A.G 1761/1- . 3. Renewing roof (Variant)
Page 140 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – In area of roof side member, apply 1K assembly adhesive -D 190 MKD A3- -1- using pneumatic cartridge gun - V.A.G 1761/1- . ♦ Dimension -a- = approx. 12 mm ♦...
Page 141 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Apply 1K assembly adhesive -D 190 MKD A3- on inner side of roof parallel to left and right roof flange with pneumatic car‐ tridge gun -V.A.G 1761/1- .
Page 142 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Cut first step of static mixer -D- off to achieve corresponding bead cross-section. – Carefully operate double cartridge gun -VAS 5237- without static mixer until adhesive is discharged uniformly from both chambers of cartridge connector.
Page 143 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Coat roof flanges with 2K body adhesive -D 180 KD3 A2- . – Immediately position and align roof. – Secure roof in area of windscreen aperture and tailgate aper‐...
Page 144 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 3.3.4 Welding in – Weld roof in windscreen aperture, RP spot weld seam. – Weld roof in tailgate aperture, SG plug weld seam and MIG solder seam.
Page 145 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Apply adhesive sealant -AKD 476 KD5 05- to seam between roof and roof side member to fully seal bonded seam -1-. – After painting, preserve roof cavities -arrow- with corrosion- preventive wax -AKR 321 M15 4- .
Page 146: Renewing Roof - Variant With Panorama Sliding Sunroof
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 RO: 51 03 55 13 Renewing roof - Variant with panora‐ ma sliding sunroof WARNING Observe safety notes! Safety notes ⇒ General Information; Body Repairs, General Body Repairs ;...
Page 147: Tools
The use of different types and different thicknesses of steel ♦ requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 148 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 ♦ Setting gauge -3371- ♦ Tensioning strap -T10038- ♦ Suction lifter -V.A.G 1344- Rep. gr.51 - Body - centre...
Page 149: Removing
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Removing Note Apply textile adhesive tape on left and right roof members parallel to laser solder seams. This reduces ♦ danger of damage and contamination during repairs.
Page 150 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Release bonded joints -1- from reinforcing frame -2-. – Separate original joint to inner side panel on left and right. Note Roof side member -1- must not be damaged when removing residual remains of roof -2-.
Page 151: Installing
– Remove all adhesive residues from left and right roof side members. – Touch up paint damage in accordance with Paint Workshop Manual. Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 141 4.3.1 Preparing new part New part ♦ Roof ♦...
Page 152 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 ♦ 2K body adhesive -D 180 KD3 A2- (2 cartridge sets) ♦ Adhesive sealant -AKD 476 KD5 05- ♦ Cavity sealant -AKR 321 M15 4- ♦ Felt -533 867 910 B-...
Page 153 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – 4 suction lifters -V.A.G 1344- are positioned on outer sides of roof. – Position roof on roof frame. – Check roof fit with windscreen and tailgate.
Page 154 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Check line of roof versus roof side members. ♦ Dimension -a- = 4.0 ± 0.5 mm – If necessary for compensation purposes, place pieces of felt -533 867 910 B- on roof frame.
Page 155 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Apply 1K assembly adhesive -D 190 MKD A3- to roof cross member and roof frame in area of the factory-fitted bonds us‐ ing pneumatic cartridge gun -V.A.G 1761/1- .
Page 156 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – In area of roof side member, apply 1K assembly adhesive -D 190 MKD A3- -1- using pneumatic cartridge gun - V.A.G 1761/1- . ♦ Dimension -a- = approx. 12 mm ♦...
Page 157 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Apply 1K assembly adhesive -D 190 MKD A3- on inner side of roof parallel to left and right roof flange with pneumatic car‐ tridge gun -V.A.G 1761/1- .
Page 158 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Cut first step of static mixer -D- off to achieve corresponding bead cross-section. – Carefully operate double cartridge gun -VAS 5237- without static mixer until adhesive is discharged uniformly from both chambers of cartridge connector.
Page 159 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Coat roof flanges with 2K body adhesive -D 180 KD3 A2- . – Immediately position and align roof. – Secure roof in area of windscreen aperture and tailgate aper‐...
Page 160 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 4.3.4 Welding in – Weld roof in windscreen aperture, RP spot weld seam. – Weld roof in tailgate aperture, SG plug weld seam and MIG solder seam.
Page 161 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Weld reinforcing frame to inside of side panel, SG staggered continuous weld seam. 4. Renewing roof - Variant with panorama sliding sunroof...
Page 162 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Apply adhesive sealant -AKD 476 KD5 05- to seam between roof and roof side member to fully seal bonded seam -1-. – After painting, preserve roof cavities -arrow- with corrosion- preventive wax -AKR 321 M15 4- .
Page 163: Renewing Roof Side Member
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 RO: 51 05 55 50 Renewing roof side member WARNING Observe safety notes! Welding, parting using spark generating machines/tools or tin‐ ning in foam treated areas creates gases which are hazardous to health and environment.
Page 164: Tools
The use of different types and different thicknesses of steel ♦ requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 165 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Dimension -a- = 120 mm Partial renewal A part section repair is possible using parting cut -1-. Dimension -b- approx. 250 mm Keep the cutting of the replacement part in mind.
Page 166: Installing
Body Repairs - Edition 04.2011 – Remove remaining material. – Remove remaining adhesive completely and grind bonded surface back to bare metal. Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 158 Rep. gr.51 - Body - centre...
Page 167 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Note MIG solder seams or SG continuous weld seams are permitted at the parting cuts shown in the illustration. 5.3.1 Preparing new part New part ♦ Side panel ♦...
Page 168 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Transfer parting cut to new part and cut out. – Generously mask interior area to be foam treated -1- using textile adhesive tape ⇒ Item 4 (page 167) from roof member cavity foam treatment kit -D 506 110 A2- .
Page 169 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 5.3.3 Welding in Note New part must be welded in within 90 minutes or adhesion of ad‐ hesive will be impaired. – Apply 2K body adhesive -D 180 KD3 A2- in the areas indica‐...
Page 170 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Weld in parting cuts, MIG solder seam or SG continuous weld seam are permitted. Note Both weld symbols are shown in the figure. Note In the area of the A, B and C-pillars, high tensile, highest tensile and hot formed steels are used. The weld ♦...
Page 171 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Therefore, locate spot welds as close to the centre as possible. • Dimension -a- of 8mm can be achieved using angled welding tips. 5. Renewing roof side member...
Page 172: Foam Treating Roof Side Member
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Weld in B-pillar parting cut, MIG solder seam or SG continuous weld seam are permitted. Note Both weld symbols are shown in the figure. – Weld roof side member to door apertures, RP spot weld seam (inverter).
Page 173 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 1 - 2K structural foam cartridge – Open cap 2 - Static mixer – Cut of the front section of the cone only. 3 - Extension hose...
Page 174 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Inject structural foam through opening for blind rivet nuts -arrow- in roof -1- using pneumatic cartridge gun -V.A.G 1761/1- and static mixer. – Then seal opening with a blind rivet nut.
Page 175: Renewing Front Roof Cross Member
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 RO: 51 07 55 50 Renewing front roof cross member WARNING Observe safety notes! Safety notes ⇒ General Information; Body Repairs, General Body Repairs ; Safety notes Roof already removed.
Page 176: Tools
The use of different types and different thicknesses of steel ♦ requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 177: Installing
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Remove residues at transition to left and right roof frame. Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 170 6.3.1 Welding in New part ♦...
Page 178 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Weld in front roof cross member, RP spot weld seam and SG plug weld seam. Install roof. • Saloon ⇒ page 96 • Saloon with sliding/tilting sunroof ⇒...
Page 179: Renewing Rear Roof Cross Member (Saloon)
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 RO: 51 09 55 50 Renewing rear roof cross member (saloon) WARNING Observe safety notes! Safety notes ⇒ General Information; Body Repairs, General Body Repairs ; Safety notes Roof already removed.
Page 180: Tools
The use of different types and different thicknesses of steel ♦ requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 181: Installing
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Remove residues at transition to left and right roof frame. Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 174 7.3.1 Welding in New part ♦...
Page 182 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Weld in roof cross member, SG plug weld seam and RP spot weld seam. – Install roof ⇒ page 96 Rep. gr.51 - Body - centre...
Page 183: Renewing Rear Roof Cross Member (Variant)
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 RO: 51 09 55 60 Renewing rear roof cross member (Variant) WARNING Observe safety notes! Safety notes ⇒ General Information; Body Repairs, General Body Repairs ; Safety notes Roof already removed.
Page 184: Tools
The use of different types and different thicknesses of steel ♦ requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 185: Installing
– Remove remaining material. – Remove remaining adhesive completely and grind bonded surface back to bare metal. Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 178 8.3.1 Preparing new part New part ♦ Rear roof cross member (Variant) ♦...
Page 186 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Drill holes for SG plug weld seam (8 mm ∅). 8.3.2 Welding in Note New part must be welded in within 90 minutes or adhesion of adhesive will be impaired.
Page 187 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Adapt new part with vehicle standing on its wheels or align‐ ment bracket set and fix in position. – Check fit to roof and tailgate. – Weld rear roof cross member to left and right D-pillars -1- from inside, SG continuous weld seam.
Page 188: Renewing A-Pillar
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 RO: 51 37 55 00 Renewing A-pillar WARNING Observe safety notes! Welding, parting using spark generating machines/tools or tin‐ ning in foam treated areas creates gases which are hazardous to health and environment.
Page 189: Tools
The use of different types and different thicknesses of steel ♦ requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 190 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Locate parting cuts -1- and -2- according to degree of damage and cut out. – Separate original joint. Retainer for wing -3- is cut out as well and replaced.
Page 191: Installing
Body Repairs - Edition 04.2011 – Remove remaining material. – Remove remaining adhesive completely and grind bonded surface back to bare metal. Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 183 9. Renewing A-pillar...
Page 192 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Note MIG solder seams or SG continuous weld seams are permitted at the parting cuts shown in the illustration. 9.3.1 Preparing new part New part ♦ Front side panel subpart (replacement part designation: sub‐...
Page 193 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Transfer parting cut to new part and cut out. – Drill holes for SG plug weld seam (8 mm ∅). 9.3.2 Moulded foam elements Follow repair instructions.
Page 194 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 9.3.3 Welding in Note New part must be welded in within 90 minutes or adhesion of adhesive will be impaired. ♦ Adhesive must be cleaned from holes for fastening hinges after bonding in.
Page 195 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Therefore, locate spot welds as close to the centre as possible. • Dimension -a- of 8mm can be achieved using angled welding tips. – Adapt new part with vehicle standing on its wheels or align‐...
Page 196 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Weld in parting cuts, MIG solder seam or SG continuous weld seam are permitted. Note Both weld symbols are shown in the figure. – Weld in door aperture and windscreen aperture, RP spot weld seam (inverter).
Page 197 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Adapt retainers -1- for wing when adapting wing and secure. – Check gaps/shut lines ⇒ page 10 – Weld in wing retainer, SG plug weld seam.
Page 198: Renewing A-Pillar Reinforcement - Part Section
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 RO: 51 38 55 53 Renewing A-pillar reinforcement - part section WARNING Observe safety notes! Welding, parting using spark generating machines/tools or tin‐ ning in foam treated areas creates gases which are hazardous to health and environment.
Page 199: Tools
The use of different types and different thicknesses of steel ♦ requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 200 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Dimension -a- = 90 mm – Position parting cut -2- at A-pillar reinforcing as shown and cut out. Dimension -b- = 140 mm – Separate original joint of A-pillar reinforcement.
Page 201: Installing
– Remove remaining material. – Remove remaining adhesive completely and grind bonded surface back to bare metal. 10.3 Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 193 10.3.1 Preparing new part New part ♦ A-pillar reinforcement ♦...
Page 202 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Transfer parting cut to new part and cut out. – Drill holes for SG plug weld seam (8 mm ∅). – Clip new moulded foam element -2- into hinge reinforcing -1-.
Page 203 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 10.3.3 Welding in Note In the area of the A, B and C-pillars, high tensile, highest tensile and hot formed steels are used. The weld ♦ flanges in these areas are about 13mm wide.
Page 204 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Weld in A-pillar reinforcement, SG plug weld seam and RP spot weld seam (inverter). – Recreate original joint to front wheel housing, MIG solder seam. – Weld in parting cut, SG continuous weld seam.
Page 205: Renewing B-Pillar
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 RO: 51 41 55 02 Renewing B-pillar WARNING Observe safety notes! Welding, parting using spark generating machines/tools or tin‐ ning in foam treated areas creates gases which are hazardous to health and environment.
Page 206: Tools
The use of different types and different thicknesses of steel ♦ requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 207 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Make parting cut -1- as shown. Dimension -a- = 120 mm Partial renewal A part section repair of B-pillar is possible using parting cut -2-. – Place parting cuts -3- according to degree of damage.
Page 208: Installing
Body Repairs - Edition 04.2011 – Remove remaining material. – Remove remaining adhesive completely and grind bonded surface back to bare metal. 11.3 Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 183 Rep. gr.51 - Body - centre...
Page 209 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Note MIG solder seams or SG continuous weld seams are permitted at the parting cuts shown in the illustration. 11.3.1 Preparing new part New part ♦ Subpart side panel ♦...
Page 210 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Transfer parting cut to new part and cut out. – Drill holes for SG plug weld seam (8 mm ∅). 11.3.2 Marking area where no welding work may be carried out –...
Page 211 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 ♦ Dimension -a- = 50 mm ♦ Dimension -b- = 160 mm 11.3.3 Moulded foam elements Follow repair instructions. Moulded foam elements ⇒ General Information; Body Repairs, General Body Repairs ;...
Page 212 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Apply sealing cord -AKD 497 010 04 R10- to area -1-. – Apply 2K body adhesive -D 180 KD3 A2- to areas bonded in the factory.
Page 213 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Therefore, locate spot welds as close to the centre as possible. • Dimension -a- of 8mm can be achieved using angled welding tips. – Adapt new part with vehicle standing on its wheels or align‐...
Page 214 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Weld in parting cuts, MIG solder seam or SG continuous weld seam are permitted. – Weld in B-pillar, RP spot weld seam (inverter). Note Note prohibited weld areas -1- where welding is not allowed.
Page 215 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Recreate remaining joint to side member reinforcement, SG plug weld seam. 11. Renewing B-pillar...
Page 216: Renewing B-Pillar Reinforcement - Part Section
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 RO: 51 42 55 53 Renewing B-pillar reinforcement - part section Includes: front side member reinforcement (part section) and rear side member reinforcement (part section) WARNING Observe safety notes! Welding, parting using spark generating machines/tools or tin‐...
Page 217: Tools
The use of different types and different thicknesses of steel ♦ requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 218 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Position and make parting cuts as shown. Dimension -a- = 240 mm Dimension -b- = 140 mm Dimension -c- = 100 mm – Separate original joint.
Page 219: Installing
– Remove remaining material. – Remove remaining adhesive completely and grind bonded surface back to bare metal. 12.3 Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 211 12.3.1 Preparing new part New part ♦ B-pillar reinforcement ♦...
Page 220 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 ♦ 2K body adhesive -D 180 KD3 A2- Note B-pillar reinforcement is identical for saloon and Variant. – Transfer parting cuts to B-pillar reinforcing -1-, side member rear reinforcing -3- and side member front reinforcing -5- and cut new parts accordingly.
Page 221 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Adapt crash reinforcing -1- to fit into B-pillar reinforcing -2- and weld in, RP spot weld seam (inverter). Distance between weld points: Dimension -a- = 40 mm –...
Page 222 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Mark areas where welding is not permitted. ♦ Dimension -a- = 50 mm ♦ Dimension -b- = 160 mm – Adapt new parts with vehicle positioned on alignment bracket set and fix in place.
Page 223 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Tack weld front and rear side member reinforcements -1 and 2- centrally at top and bottom -shaded areas- to B-pillar reinforcement -3- using one small SG weld at each point. Re‐...
Page 224 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Weld rear web plate -1- to B-pillar reinforcement -2- at existing elongated holes, SG continuous seam. Rep. gr.51 - Body - centre...
Page 225 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Adapt web plate -2- to side member front reinforcement -1-. Note The holes -3- must align. – Weld web plate to side member front reinforcement -1- and to B-pillar reinforcement -4-, RP spot weld seam.
Page 226 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 12.3.4 Welding in Note New part must be welded in within 90 minutes or adhesion of ad‐ hesive will be impaired. – Drill 8 mm ∅ holes in B-pillar reinforcement on vehicle for SG plug weld seam.
Page 227 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Note In the area of the A, B and C-pillars, high tensile, highest tensile and hot formed steels are used. The weld ♦ flanges in these areas are about 13mm wide.
Page 228 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Note Note areas -1- where welding is not permitted. – Weld in B-pillar reinforcement, RP spot weld seam (inverter). – Weld crash reinforcement to B-pillar reinforcement, SG plug weld seam.
Page 229: Renewing Inner B-Pillar
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 RO: 51 44 55 50 Renewing inner B-pillar WARNING Observe safety notes! Safety notes ⇒ General Information; Body Repairs, General Body Repairs ; Safety notes • B-pillar reinforcement already removed ⇒...
Page 230: Tools
The use of different types and different thicknesses of steel ♦ requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 231 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Separate original joint. 13. Renewing inner B-pillar...
Page 232: Installing
– Remove remaining material. – Remove remaining adhesive completely and grind bonded surface back to bare metal. 13.3 Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 224 13.3.1 Welding in New part ♦ Inner B-pillar ♦...
Page 233 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Note New part must be welded in within 90 minutes or adhesion of adhesive will be impaired. ♦ Before installing inner B-pillar, adapt B-pillar reinforcement to fit to assure the welding period in the bonded ♦...
Page 234 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Weld in new part, SG continuous weld seam and RP spot weld seam (inverter). Note The joint to inner side member is welded when installing B-pillar reinforcing.
Page 235: Renewing Side Member
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 RO: 51 45 55 10 Renewing side member WARNING Observe safety notes! Welding, parting using spark generating machines/tools or tin‐ ning in foam treated areas creates gases which are hazardous to health and environment.
Page 236: Tools
The use of different types and different thicknesses of steel ♦ requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 237 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Mark parting cuts according to dimensions -a and b- and cut. Partial renewal A part replacement is possible with parting cut -2-. – Make cuts as shown.
Page 238: Installing
– Clean any dust and grease off flange area on wheel arch. 14.3 Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 230 Note MIG solder seams or SG continuous weld seams are permitted at the parting cuts shown in the illustration.
Page 239 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 14.3.1 Preparing new part New part ♦ Side panel ♦ Wing bracket ♦ Moulded foam element ♦ Sealing cord -AKD 497 010 04 R10- ♦ 2K body adhesive -D 180 KD3 A2- –...
Page 240 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 14.3.2 Marking areas where no welding work may be carried out Note Mark areas on outer side member where welding is not per‐ ♦ mitted due to safety reasons »crash safety«.
Page 241 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Apply sealing cord -AKD 497 010 04 R10- in area -1-. – Apply 2K body adhesive -D 180 KD3 A2- in the areas indica‐ ted. Note In the area of the A, B and C-pillars, high tensile, highest tensile and hot formed steels are used.
Page 242 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Therefore, locate spot welds as close to the centre as possible. • Dimension -a- of 8mm can be achieved using angled welding tips. – Adapt new part with vehicle standing on its wheels or on align‐...
Page 243 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Weld in parting cuts, MIG-L stepped seam or SG continuous weld seam are permitted. – Weld in door aperture, RP spot weld seam. – Weld in remaining joint, SG plug weld seam and RP spot weld seam.
Page 244: Renewing Front Side Member Reinforcement
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 RO: 51 48 55 50 Renewing front side member rein‐ forcement WARNING Observe safety notes! Safety notes ⇒ General Information; Body Repairs, General Body Repairs ; Safety notes •...
Page 245: Tools
The use of different types and different thicknesses of steel ♦ requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 246: Installing
– Remove remaining material. – Remove remaining adhesive completely and grind bonded surface back to bare metal. 15.3 Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 239 Rep. gr.51 - Body - centre...
Page 247 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 15.3.1 Preparing new part New part ♦ Front side member reinforcement ♦ 2K body adhesive -D 180 KD3 A2- – Transfer parting cut to new part and cut out.
Page 248 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Apply 2K body adhesive -D 180 KD3 A2- in the areas indica‐ ted. Note In the area of the A, B and C-pillars, high tensile, highest tensile and hot formed steels are used. The weld ♦...
Page 249 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Therefore, locate spot welds as close to the centre as possible. • Dimension -a- of 8mm can be achieved using angled welding tips. – Adapt new part with vehicle positioned on alignment bracket set and fix in place.
Page 250 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Weld in side member front reinforcement, SG plug weld seam and RP spot weld seam (inverter). – Weld in parting cut, SG continuous weld seam. – Weld in transition to A-pillar reinforcement, SG continuous weld seam (qty 3).
Page 251: Renewing Rear Side Member Reinforcement
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 RO: 51 48 55 53 Renewing rear side member rein‐ forcement WARNING Observe safety notes! Safety notes ⇒ General Information; Body Repairs, General Body Repairs ; Safety notes •...
Page 252: Tools
The use of different types and different thicknesses of steel ♦ requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 253: Installing
– Remove remaining adhesive completely and grind bonded surface back to bare metal. 16.3 Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 246 16.3.1 Preparing new part New part ♦ Rear side member reinforcement ♦...
Page 254 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Transfer parting cut to new part and cut out. 16.3.2 Welding in New part Note The new part must be welded in within 90 minutes, or adhesion of adhesive will be impaired.
Page 255 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Apply 2K body adhesive -D 180 KD3 A2- to area indicated. – Adapt new part with vehicle positioned on alignment bracket set and fix in place.
Page 256: Renewing Seat Middle Cross Member
The use of different types and different thicknesses of steel ♦ requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 257: Removing
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 17.2 Removing – Separate original joint to inner mounting for seat cross mem‐ ber and to floor panel. – Separate bonded connection -1- to floor panel. 17. Renewing seat middle cross member...
Page 258: Installing
– Remove remaining material. – Remove remaining adhesive completely and grind bonded surface back to bare metal. 17.3 Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 250 17.3.1 Preparing new part New part ♦ Seat mounting ♦...
Page 259 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Drill holes for SG plug weld seam (8 mm ∅). 17.3.2 Welding in – Adapt new part and fix in position. 17. Renewing seat middle cross member...
Page 260 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Check fit to outer mounting for seat cross member and seat. – Apply 2K body adhesive -D 180 KD3 A2- to areas bonded in the factory.
Page 261: Renewing Inner Mounting For Seat Cross Member
The use of different types and different thicknesses of steel ♦ requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 262: Removing
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 18.2 Removing – Separate original joint to centre tunnel, to floor panel and to middle seat cross member -1-. Rep. gr.51 - Body - centre...
Page 263: Installing
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Remove remaining material. 18.3 Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 255 18.3.1 Preparing new part New part ♦ Inner mounting for seat cross member...
Page 264 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Drill holes for SG plug weld seam (8 mm ∅). 18.3.2 Welding in – Adapt new part and fix in position. – Check fit to middle seat cross member and to seat.
Page 265 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Weld inner mounting of seat cross member to centre tunnel and middle seat cross member, SG plug weld seam. – Weld in remaining joint, SG staggered continuous weld seam.
Page 266: Renewing Outer Mounting For Seat Cross Member
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 RO: 51 87 55 56 Renewing outer mounting for seat cross member WARNING Observe safety notes! Safety notes ⇒ General Information; Body Repairs, General Body Repairs ; Safety notes...
Page 267: Tools
The use of different types and different thicknesses of steel ♦ requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 268: Removing
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 19.2 Removing – Separate original joints to middle cross member -1- for seat, to floor panel -2- and to side member -3-. Rep. gr.51 - Body - centre...
Page 269: Installing
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Remove remaining material. 19.3 Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 261 19.3.1 Preparing new part New part ♦ Outer mounting for seat cross member Note Before installing, reinstate vehicle identification number if necessary.
Page 270 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Drill holes for SG plug weld seam (8 mm ∅). 19.3.2 Welding in – Adapt new part to fit and fix in position. Rep. gr.51 - Body - centre...
Page 271 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Check fit to seat. – Weld outer mounting for seat cross member to floor panel -1-, to middle cross member -2- for seat and to inner side member -3-, SG plug weld.
Page 272: Body - Rear
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 53 – Body - rear RO: 53 05 55 50 Renewing rear cross panel Includes: cross member for rear cross panel, left and right exhaust system retainers and lock carrier...
Page 273: Tools
The use of different types and different thicknesses of steel ♦ requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 274 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Separate original joint for lock carrier. – Separate bonded areas -1-. – Separate original joints of left and right exhaust system re‐ tainers -2 and 3-.
Page 275: Installing
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Remove remaining material. Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 267 1.3.1 Preparing new part New part ♦ Lock carrier ♦...
Page 276 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Drill holes for SG plug weld seam (8 mm ∅). – Grind bonding surfaces back to bare metal. – Apply 2K body adhesive -D 180 KD3 A2- to areas bonded in the factory.
Page 277 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Weld in rear cross panel, RP spot weld seam and SG plug weld seam or MIG solder seam. 1. Renewing rear cross panel...
Page 278 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Weld in exhaust system retainers and cross member for rear cross panel, SG plug weld seam and RP spot weld seam. – Weld in lock carrier, RP spot weld seam and SG staggered continuous weld seam or MIG staggered continuous weld seam.
Page 279: Renewing Rear Cross Panel (Variant)
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 RO: 53 05 55 60 Renewing rear cross panel (Variant) Includes: cross member for rear cross panel, left and right exhaust system retainers and lock carrier WARNING Observe safety notes! Safety notes ⇒...
Page 280: Tools
The use of different types and different thicknesses of steel ♦ requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 281 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Note It is advisable to additionally open a section of the original joint to left and right tail light mountings -1- and to pull the tail light mounting outwards slightly, to ease the removal of the old rear cross panel and the installation of the new rear cross panel.
Page 282: Installing
– Remove remaining material. – Remove remaining adhesive completely and grind bonded surface back to bare metal. Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 274 2.3.1 Preparing new part New part ♦ Cross panel with lock carrier ♦...
Page 283 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Drill holes for SG plug weld seam (8 mm ∅). – Grind bonding surfaces back to bare metal. – Apply 2K body adhesive -D 180 KD3 A2- to areas bonded in the factory.
Page 284 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Check fit with bolt-on parts. – Weld in rear cross panel, RP spot weld seam and SG plug weld seam or MIG solder seam. Rep. gr.53 - Body - rear...
Page 285 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Weld in exhaust system retainers and cross member for rear cross panel, SG plug weld seam and RP spot weld seam. – Weld in lock carrier, SG staggered continuous weld seam or MIG staggered continuous weld seam.
Page 286: Renewing Lock Carrier
The use of different types and different thicknesses of steel ♦ requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 287: Removing
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Removing – Separate original joint. – Separate bonded areas -1-. 3. Renewing lock carrier...
Page 288: Installing
– Remove remaining material. – Remove remaining adhesive completely and grind bonded surface back to bare metal. Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 280 3.3.1 Preparing new part New part ♦ Lock carrier...
Page 289 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Apply 2K body adhesive -D 180 KD3 A2- to areas bonded in the factory. 3.3.2 Welding in – Adapt new part with vehicle standing on its wheels and fix in place.
Page 290: Renewing Tail Light Mounting
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 RO: 53 10 55 50 Renewing tail light mounting WARNING Observe safety notes! Safety notes ⇒ General Information; Body Repairs, General Body Repairs ; Safety notes 1 - Bonded areas...
Page 291: Tools
The use of different types and different thicknesses of steel ♦ requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 292 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Release original joint to lock carrier -2-. – Separate bonded areas -1-. Rep. gr.53 - Body - rear...
Page 293: Installing
– Remove remaining material. – Remove remaining adhesive completely and grind bonded surface back to bare metal. Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 285 4.3.1 Preparing new part New part ♦ Tail light mounting ♦...
Page 294 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Drill holes for SG plug weld seam (8 mm ∅). – Apply 2K body adhesive -D 180 KD3 A2- to areas bonded in the factory. 4.3.2...
Page 295 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Weld in new part, SG plug weld seam and RP spot weld seam. – Weld in remaining joints to side panel and sealing channel, SG staggered continuous weld seam or MIG staggered continu‐...
Page 296 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Weld in remaining joints to lock carrier, SG staggered contin‐ uous weld seam or MIG staggered continuous weld seam. Rep. gr.53 - Body - rear...
Page 297: Renewing Tail Light Mounting (Variant)
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 RO: 53 10 55 60 Renewing tail light mounting (Var‐ iant) WARNING Observe safety notes! Safety notes ⇒ General Information; Body Repairs, General Body Repairs ; Safety notes •...
Page 298: Tools
The use of different types and different thicknesses of steel ♦ requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 299: Installing
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Remove remaining material. Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 292 5.3.1 Preparing new part New part ♦ Tail light mounting...
Page 300 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Drill holes for SG plug weld seam (8 mm ∅). 5.3.2 Welding in – Adapt new part with vehicle standing on its wheels or align‐ ment bracket set and fix in position.
Page 301 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Check fit with bolt-on parts. – Weld in new part, SG plug weld seam and RP spot weld seam. – Weld in remaining joints to sealing channel, MIG continuous weld seam.
Page 302: Renewing C-Pillar Reinforcement
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 RO: 53 29 55 50 Renewing C-pillar reinforcement WARNING Observe safety notes! Welding, parting using spark generating machines/tools or tin‐ ning in foam treated areas creates gases which are hazardous to health and environment.
Page 303: Tools
The use of different types and different thicknesses of steel ♦ requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 304: Installing
– Separate original joints to inner side panel and to wheel hous‐ ing. – Remove remaining material. Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 297 6.3.1 Preparing new parts New part ♦ C-pillar reinforcement...
Page 305 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Transfer parting cut to new part and cut out. 6.3.2 Moulded foam elements Follow repair instructions. Moulded foam element ⇒ General Information; Body Repairs, General Body Repairs ; General Notes; Moulded foam elements...
Page 306 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 6.3.3 Welding in Note In the area of the A, B and C-pillars, high tensile, highest tensile and hot formed steels are used. The weld ♦ flanges in these areas are about 13mm wide.
Page 307 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Weld in C-pillar reinforcement, RP spot weld seam and SG plug weld seam. – Weld in parting cut, SG continuous weld seam. – Install side panel ⇒...
Page 308: Renewing C-Pillar Reinforcement (Variant)
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 RO: 53 29 55 60 Renewing C-pillar reinforcement (Variant) Includes: lock reinforcement WARNING Observe safety notes! Welding, parting using spark generating machines/tools or tin‐ ning in foam treated areas creates gases which are hazardous to health and environment.
Page 309: Tools
The use of different types and different thicknesses of steel ♦ requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 310 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Note Do not damage underlying panels when cutting out. ♦ Do not damage water drain hose -1- on models with a panorama sliding sunroof. ♦ – Make parting cut -2- according to degree of damage.
Page 311: Installing
– Remove remaining material. – Remove remaining adhesive completely and grind bonded surface back to bare metal. Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 303 7.3.1 Preparing new parts New part ♦ C-pillar reinforcement ♦...
Page 312 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Transfer parting cut to new part and cut out. 7.3.2 Moulded foam elements Follow repair instructions. Moulded foam element ⇒ General Information; Body Repairs, General Body Repairs ; General Notes; Moulded foam elements...
Page 313 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 7.3.3 Welding in Note In the area of the A, B and C-pillars, high tensile, highest tensile and hot formed steels are used. The weld ♦ flanges in these areas are about 13mm wide.
Page 314 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Weld in C-pillar reinforcement, RP spot weld seam. – Weld in parting cut, SG continuous weld seam. Lock reinforcing plate -1- must be welded in within 90 minutes or adhesion of adhesive will be impaired.
Page 315 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Apply 2K body adhesive -D 180 KD3 A2- to areas bonded in the factory. – Weld in lock reinforcement -1-, RP spot weld seam. – Install side panel ⇒...
Page 316: Renewing D-Pillar Reinforcement - Part Section
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 RO: 53 30 55 50 Renewing D-pillar reinforcement - part section Includes: sealing channel - part section WARNING Observe safety notes! Welding, parting using spark generating machines/tools or tin‐...
Page 317: Tools
The use of different types and different thicknesses of steel ♦ requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 318 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Separate original joint. – Position parting cut at D-pillar reinforcing as shown and cut out. – Separate original joint. Rep. gr.53 - Body - rear...
Page 319: Installing
– Remove remaining material. – Remove remaining adhesive completely and grind bonded surface back to bare metal. Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 311 8.3.1 Preparing new part New part ♦ Inner side panel ♦...
Page 320 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Transfer parting cut to sealing channel -1- and to D-pillar re‐ inforcing -2- and cut to size. – Separate original joint from D-pillar reinforcement part section.
Page 321 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Apply 2K body adhesive -D 180 KD3 A2- to areas bonded in the factory. – Adapt D-pillar reinforcing to fit and secure in position. – Weld in parting cut, SG continuous weld seam.
Page 322 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Weld in parting cut on sealing channel -1-, MIG continuous weld seam or SG continuous weld seam are permitted. – Spot weld remaining joint in, RP spot weld seam.
Page 323: Renewing Inner D-Pillar
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 RO: 53 30 55 52 Renewing inner D-pillar WARNING Observe safety notes! Safety notes ⇒ General Information; Body Repairs, General Body Repairs ; Safety notes • Side panel already removed ⇒...
Page 324: Tools
The use of different types and different thicknesses of steel ♦ requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 325: Installing
– Remove remaining material. – Remove remaining adhesive completely and grind bonded surface back to bare metal. Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 318 9.3.1 Preparing new part New part ♦ Inner D-pillar (parts designation: reinforcement) ♦...
Page 326 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Apply 2K body adhesive -D 180 KD3 A2- to areas bonded in the factory. 9.3.2 Welding in – Adapt new part with vehicle standing on its wheels or align‐...
Page 327 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Check fit with bolt-on parts. – Weld new part to longitudinal member and inner side panel, RP spot weld seam and SG continuous weld seam. – Install tail light mounting ⇒...
Page 328: Renewing Rear Longitudinal Member - Part Section
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 RO: 53 48 55 50 Renewing rear longitudinal member - part section Includes: floor panel, rear cross panel, longitudinal member cover plate and bumper mounting WARNING Observe safety notes! Safety notes ⇒...
Page 329: Tools
The use of different types and different thicknesses of steel ♦ requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 330: Removing
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 10.2 Removing – Release original joint to floor panel and connecting plate. – Roughly cut floor panel out using parting cut -1-. Rep. gr.53 - Body - rear...
Page 331 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Position offset parting cuts on longitudinal member -2- and on longitudinal member cover part -1- and cut out. Dimension -a- approx. 50 mm 10. Renewing rear longitudinal member - part section...
Page 332: Installing
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Remove remaining material. 10.3 Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 323 10.3.1 Preparing new part New part ♦ Rear longitudinal member ♦...
Page 333 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Transfer parting cuts to new parts and cut out. 10. Renewing rear longitudinal member - part section...
Page 334 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 10.3.2 Welding in Note In the area of the A, B and C-pillars, high tensile, highest tensile and hot formed steels are used. The weld ♦ flanges in these areas are about 13mm wide.
Page 335 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Weld in longitudinal member part section -1-, SG continuous weld seam. – Weld in bumper mounting -2-, RP spot weld seam. 10. Renewing rear longitudinal member - part section...
Page 336 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Weld in floor panel and rear cross panel, RP spot weld seam. Rep. gr.53 - Body - rear...
Page 337 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Saloon • Install cross panel ⇒ page 269 • Install tail light mounting ⇒ page 287 • Install side panel ⇒ page 335 Variant • Install cross panel ⇒...
Page 338: Renewing Side Panel - Part Section
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 RO: 53 55 55 50 Renewing side panel - part section WARNING Observe safety notes! Welding, parting using spark generating machines/tools or tin‐ ning in foam treated areas creates gases which are hazardous to health and environment.
Page 339: Tools
The use of different types and different thicknesses of steel ♦ requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 340 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Recommended parting cuts: Dimension -a- = 100 mm Dimension -b- = 130 mm – Grind through outer edge at wheel arch. – Separate original joint. – Separate original joint to sealing channel and to tail light mounting.
Page 341: Installing
– Clean any dust and grease off flange area on wheel arch. 11.3 Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 333 11. Renewing side panel - part section...
Page 342 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Note MIG solder seams or SG continuous weld seams are permitted at the parting cuts shown in the illustration. 11.3.1 Preparing new part New part ♦ Side panel subpart ♦...
Page 343 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Transfer parting cut to new part and cut out. – Drill holes for SG plug weld seam (8 mm ∅). – Grind bonding surfaces back to bare metal.
Page 344 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 11.3.3 Welding in Note New part must be welded in within 90 minutes or adhesion of ♦ adhesive will be impaired. When applying 2K body adhesive -D 180 KD3 A2- , do not ♦...
Page 345 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Note Before starting welding on right side panel, apply sealing cord -AKD 497 010 04 R10- in area of fuel filler neck. Note In the area of the A, B and C-pillars, high tensile, highest tensile and hot formed steels are used. The weld ♦...
Page 346 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Weld in side panel, RP spot weld seam and SG plug weld seam. – Weld in parting cuts, MIG solder seam or SG continuous weld seam are permitted.
Page 347 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Weld in original joint of rear window aperture, RP spot weld seam. – Weld in remaining joint, SG plug weld seam, MIG solder seam or SG continuous weld seam.
Page 348: Renewing Side Panel (Variant) - Part Section
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 RO: 53 55 55 60 Renewing side panel (Variant) - part section WARNING Observe safety notes! Welding, parting using spark generating machines/tools or tin‐ ning in foam treated areas creates gases which are hazardous to health and environment.
Page 349: Tools
The use of different types and different thicknesses of steel ♦ requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 350 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Recommended parting cut on side member: Dimension -a- = 130 mm – Grind through outer edge at wheel arch. – Separate original joint. – Separate original joint to sealing channel and to tail light mounting.
Page 351: Installing
– Clean any dust and grease off flange area on wheel arch. 12.3 Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 343 12. Renewing side panel (Variant) - part section...
Page 352 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Note MIG solder seams or SG continuous weld seams are permitted at the parting cuts shown in the illustration. 12.3.1 Preparing new part New part ♦ Side panel subpart for Variant ♦...
Page 353 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Transfer parting cut to new part and cut out. – Drill holes for SG plug weld seam (8 mm ∅). – Grind bonding surfaces back to bare metal.
Page 354 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 12.3.3 Welding in Note New part must be welded in within 90 minutes or adhesion of ♦ adhesive will be impaired. When applying 2K body adhesive -D 180 KD3 A2- , do not ♦...
Page 355 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 Note Before starting welding on right side panel, apply sealing cord -AKD 497 010 04 R10- in area of fuel filler neck. Note In the area of the A, B and C-pillars, high tensile, highest tensile and hot formed steels are used. The weld ♦...
Page 356 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Weld in side panel, RP spot weld seam and SG plug weld seam. – Weld in parting cuts, MIG solder seam or SG continuous weld seam are permitted.
Page 357 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Weld in remaining joint to sealing channel, SG plug weld seam and MIG staggered continuous seam or SG staggered con‐ tinuous weld seam. – Weld in remaining joints to tail light mounting, SG plug weld seam.
Page 358: Renewing Outer Wheel Housing Liner
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 RO: 53 68 55 50 Renewing outer wheel housing liner WARNING Observe safety notes! Welding, parting using spark generating machines/tools or tin‐ ning in foam treated areas creates gases which are hazardous to health and environment.
Page 359: Tools
♦ The use of different types and different thicknesses of steel requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 360 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Separate remaining joint to rear side member reinforcement -1- and to rear connecting plate -2-. Rep. gr.53 - Body - rear...
Page 361: Installing
Body Repairs - Edition 04.2011 – Remove remaining material. – Remove remaining adhesive completely and grind bonded surface back to bare metal. 13.3 Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 353 13. Renewing outer wheel housing liner...
Page 362 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 13.3.1 Preparing new part New part ♦ Outer wheel housing liner -1- ♦ Reinforcing plate -2- ♦ 2K body adhesive -D 180 KD3 A2- – Grind bonding surfaces back to bare metal.
Page 363 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Apply 2K body adhesive -D 180 KD3 A2- to areas bonded in the factory. – Adapt new part with vehicle standing on its wheels or align‐...
Page 364 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Weld outer wheel housing liner to C-pillar reinforcement and inner wheel housing, RP spot weld seam and SG plug weld seam. Rep. gr.53 - Body - rear...
Page 365 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Recreate original joint to side member rear reinforcement -1- and to rear connecting plate -2-, RP spot weld seam. – Install side panel ⇒ page 335...
Page 366: Renewing Outer Wheel Housing Liner (Variant)
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 RO: 53 68 55 60 Renewing outer wheel housing liner (Variant) Includes: lock reinforcement WARNING Observe safety notes! Welding, parting using spark generating machines/tools or tin‐ ning in foam treated areas creates gases which are hazardous to health and environment.
Page 367: Tools
♦ The use of different types and different thicknesses of steel requires that only the welding units (inverters) authorised by Volkswagen AG may be used to carry out repairs properly. The welding units (inverters) and body tools authorised by ♦...
Page 368 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Separate original joint to C-pillar reinforcing and to inner wheel housing liner. Rep. gr.53 - Body - rear...
Page 369 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Separate remaining joint to rear side member reinforcement -1- and to rear connecting plate -2-. 14. Renewing outer wheel housing liner (Variant)
Page 370: Installing
Body Repairs - Edition 04.2011 – Remove remaining material. – Remove remaining adhesive completely and grind bonded surface back to bare metal. 14.3 Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 361 Rep. gr.53 - Body - rear...
Page 371 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 14.3.1 Preparing new part New part ♦ Outer wheel housing liner -1- ♦ Reinforcing plate -2- ♦ Lock reinforcement ♦ 2K body adhesive -D 180 KD3 A2- –...
Page 372 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Apply 2K body adhesive -D 180 KD3 A2- to areas bonded in the factory. – Adapt new part with vehicle standing on its wheels or align‐...
Page 373 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Weld outer wheel housing liner to C-pillar reinforcement and inner wheel housing, RP spot weld seam and SG plug weld seam. 14. Renewing outer wheel housing liner (Variant)
Page 374 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Recreate original joint to side member rear reinforcement -1- and to rear connecting plate -2-, RP spot weld seam. Rep. gr.53 - Body - rear...
Page 375 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Apply 2K body adhesive -D 180 KD3 A2- in areas shown be‐ tween lock reinforcement and wheel housing liner. – Check fit with side panel. – Weld in lock reinforcing, RP spot weld seam.
Page 376: Renewing Spare Wheel Well
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 RO: 53 80 55 00 Renewing spare wheel well WARNING Observe safety notes! Safety notes ⇒ General Information; Body Repairs, General Body Repairs ; Safety notes 1 - Spare wheel well (bonded)
Page 377 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 ♦ Cartridge heater -V.A.G 1939 A- ♦ Double-cartridge gun -VAS 5237- ♦ Electric cutter -V.A.G 1561/A- 15. Renewing spare wheel well...
Page 378: Removing
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 15.2 Removing – Roughly cut out spare wheel well at edge -parting line- using pneumatic sabre saw -V.A.G 1523/A- . – Leave bonding flange -1-. Rep. gr.53 - Body - rear...
Page 379: Installing
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – Remove residual material of spare wheel well (bonding flange -1-) using electric cutter -V.A.G 1561/A- and a suitable blade, e.g. offset blade (25 mm) -V.A.G 1561/4- or offset blade - V.A.G 1561/10- .
Page 380: Passat 2011 ➤ , Passat Variant
Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 ♦ Cleaning solution -D 009 401 04- ♦ Activator -D 181 801 A1- ♦ Adhesive remover -D 002 000 10- – The circumferential adhesive bead -1- on the new part must be cut back to approx.
Page 381 Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 WARNING Spare wheel well must be welded in within 10 minutes or ad‐ hesion of glass adhesive will be impaired. – Apply 2K glass adhesive -DA 004 600 A2- -A- to bonding sur‐...

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Volkswagen Passat 2011 Body Repair Manual

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