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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
50 - Body - front
55 - Bonnet, rear lid
57 - Front doors, door components, central locking
58 - Rear doors, door components
60 - Sunroof
63 - Bumpers ksw
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66 - Exterior equipment s aut
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. 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 © 2019 Volkswagen AG, Wolfsburg D4B804A2FD1

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Contents
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00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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50 - Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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1 Lock carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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1.1 Assembly overview – lock carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Removing and installing lock carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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1.3 Moving to and back from service position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Wings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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2.1 Assembly overview - wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.2 Removing and installing wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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3 Bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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3.1 Assembly overview - plenum chamber bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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3.2 Assembly overview - plenum chamber cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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3.3 Removing and installing plenum chamber bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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3.4 Removing and installing plenum chamber cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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55 - Bonnet, rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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1 Bonnet (hood) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.1 Assembly overview - bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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1.2 Assembly overview - Bowden cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.3 Assembly overview - gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.4 Removing and installing bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.5 Adjusting bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.6 Removing and installing bonnet lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.7 Removing and installing bonnet release lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.8 Removing and installing striker pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.9 Removing and installing hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.10 Removing and installing insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.11 Removing and installing gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.12 Releasing gas from gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.13 Removing and installing Bowden cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2 Rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.1 Assembly overview - rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.2 Removing and installing rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.3 Adjusting rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.4 Removing and installing bonnet lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.5 Removing and installing operating mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.6 Removing and installing hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.8 Removing and installing rear lid seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2.9 Removing and installing gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.10 Releasing gas from gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.11 Removing and installing drive unit for rear lid VX69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3 Tank flap unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3.1 Assembly overview - tank flap unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3.2 Removing and installing tank flap unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3.3 Removing and installing fuel tank flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
57 - Front doors, door components, central locking . . . . . . . . . . . . . . . . . . . . . . . . . . 96

1 Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.1 Assembly overview - door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.2 Removing and installing inner door seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
1.3 Removing and installing outer door seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Contents i
Passat 2015 ➤
General body repairs, exterior - Edition 03.2019
1.4 Removing and installing door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

1.5 Adjusting door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
1.6 Adjusting striker pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.7 Removing and installing door arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
2 Door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
2.1 Assembly overview - door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
2.2 Assembly overview - window regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2.3 Assembly overview - door handle and door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
2.4 Removing and installing window regulator motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2.5 Removing and installing window regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
2.6 Removing and installing inner door cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
2.8 Removing and installing cap for door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
2.9 Removing and installing lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
2.10 Removing and installing door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
2.11 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
2.12 Removing and installing door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
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2.14 Removing and installing window slot ed b outer seal . . . . . . . . . . . . . . . . . .u.ar.a . . . . . . . . . . . . . .
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2.15 Removing and installing window ho slot inner seal . . . . . . . . . . . . . . . . . . . . . .e.o . . . . . . . . . . . 151
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3.1 Overview of fitting locations - central locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

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3.2 Assembly overview - ignition key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
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3.3 Removing and installing bonnet contact switch F266 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
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3.4 Removing and installing driver door control unit J386 and front passenger door control unit
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3.5 Removing and installing rear left door control unit J926 and rear right door control unit J927
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3.6 Removing and installing tank filler flap locking motor V155 . . . . . . . . . . . . . . . . . . . . . . . . 159
3.7 Removing and installing ignition key battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
3.8 Removing and installing cap on ignition key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
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58 - Rear doors, door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

1 Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
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1.1 Assembly overview - door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

1.2 Removing and installing door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
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1.3 Adjusting door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

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1.4 Adjusting striker pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

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1.5 Removing and installing door arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

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1.6 Removing and installing inner door seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

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1.7 Removing and installing outer door seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
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2 Door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.1 Assembly overview - door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
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2.2 Assembly overview - window regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
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2.3 Assembly overview - door handle and door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

2.4 Removing and installing window regulator motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
2.5 Removing and installing window regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
2.6 Removing and installing inner door cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
2.8 Removing and installing cap on door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
2.9 Removing and installing door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
2.10 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
2.11 Removing and installing door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
2.12 Removing and installing window channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
2.13 Removing and installing window slot outer seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
2.14 Removing and installing window slot inner seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
ii Contents
Passat 2015 ➤
60 - Sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
1 Sliding sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
1.1 Assembly overview - sliding sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
1.2 Assembly overview - sunroof roller blind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
1.3 Removing and installing sliding sunroof frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
1.4 Removing and installing wind deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
1.5 Removing and installing glass panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
1.6 Adjusting sunroof panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
1.7 Removing and installing guide plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
1.8 Removing and installing front trim for sliding sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
1.9 Removing and installing sliding sunroof motor V1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
1.10 Removing and installing sliding sunroof adjustment control unit J245 . . . . . . . . . . . . . . . . 252
1.11 Operating without current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
1.12 Removing and installing sliding sunroof seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
1.13 Removing and installing sunroof roller blind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
1.14 Programming sliding sunroof adjustment control unit J245 . . . . . . . . . . . . . . . . . . . . . . . . 270
2 Water drain hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
2.1 Assembly overview - water drainage hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
2.2 Cleaning water drainage hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
2.3 Removing and installing water drain hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
63 - Bumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
1 Bumper, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
1.1 Assembly overview - bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
1.2 Assembly overview - add-on parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
1.3 Assembly overview - impact bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
1.4 Removing and installing bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
1.5 Removing and installing add-on parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
1.6 Repairing bumper cover . . . . . . .n .A.G.. V. o.lk.s.w.ag. e.n.A.G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
1.7 Installing brackets for parking wage doe
Volks aid system . . . . . . . . .s.n.ot.g. . . . . . . . . . . . . . . . . . . . . . . . . . 287
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1.8 Installing brackets forisepark
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assist steering . . . . . . . . . . . . .a.ra.nt. . . . . . . . . . . . . . . . . . . . . . . 291
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2 Bumper, rear . .au.th. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o.r a. . . . . . . . . . . . . . . . . . . . 294
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2.1 Assembly overview
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- bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
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2.2 Assembly overview - bumper guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

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2.3 Assembly overview - add-on parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296

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2.4 Assembly overview - impact bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298

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2.5 Removing and installing bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298

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2.6 Removing and installing impact bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301

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2.7 Repairing bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303

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2.8 Installing brackets for parking aid system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304

2.9 Installing brackets for park assist steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
rrectness of i
64 - Glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
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1 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

1.1 Minimum curing periods for bonded windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
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1.2 Window repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

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1.3 Installation instructions for bonded windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312

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1.4 Preparing old undamaged windows for fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313

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1.5 Preparing new windows for installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313

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1.6 Preparing body flange for fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315

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1.7 Cleaning off excess adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315

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2 Windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
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2.2 Removing and installing windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
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Contents iii
AG. Volkswagen AG d
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Passat 2015 ➤ thor eo
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3 Rear windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
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3.1 Assembly overview - rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
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3.2 Removing and installing rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
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4 Door windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
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4.1 Assembly overview - front door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
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4.2 Assembly overview - rear door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
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4.3 Removing and installing front door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
4.4 Removing and installing rear door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
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4.5 Removing and installing fixed front door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
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4.6 Removing and installing fixed rear door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
66 - Exterior equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
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1 Radiator grille and front trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
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1.1 Assembly overview - radiator grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
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1.2 Removing and installing radiator grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
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2 Mouldings, trims, extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
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2.1 Assembly overview - trim strip and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
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2.2 Assembly overview - side member trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351

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2.3 Assembly overview - water deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
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2.4 Assembly overview - heat shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
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2.5 Removing and installing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cted
353
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2.6 Removing and installing side member trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
2.7 Removing and installing water deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
2.8 Removing and installing B-pillar trim on door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
2.9 Removing and installing trim strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
2.10 Removing and installing entry moulding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
2.11 Removing and installing underbody heat shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
3 Noise insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
3.1 Assembly overview - noise insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
4 Underbody cladding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
4.1 Overview of fitting locations - underbody cladding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
4.2 Assembly overview - bracing on underbody . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
4.3 Removing and installing underbody cladding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
4.4 Removing and installing tunnel cross-piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
5 Exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
5.1 Assembly overview - exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
5.2 Removing and installing exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
5.3 Removing and installing mirror glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
5.4 Removing and installing mirror adjustment unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
5.5 Removing and installing mirror cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
5.6 Removing and installing mirror trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
6 Wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
6.1 Assembly overview - front wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
6.2 Assembly overview - rear wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
6.3 Removing and installing front wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
6.4 Removing and installing rear wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
7 Lettering and emblems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
7.1 Dimensions - lettering and emblems on rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
7.2 Dimensions - lettering and emblems on sides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
7.3 Removing and installing badges at front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
7.4 Renewing lettering and badges at rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
8 Decorative film / protective film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
8.1 Removing and installing protective film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
9 Special add-on parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
iv Contents
Passat 2015 ➤
AG. Volkswagen AG d
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9.1 Assembly overview – special add-on parts Vol . . . . . . . . . . . . . . . . . . . . o.t g. u. . . . . . . . . . . . . .
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10 Towing bracket . . . . . . . . . . . . . o.ri.se. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ra. n.te. . . . . . . . . . .
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10.1 Assembly overview - towing bracket au
t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o.r a.c. . . . . . . . 418
s
10.2 Removing and installing towing s
bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
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10.3 Removing and installing trigger unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
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Contents v
Passat 2015 ➤
AG. Volkswagen AG d
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vi Contents
Passat 2015 ➤
General body repairs,
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Edition
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00 – Technical data
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1
Passat 2015 ➤
50 – Body - front
1 Lock carrier
(VRL012910; Edition 03.2019)
⇒ “1.1 Assembly overview – lock carrier”, page 2
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⇒ “1.3 Moving to and back from service position”, pageris6ed ara
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❑ Moving to and back from
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5 - Bolts
❑ 2 Nm
6 - Air guide
❑ Left and right
❑ Different versions; for
allocation refer to ⇒
Electronic parts cata‐
logue “ETKA” .
7 - Support for lock carrier
8 - Bolts
❑ Qty. 2
❑ 12 Nm
9 - Caps
❑ Qty. 2
10 - Charging socket
❑ Instructions and work specifications for charging socket ⇒ Rep. gr. 93 ; Charging socket; Assembly
overview - charging socket
2 Rep. gr.50 - Body - front

Passat 2015 ➤
11 - Centre guide profile

12 - Expanding nuts
❑ Qty. 2
13 - Bolts
❑ Qty. 4
❑ 8 Nm
14 - Bolts
❑ 8 Nm
15 - Bolts
❑ 55 Nm
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17 - Adaptive cruise control unit J428 rise
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Electrical system; Rep. gr. 27s ; Adaptive cruise control
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1.2 Removing and installing lock carrier
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♦ Guide pins - T10093-
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♦ Torque wrench - V.A.G 1331-

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1. Lock carrier 3
Passat 2015 ➤
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♦ The lock carrier is a safety-relevant component. For this reason, the lock carrier must only be repaired at
the points indicated.
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♦ In the event of damage, renew lock carrier.
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♦ For vehicles with adaptive cruise control unit - J428- , the adaptive cruise control unit - J428- must be
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Passat 2015 ➤
AG. Volkswagen AG d
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Removing
– Always use guide pins - T10093- to move lock carrier to serv‐
ice position ⇒ page 6 .
– Remove guide pins - T10093- from left and right longitudinal
members with the aid of a second mechanic. Put down lock
carrier -1- with attachments. Place it for example onto scissor-
type assembly platform - VAS 6131 A- .
– Remove bumper carrier and support arm
⇒ “1.1 Assembly overview – lock carrier”, page 2 .
– Release radiator module from lock carrier -arrow a-, but do not
remove it ⇒ Rep. gr. 19 ; Radiator/radiator fan .
– Lift condenser -3- off radiator module -2- -arrow b-, swing it
slightly out of lock carrier -arrow c-, but do not remove it.
– Pull out lock carrier -1- upwards between radiator module and
condenser -arrows d-.
Note
♦ Do not hang condenser and hydraulic oil cooler from lines.

♦ Do not kink lines for condenser and hydraulic systems.
1. Lock carrier 5
Passat 2015 ➤
Installing
Install in the reverse order of removal observing the following:
Note
♦ Always fit lock carrier on the bolting points at the foremost po‐
sition in the elongated hole. Only then can the lock carrier
move in a crash situation.
♦ On vehicles equipped with adaptive cruise control unit - J428- ,
the adaptive cruise control unit - J428- must be readjusted
whenever the lock carrier has been removed, installed or re‐
newed.
♦ General information and work instructions for the adaptive
cruise control unit - J428- can be found in ⇒ Electrical system;
Rep. gr. 27 ; Adaptive cruise control
♦ For »GTE« hybrid vehicles, the instructions and work specifi‐
cations for the charging socket are located in ⇒ Rep. gr. 93 ;
Charging socket; Assembly overview - charging socket
Specified torques
♦ Lock carrier
1.3 Moving to and back from service posi‐

tion
♦ Guide pins - T10093-
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Passat 2015 ➤
Moving to service position
Note
♦ The lock carrier is a safety-relevant component. The lock carrier must not be repaired for this reason.
♦ In the event of damage, renew lock carrier. agen
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1. Lock carrier 7
Passat 2015 ➤
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– Remove front bumper cover ⇒ page 282 .

rrectness of i
– Remove headlights ⇒ Electrical system; Rep. gr. 94 ; Head‐

l purpos
lights; Removing and installing headlights .

– Remove cable on mounting bracket of electrically operated lid
nform
ercia
⇒ page 47 .
m
– Unhook filler neck for washer fluid reservoir on carrier -2- ⇒

com
tion in
Electrical system; Rep. gr. 92 ; Window washer system; Re‐

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moving and installing washer fluid reservoir .

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nal members.
– The lock carrier with add-on parts -1- can be pulled forwards
about 10 cm on the special tool guide pins - T 10093- . When
doing this, be careful with the electrical wires/cables leading
to lock carrier and, if necessary, detach connectors.
– Install special tool adapter - 10467- (2 on each side) on left
and right between bumper carrier and longitudinal member.

Passat 2015 ➤
Moving from service position
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between bumper carrier and longitudinal member.
AG.
– Push lock carrier together with add-on parts -1- on the guide
pins - T10093- and onto the longitudinal member.
– Place bolts -3- on left and right.
– Unscrew guide pins - T10093- on left and right.
– Align lock carrier together with add-on parts -1- to longitudinal
members and between wings ⇒ Body Repairs; Rep. gr. 00 ;
Body gaps/shut lines; Body - front .
1. Lock carrier 9
Passat 2015 ➤
Note
♦ Always fit lock carrier on the bolting points at the foremost position in the elongated hole. Only then can the
lock carrier move in a crash situation.
♦ On vehicles equipped with adaptive cruise control unit - J428- , the adaptive cruise control unit - J428- must
be readjusted whenever the lock carrier has been removed, installed or renewed.
♦ General information and work instructions for the adaptive cruise control unit - J428- can be found in ⇒
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– Adjust headlights ⇒ Electrical system; Rep. gr. 94 ; Head‐
spec
lights; Adjusting headlights .
es, in part or in w
t to the co
Specified torques
♦ Lock carrier
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⇒ “2.1 Assembly overview - wing”, page 11
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1 - Wings
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⇒ page 11
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2 - Insulation for rib section
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4 - Centre hex stud

❑ Qty. 2, wing bracket
❑ 6.0 Nm
5 - Deformation element
6 - Bolt
❑ Qty. 3
❑ 6.0 Nm
7 - Wing bracket
8 - Bolt
❑ Qty. 2
❑ 6.0 Nm
9 - Deformation element
❑ Shape may vary
10 - Wing insulation
❑ Inserted between wing
and upper A-pillar
2.2 Removing and installing wing

2. Wings 11
Passat 2015 ➤
Removing
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– Remove front wheel housing liner ⇒ page 401 .

Passat 2015 ➤
– Remove front bumper cover ⇒ page 282 .

– Remove headlights ⇒ Electrical system; Rep. gr. 94 ; Head‐
lights .
– If fitted, detach washer fluid reservoir on right side ⇒ Electrical
system; Rep. gr. 92 ; Windscreen washer system; Removing
and installing washer fluid reservoir .
– Removing left plenum chamber cover ⇒ page 18 .
– Remove water deflector ⇒ page 359 .
– Release retaining hooks of trim strip -5-, and pull off trim strip.
– Unscrew hexagon nut -6-, and remove guide bracket.
– Pull out wing insulation -3 and 4-.
– Unscrew centre hex studs -6-.
– Unscrew bolts -2-.
– Loosen bolt -2- on windscreen, but do not unscrew it com‐
pletely.
– Remove wing -1- carefully.
Note
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2. Wings 13
Passat 2015 ➤
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– The wing is aligned free of tension with wing bracket loosened.
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– Always insert zinc intermediate piece - AKL 381 035 50- -7-
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between wing and side member.
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– Ensure joints are parallel and shut lines are equal ⇒ Body Re‐
pairs; Rep. gr. 00 ; Body gaps; Body, front .
Specified torques
♦ Wing ⇒ “2.1 Assembly overview - wing”, page 11

Passat 2015 ➤
3 Bulkhead
⇒ “3.1 Assembly overview - plenum chamber bulkhead”,
page 15
⇒ “3.2 Assembly overview - plenum chamber cover”, page 16
⇒ “3.3 Removing and installing plenum chamber bulkhead”, page
16
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❑ 8.0 Nm
3 - Seal, plenum chamber bulk‐
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3. Bulkhead 15
Passat 2015 ➤
3.2 Assembly overview - plenum chamber cover
1 - Plenum chamber cover

❑ Right side
⇒ page 18
❑ Left side
⇒ page 18
3 - Clip
❑ Qty. 3
4 - Foam element
❑ Left and right
5 - Seal
6 - Windscreen seal
❑ Part of windscreen
7 - Seal
8 - Windscreen
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Passat 2015 ➤
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Removing
– Removing plenum chamber cover ⇒ page 16 .
– Unscrew hexagon nuts -2- and remove plenum chamber bulk‐
head -1-.
Installing
Specified torques
Hexagon nut ⇒ Item 2 (page 15)
3. Bulkhead 17
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Passat 2015 ➤ ho ris nte
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General body srepairs, exterior - Edition 03.2019
au ra
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3.4 Removing and installing plenum chamber cover
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Removing
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The procedures for removing and installing the plenum chamber covers may have to be modified slightly de‐
pending on model variants.
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– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐

screen wiper system; Removing and installing wiper arms .
– Pull off entire length of seal -5- from plenum chamber covers
-1- and -2-.
– Loosen clips -3- (qty. 3) at bottom.
– First pull plenum chamber covers -2- by hand, starting from
middle, upwards from windscreen seal -6-.
– Pull plenum chamber covers -2- forwards out of wing and re‐
move.
– Then, pull plenum chamber covers -1- by hand, starting from
middle, upwards from windscreen seal -6-.

Passat 2015 ➤
– Pull plenum chamber covers -1- forwards out of wing and re‐
move. Volkswa AG. gen AG
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Note
♦ An insert is fitted in windscreen seal of new windscreens. Remove this insert before installing plenum
chamber cover.
♦ Push the plenum chamber cover into the windscreen seal by hand using only slight force. Never force it in
by hitting or using tools.
♦ Striking or banging the plenum chamber cover into the windscreen seal may crack the windscreen.
– Spray windscreen seal -6- with a soapy solution so that ple‐

num chamber covers -1- and -2- are easier to press in.
– First insert plenum chamber cover -1- into wing.
– Place plenum chamber covers -1- on windscreen seal -6-.
Starting from the outside, press into beading -5- by applying
light pressure.
– Then insert plenum chamber cover -2- into wing.
3. Bulkhead 19
Passat 2015 ➤
– Place plenum chamber covers -2- on windscreen seal -6-.

Starting from the outside, press into beading -5- by applying
light pressure.
– Attach clips -3- (qty. 3) at bottom. wage
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– Fit seal -5- on plenum chamber d by covers -1- and -2-. ua
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– Install wiper arms ⇒ Electrical
auth
system; Rep. gr. 92 ; Wind‐ or
ac
screen wiper system; Removing and installing wiper arms .
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Passat 2015 ➤
55 – Bonnet, rear lid

1 Bonnet (hood)
⇒ “1.1 Assembly overview - bonnet”, page 21
⇒ “1.2 Assembly overview - Bowden cable”, page 23
⇒ “1.4 Removing and installing bonnet”, page 24
⇒ “1.5 Adjusting bonnet”, page 26
⇒ “1.6 Removing and installing bonnet lock”, page 32
⇒ “1.7 Removing and installing bonnet release lever”, page 37
⇒ “1.8 Removing and installing striker pin”, page 39
⇒ “1.9 Removing and installing hinges”, page 41
⇒ “1.10 Removing and installing insulation”, page 43
⇒ “1.11 Removing and installing gas strut”, page 46
⇒ “1.12 Releasing gas from gas strut”, page 47
⇒ “1.13 Removing and installing Bowden cable”, page 47
1.1 Assembly overview - bonnet

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1. Bonnet (hood) 21
Passat 2015 ➤
1 - Bonnet (hood)
⇒ page 24
❑ Adjusting ⇒ page 26
2 - Dampers
⇒ page 43
3 - Striker
⇒ page 39
4 - Hexagon nut agen
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t to the co
❑ The contact point for the
buffer is always protec‐
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ted by a protective film.
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6 - Seal on side
❑ Left and right
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7 - Hinge
m
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⇒ page 41
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8 - Hexagon nut
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9 - Bolt Prote
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❑ For securing hinge

❑ 22 Nm
10 - Bonnet lock
❑ Removing and installing ⇒ page 32
11 - Bowden cable
12 - Bolt
❑ Qty. 2
❑ 12 Nm
❑ Renew after each removal
13 - Wire
❑ To lid lock
14 - Gas strut
22 Rep. gr.55 - Bonnet, rear lid

Passat 2015 ➤
1.2 Assembly overview - Bowden cable
1 - Operating lever
❑ Removing andsw AG. Volkswagen AG d
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❑ From clutch -4- to bon‐
spec
net lock -6-
t to the co
6 - Bonnet lock
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⇒ page 32
7 - Bolt
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❑ Qty. 2
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❑ 12 Nm
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8 - Mounting plate atio

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1. Bonnet (hood) 23
Passat 2015 ➤
General body repairs, exterior - Edition 03.2019 AG. Volkswagen AG d
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1.3 Assembly overview - gas strut orised by ara
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1 - Gas strut
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⇒ page 46
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❑ Not an individual part,
cannot be renewed indi‐ es, in part or in w
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1.4 Removing and installing bonnet

Removing

Passat 2015 ➤
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ility
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
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en
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– Remove spray jets -5- ⇒ Electrical system; Rep. gr. 92 ; Win‐

t.
yi Co
op
dow washer system; Removing and installing spray jets . C py
t. rig
gh ht
yri by
– Pull line -2- out of opening in bonnet -1-.
op Vo
by c lksw
cted agen
Prote
– Loosen hexagon nuts -3- in left and right hinges -4- (do not
AG.
remove).
Further dismantling requires the assistance of a second mechan‐
ic.
– Remove gas strut -6-.
– Now, and only now, unscrew and remove hexagon nuts -3-
and lift bonnet -1- out of hinges -4-.
Installing
1. Bonnet (hood) 25
Passat 2015 ➤
lkswage es n
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ab
ility
Installation of bonnet -1- is carried out accordingly in reverse or‐

ot p
der of removal.
wit
, is n
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hole
spec
es, in part or in w
Note
t to the co
Install the line -2- in a curve. If line is installed twisted it will kink.
rrectness of i
– Adjusting bonnet -1- ⇒ page 26 .

l purpos
Specified torques
nf
ercia
♦ Hexagon nuts ⇒ “1.1 Assembly overview - bonnet”, page 21

orm
m
1.5 Adjusting bonnet

atio
om
n in
or c

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Prote AG.

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
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ris nte
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nl
pt
du
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ility
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hole
spec
es, in part or in w
t to the co
Note
rrectness of i
♦ Vehicle must be standing on its wheels to enable bonnet to be adjusted.
l purpos
♦ The adjusting buffers -2- on the left and right sides cannot be used to adjust the rear lid. They have the
function of stabilising and damping the bonnet.
nf
ercia
♦ The bonnet is correctly adjusted when all shut lines are even when closed. The bonnet must not protrude
or
too far inwards or outwards. The contours must also be flush with each other.
m
m
atio
om
♦ The bonnet must engage into the lid lock without excessive force.
n in
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t.
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rig ht
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co Vo
by lksw
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Prote AG.
1. Bonnet (hood) 27
Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
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Prote AG.
– Remove striker pin ⇒ page 39 .

– The gaps/shut lines are adjusted via the hinges ⇒ page 28 .
Note
♦ A protective film must always be fitted under the adjusting buffers on the support arm -3-.
♦ The threads of the adjusting buffers and the key hole must be sprayed with preservative wax before screwing
in and adjusting.
– Turn adjustment buffer -2- to adjust -arrows-.

– After bonnet -1- has been adjusted, the striker pin can be re‐
installed and adjusted ⇒ page 29 .
Specified torques
♦ Lid lock ⇒ “1.2 Assembly overview - Bowden cable”, page 23
Adjusting hinges
Note
Do not unscrew hexagon nuts -3- and bolts -2- completely, just loosen them.

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
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Prote AG.
– By loosening hexagon nuts -3- on left and right lid hinges -1-,
the bonnet can be centred laterally -arrow b- and in longitudi‐
nal direction -arrow a- between wings.
– By loosening bolts -2- on left and right lid hinges -1-, the bonnet
can be centred vertically -arrow c- between wings.
– Ensure that gaps are uniform ⇒ Body Repairs; Rep. gr. 00 ;
Technical data; Body panel gaps/shut lines; Body - front .
– Specified torque for hexagon nuts -5- and bolts -2-: 22 Nm.
– After adjusting, carry out corrosion protection measures on
bonnet hinges -1-, hexagon nuts -3- and bolts -2-.
– If necessary, readjust adjustment buffers.
Specified torques
♦ Hinges ⇒ “1.1 Assembly overview - bonnet”, page 21
Adjusting striker pin
1. Bonnet (hood) 29
Passat 2015 ➤
lkswage es n
o ot g
byV ua
d ran
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tho
u or
a ac
ss
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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t.
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op py
– Loosen hexagon nuts -2-. t. C rig
gh ht
yri by
– Striker pin -1- can now be adjusted on bonnet in lateral direc‐
cop Vo
by lksw
cted
tion via elongated holes.
agen
Prote AG.
Specified torques
Adjusting lid lock

Passat 2015 ➤
♦ Setting gauge - 3371-
AG. Volkswagen AG d
agen oes
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or eo
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un
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pe
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spec
es, in part or in w
t to the co
Note
Use new bolts when adjusting the lid lock.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
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Cop py
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by c lksw
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Prote AG.
1. Bonnet (hood) 31
Passat 2015 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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fo
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t.
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Cop py
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Vo
co lksw
by
cted agen
Prote AG.
– Remove caps -3- from bolts.

– Loosen bolts -2- to adjust lid lock -1- laterally -arrow a- and
vertically -arrows b- relative to bonnet ⇒ Body Repairs; Rep.
gr. 00 ; Body panel gaps/shut lines; Body - front .
Specified torques
1.6 Removing and installing bonnet lock

⇒ “1.6.1 Removing and installing lid lock, LHD vehicle”,
page 32
⇒ “1.6.2 Removing and installing lid lock, RHD vehicle”,
page 35
1.6.1 Removing and installing lid lock, LHD

vehicle

oes Passat 2015 ➤
AG. Volkswagen AG d
agen
ksw not
General
by Vol
body repairs, exterior - Edition
gu
ara
03.2019
d
rise nte
♦ Torque wrench - V.A.G 1331- tho eo
s au ra
c
s
ce
e
nl
pt
du
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itte
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ility
ot p
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es, in part or in w
t to the co
rrectness of i
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Removing
nform
ercia
Note
m
at
om
ion
c
Renew bolts -3- every time they have been unscrewed.
in t
or
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ate
do
priv
cum
for
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t.
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Prote AG.
– Open bonnet.
– Remove Bowden cable on mounting bracket ⇒ page 47 .
1. Bonnet (hood) 33
Passat 2015 ➤
– Disconnect connector for bonnet contact switch -5-.
Note
The connector is secured next to the right headlight.
– Remove caps -4- from bolts.

– Remove bolts -3- from lock carrier andGremove lid lock -1- up‐
A . Volkswagen AG d
wards -arrow a-. lkswagen oes
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yV ua
– Unclip retainer -7- from
iselid lock.
db ran
r tee
tho
– Pull off retainer -7- aufrom lid lock -1- slightly -arrow b- and un‐ or
ac
ss
hook cable -6- -arrow c-.
ce
le
un
pt
– Remove microswitch -5- from lid lock.
an
d
itte
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erm
ab
Installing
ility
ot p
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
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c
i
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Prote AG.
– Hook in cable -4- -arrow a- and clip retainer -5- into bonnet
lock -1- -arrow b-.
– Install microswitch -6- in lid lock.
– Insert lid lock -1- into lock carrier -arrow c-.

Passat 2015 ➤
– Screw in new bolts -3-.

– Connect connector for bonnet contact switch -6-.
– Install Bowden cable on mounting bracket ⇒ page 37 .
– Adjust lid lock ⇒ page 26 .
– Install caps -4-.
– Before closing bonnet, check function of release lever and ca‐
ble.
Specified torques
1.6.2 Removing and installing lid lock, RHD

vehicle
Removing
Note olkswage es n
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byV ua
ed ran
Renew bolts -3- everythor time they have been unscrewed.
is tee
or
au ac
ss
ce
e
nl
pt
du
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itte
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erm
ab
ility
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
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for
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Cop py
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co lksw
by
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Prote AG.
1. Bonnet (hood) 35
Passat 2015 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
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ab
pe
ility
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wit
, is n
h re
hole
spec
es, in part or in w
– Open bonnet.
t to the co
– Remove Bowden cable on mounting bracket ⇒ page 47 .

rrectness of i
– Disconnect connector for bonnet contact switch.

l purpos
Note
nform
ercia
The connector is secured next to the right headlight.

m
a
com
tion in
– Lift caps -4- off bolts.

r
te o
thi
s
iva
– Remove bolts -3- from lock carrier and remove lid lock -1- up‐
do
r
rp
wards -arrow a-.

um
fo
en
ng
t.
– Unclip retainer -7- from lid lock.
yi Co
Cop py
t. rig
– Pull off retainer -7- from lid lock -1- slightly -arrow b- and un‐
gh ht
pyri by
hook cable -6- -arrow c-.
co Vo
by lksw
cted agen
Prote AG.
– Remove microswitch -5- from lid lock.
Installing

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
– Hook in uthcable
or
-5- -arrow a- and clip retainer -4- into bonnet
eo
ra
lock s-1-
s a -arrow b-. c
ce
le
– Install microswitch -6- in lid lock -arrow c-.

un
pt
an
d
itte
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– Insert lid lock -1- into lock carrier -arrow d-.

rm
ab
pe
ility
– Screw in new bolts -3-.

ot
wit
, is n
h re
– Connect connector for bonnet contact switch -6-.

hole
spec
– Install Bowden cable -2- to mounting bracket ⇒ page 37 .

es, in part or in w
t to the co
– Adjust lid lock ⇒ page 26 .

rrectness of i
ble.
l purpos
Specified torques
nform
ercia
1.7 Removing and installing bonnet release

m
a
com
ti
lever
on in
r
te o
thi
Removing
s
iva
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Cop py
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37
cop Vo
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Prote
cted AG.
agen 1. Bonnet (hood)
. Volkswagen AG
gen AG does
Passat 2015 ➤ olks
wa not
yV gu
ise
d b ara
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ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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cum
fo
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t.
yi Co
Cop py
t. rig
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Vo
o
by c lksw
cted agen
Prote AG.
– Slightly pull operating lever -1-, and unlock bonnet.

– Insert a small screwdriver in gap between release lever -1- and
retaining clip -2-.
– Lever retaining clip -2- out of release lever -1- -arrow b- and
pull release lever off mounting bracket -3- -arrow a-.
For further work on mounting bracket -4-, remove lower A-pillar
trim -3- -4- ⇒ General body repairs, interior; Rep. gr. 70 ; Trims,
interior; Removing and installing A-pillar trim .
Installing

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
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erm
ab
ility
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spec
t to the co
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cial p
f inform
mer
• Lower A-pillar trim -3- is installed.

atio
om
n
c
– Push retaining clip -2- into release lever -1-.

i
or
n thi
te
sd
a
– Press release lever -1- onto mounting bracket -4-.

iv
o
pr
cum
r
fo

en
ng
t.
ble.
yi Co
Cop py
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1.8 Removing and installing striker pin
gh ht
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Special tools and workshop equipment required Prote AG.
1. Bonnet (hood) 39
Passat 2015 ➤
Removing AG. Volkswagen AG d

agen oes
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V gu
d by ara
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or eo
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ce
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nl
pt
du
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itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
– Open bonnet -2-.

– Remove hexagon nuts -3-.
– Remove striker pin -1- from bonnet -2-.
Installing
Note
Always use new hexagon nuts after the hexagon nuts have been
loosened.

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
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ab
pe
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
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Installation of the striker pin -1- is carried out in the reverse order
en
ng
t.
yi
of removal.
Co
Cop py
t. rig
– Adjust striker pin ⇒ page 26 .
gh ht
pyri by
Vo
co lksw
by
Specified torques cted agen
Prote AG.
♦ Striker pin ⇒ “1.1 Assembly overview - bonnet”, page 21
1.9 Removing and installing hinges

1. Bonnet (hood) 41
Passat 2015 ➤
AG. Volkswagen AG d
agen oes
Note y Volksw not
gu
d b ara
rise nte
Removal and installation are described for the right
utho hinge only. eo
ra
Removal and installation of the left hinge are ssimilar.
sa c
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e
nl
pt
du
an
Removing
itte
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erm
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ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
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ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove bonnet ⇒ page 24 .

– Pull off hinge -1-.
Installing

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
Installation
ss of the hinge -1- is carried out in the reversecorder of
ce
removal.
e
nl
pt
du
an
itte
– Install bonnet ⇒ page 24 .

y li
erm
ab
ility
Specified torques
ot p
wit
, is n

h re
hole
spec
1.10 Removing and installing insulation

es, in part or in w
t to the co
Removing
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
43
Prote AG.
1. Bonnet (hood)
Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
– Lever retaining clips -2- out of bonnet using removal lever -

ion in
80-200- .
r
te o
thi
s
iva
– Pull insulation -1- out of elongated holes -arrows a-.

do
r
rp
cum
fo
– Pull out insulation, and guide gas strut through the slot
en
ng
t.
-arrow b-.
yi Co
Cop py
t. rig
Installing
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
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y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
• When installing insulation -2-, ensure that retaining clips -2-

are fitted with wider side facing outwards -arrow c-.
l purpos
– Fit insulation -1- so that gas strut -3- is guided through the slot
-arrow b-.
nform
ercia
– Push insulation -1- with fitting lugs -arrows a- into elongated

m
holes.
com
tion in
r
– Insert all retaining clips -2- into bonnet -1-.

te o
thi
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t.
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Vo
co lksw
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Prote AG.
1. Bonnet (hood) 45
Passat 2015 ➤
1.11 Removing and installing gas strut
AG. Volkswagen AG d
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pt
du
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ab
ility
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wit
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es, in part or in w
t to the co
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nf
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orm
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Vo
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Removing
cted agen
Prote AG.
– Open and support bonnet.
NOTICE
Risk of damage to spring clip caused by levering it out too far.
The spring clip may break.
– Never lever spring clip completely out of ball socket.
– Position a small screwdriver -3- beneath spring clip -4-.

– Raise spring clip -4- in such a way that it can be moved over
ball socket -arrow a-.
– Pull off gas strut -1- from ball-head pin -2- -arrow b-.
After removing gas strut -1-, slide spring clip -4- back immediately.
– When the gas strut is disposed, gas needs to be released from
gas strut ⇒ page 47 .

Passat 2015 ➤
Installing
– Press gas strut -1- onto ball-head pins -2-.
Component Specified tor‐
ques
Ball-head pin 20 Nm
1.12 Releasing gas from gas strut

– Clamp gas strut in vice in area x = 50 mm.
CAUTION
Risk of eye injury caused by flying swarf.
Risk of eye injury or eye irritation.
– Wear protective goggles.
– Cover area of saw cut with a cloth.

– Saw through cylinder of gas strut within first third of cylinder's
overall length using piston rod end of cylinder as reference
point.
– Feed oil and cleaning clothes into existing method of disposal.
AG. Volkswagen AG d
1.13 Removing and installing BowdenVcable
olks
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Removing rise nte
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1. Bonnet (hood) 47
Passat 2015 ➤
AG. Volkswagen AG d
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– Open bonnet. f inform

mer
– Remove release lever ⇒ page 37 .

atio
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– Remove Bowden cable -6- from mounting bracket -5-

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-arrow a-.
t
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– Release Bowden cable -1- -arrow d- and remove from Bowden cted agen
Prote AG.
cable coupling -2- -arrow e-.
Note
In order to be able to remove or install the Bowden cable -3-, remove the support arm -7- ⇒ page 2 .

Passat 2015 ➤
Installing
Note
♦ If the Bowden cable -3- is not removed from mounting bracket, the Bowden cable -1- unhooks again and
again when installing the Bowden cable coupling -2-. AG. Volkswagen AG d
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♦ The bonnet cannot be opened in this case. d by V o gu
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cial p
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Prote AG.
– Hook in Bowden cable -1- into Bowden cable coupling -2-

-arrow b-.
– Slightly pull Bowden cable off Bowden cable coupling
-arrow c-.
– Close Bowden cable coupling -arrow d-.
– Push Bowden cable -1- into Bowden cable coupling
-arrow e-.
– Attach Bowden cable coupling -2- to lock carrier -4- -arrow f-.
– Install Bowden cable -3- on mounting bracket -5- -arrow a-.
– Install release lever ⇒ page 37 .
1. Bonnet (hood) 49
Passat 2015 ➤
– Before closing bonnet, check function of release lever and

Bowden cable.
AG. Volkswagen AG d
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Prote AG.

Passat 2015 ➤
2 Rear lid
AG. Volkswagen AG d
⇒ “2.1 Assembly overview - rear lid”, page 51 lksw
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⇒ “2.2 Removing and installing rear lid”, page 53 rise d ara
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⇒ “2.3 Adjusting rear lid”, page 56 aut ra
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⇒ “2.4 Removing and installing bonnet lock”, page 62
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⇒ “2.5 Removing and installing operating mechanism”,
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page 74
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⇒ “2.6 Removing and installing hinges”, page 79
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⇒ “2.7 Removing and installing striker pin”, page 81 hole
spec
es, in part or in w
⇒ “2.8 Removing and installing rear lid seal”, page 82
t to the co
⇒ “2.9 Removing and installing gas strut”, page 84
rrectness of i
⇒ “2.10 Releasing gas from gas strut”, page 87
l purpos
⇒ “2.11 Removing and installing drive unit for rear lid VX69 ”, page
87
nform
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2.1 Assembly overview - rear lid

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⇒ “2.1.1 Assembly overview - rear lid”, page 51
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⇒ “2.1.2 Overview of fitting locations - electric rear lid”,
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page 53
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2.1.1 Assembly overview - rear lid
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Prote AG.
2. Rear lid 51
Passat 2015 ➤
1 - Rear lid
⇒ page 53
2 - Bonnet lock
⇒ page 62
3 - Hexagon nut
❑ Qty. 2
❑ 20 Nm
4 - Bowden cable
❑ From power latching
system to rear lid lock
5 - Power latching system
6 - Adjusting buffer
❑ Left and right
Note
The threads of the adjusting buffers

and the key hole must be sprayed
with preservative wax before screw‐
ing in and adjusting.
7 - Bolts
❑ Qty. 2
❑ 20 Nm
8 - Hinge
❑ Left and right AG. Volkswagen AG d
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❑ Removing and installing olksw not
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⇒ page 79 rised ara
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9 - Spring aut ra
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❑ Left and right
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10 - Bolts
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12 - Bolts
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❑ Qty. 2
❑ 20 Nm
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13 - Seal
inform

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14 - Gas strut/drive for rear lid

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❑ Removing and installing drive for rear lid ⇒ page 87

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❑ Removing and installing gas strut ⇒ page 84

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❑ Releasing gas from gas strut ⇒ page 87 .

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52
agen
Prote AG.
Rep. gr.55 - Bonnet, rear lid
Passat 2015 ➤
15 - Bolts
❑ Qty. 3
❑ 5 Nm
olkswagen AG
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16 - Operating mechanism olks
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❑ The brand badge can be renewed iindividually
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❑ Removing and installing ⇒ page
au 74
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2.1.2 Overview of fitting locations - electric rear lid itte
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1 - Drive for rear lid
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⇒ page 87
2 - Mounting for drive
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3 - Rear lid power opening
sender
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❑ Fitting location only for

vehicles with towing
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❑ The bracket is bonded
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bracket
❑ The bracket is bonded
to the bumper cover us‐
ing double-sided adhe‐
sive tape
6 - Sensor wire
❑ Is bonded to the bumper
cover using double-si‐
ded adhesive tape
7 - Wire
8 - Bracket for control unit
❑ Engaged in metal
flange, release retaining
hooks from behind
9 - Connector
10 - Rear lid control unit
– Removing: release retaining hooks -arrow a-, pull control unit upwards -arrow b-, and remove it
-arrow c-.
– Installing: slide onto bracket from above, and press it on until retaining hooks can be heard to engage.
2.2 Removing and installing rear lid

2. Rear lid 53
Passat 2015 ➤
Removing
AG. Volkswagen AG d
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te o
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Prote AG.
– Remove lower rear lid trim ⇒ General body repairs, interior;
Rep. gr. 70 ; Luggage compartment trims; Removing and in‐
stalling lower rear lid trim .
– Remove connectors of all installed electrical components.
– Guide wires -2- out of rear lid.

Passat 2015 ➤
– Loosen bolts -3- of left and right hinges but do not remove
completely yet.
ic.
– Now, and only now, remove bolts -3- completely and then re‐
move rear lid -1-.
Installing
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Prote AG.
– Install rear lid -1- with the aid of a 2nd mechanic.

– Screw in bolts -3-.
– Guide wires -2- into rear lid.
– Connect connectors of all installed electrical components.
The remaining installation steps are carried out in the reverse se‐
quence of removal.
– Before closing rear lid, check function of lid release compo‐
nents.
– Adjusting rear lid ⇒ page 56 .
2. Rear lid 55
Passat 2015 ➤
2.3 Adjusting rear lid

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Note autho
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♦ Vehicle must be standing on its wheels to enable rear lid to be adjusted.

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♦ The rear lid lock -2- is bolted directly to the rear lid -1-. The rear lid lock cannot be adjusted.
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♦ The adjusting buffers -3- on the left and right sides cannot be used to adjust the rear lid. They have the
ot
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function of stabilising and damping the rear lid.
, is n
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hole
♦ The rear lid is correctly adjusted when all shut lines are even when closed. it is not protruding too far inwards
or outwards, and when the contours are flush with each other. spec
es, in part or in w
t to the co
♦ The rear lid must engage in the striker plate without excessive force being applied.
rrectness of i
l purpos
nform
mercia
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Prote AG.

Passat 2015 ➤
lkswage es n
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t to the co
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cial p
f inform
mer
Use the setting gauge - 3371- ⇒ Body Repairs; Rep. gr. 00 ;

atio
m
Bodywork gaps/shut lines; Rear body to check or set the gap di‐
o
n
c
mensions.
i
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– The rear lid lock -2- cannot be adjusted.

iv
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– Loosen striker pin -5-, and adjust it after adjustment of hinge

en
ng
t.
and adjustment buffer ⇒ page 60 .
yi Co
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– Remove rear shelf ⇒ General body repairs, interior; Rep. gr.
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pyri by
70 ; Trims, interior; Removing and installing rear shelf .
co Vo
by lksw
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Prote AG.
– If bolts -4- are loosened on left and right, it is possible to adjust
rear lid -1- in the oversized holes of hinge -7- -arrows a- and
-arrows c-.
– After bolts -6- have been loosened, there are additional op‐
tions for adjustment -arrows a and b-.
– After completing adjustments, perform corrosion protection
measures on hinge and bolts.
– Readjust adjusting buffer -3-.
Specified torques
♦ Bolts ⇒ “2.1 Assembly overview - rear lid”, page 51
2. Rear lid 57
Passat 2015 ➤
Adjusting adjusting buffer

AG. Volkswagen AG d
agen oes
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Note byV
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♦ If necessary, renew adjusting buffer
aut
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⇒ page 59 . ra
ss c
♦ The threads of the adjusting buffers and the key hole must be sprayed with preservative wax before screwing
ce
e
nl
pt
in and adjusting. du
an
itte
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es, in part or in w
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mercia
at
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ion
c
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ate
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for
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Prote AG.
– Loosen clamping bolt -4- until it is visible in rubber buffer.

– Pull detent slide -3- out of adjusting buffer -1-.
– Adjust detent slide to dimension -a- = 12.5 mm.
– Close rear lid in preliminary detent position with slight pressure
in the middle.
– Open rear lid again.

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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aut ra
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un
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d
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wit
is n
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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cum
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fo
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t.
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Cop py
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rig ht
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co Vo
by lksw
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Prote AG.
– Screw in clamping screw -1- of adjustment buffer -2- to a depth

of -a- = 20 mm.
– Check the adjustment.
Renew adjustment buffer.
2. Rear lid 59
Passat 2015 ➤
AG. Volkswagen AG d
agen oes
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Removing ss a c
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– To remove adjustment buffer, turn entire buffer -1- through 90°

pt
an
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-arrow a-.
itte
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– Remove buffer from rear lid -2-.

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Installing
h re
hole
spec
– Carefully check that stop -3- is correctly seated in side panel

es, in part or in w
-4-.
t to the co
Note
rrectness of i
l purpos
The threads of the adjusting buffers and the key hole must be sprayed with preservative wax before screwing
in.
nform
ercia
– To install, insert entire buffer -1- at right-angle into rear lid

m
-2- -arrow c-.

com
tion in
– Turn buffer -1- through 90° -arrow b-.

r
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s
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– Adjust adjustment buffer -1- ⇒ page 58 .

do
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Adjusting striker pin

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60
Prote AG.
Rep. gr.55 - Bonnet, rear lid
Passat 2015 ➤
Note
♦ If hexagon nuts are loosened -2-, it is possible to adjust striker pin -1- Ain the oversized holes of hinge
G. Volkswagen
-arrow a- and -arrow b-. ksw
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♦ Adjust striker pin -1- so that the recess of the rear lid lock
ris
edwith rotary latch
b
is centred relative toarathe
nte striker
pin -1- when it engages. tho eo
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2. Rear lid 61
Passat 2015 ➤
General body repairs, exterior - Edition 03.2019 AG. Volkswagen AG d
agen oes
olksw not
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– Remove trim for rear lid lock ⇒ General body repairs,
d b interior; ara
ise nte
Rep. gr. 70 ; Luggage compartment trims; tRemoving
ho
r and in‐ eo
stalling trim for rear lid lock . ss au ra
c
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– Loosen bolts -2-.
nl
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– Move striker pin -1- into upper position and tighten hexagon
erm
ab
nuts -2-.
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– Close rear lid and make sure adjustment has been carried out
, is n
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correctly.
hole
spec
Specified torques
es, in part or in w
t to the co
♦ Hexagon nut ⇒ “2.1 Assembly overview - rear lid”, page 51
2.4 Removing and installing bonnet lock
rrectness of i
l purpos
⇒ “2.4.1 Removing and installing bonnet lock”, page 62

⇒ “2.4.2 Removing and installing lid lock with power latching sys‐
nform
ercia
tem”, page 64
m
⇒ “2.4.3 Installing new lid lock with power latching system”, page
at
om
io
69
n
c
in t
or
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e
⇒ “2.4.4 Removing and installing power latching motor”,

at
do
riv
page 70
p
cum
for
⇒ “2.4.5 Installing new power latching motor”, page 73
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2.4.1 Removing and installing bonnet lock
t. C rig
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Removing

Passat 2015 ➤
agen General
AG. Volkswagen AG does body repairs, exterior - Edition 03.2019
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es, in part or in w
t to the co
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nf
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orm
m
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or c
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Prote AG.
Note
♦ If the rear lid does not open, it can be opened in an emergency by reaching through the rear lid trim and
actuating the emergency release by hand ⇒ Operating Manual .
♦ The Bowden cable -2- is only fitted on vehicles with power latching system.
– Remove rear lid trim ⇒ General body repairs, interior; Rep.

gr. 70 ; Luggage compartment trims; Removing and installing
lower rear lid trim .
– Pull off anti-theft protection device -5- -arrow b-.
– Disconnect connector on lid lock.
– Press together retaining hooks -6- -arrows d- and remove lid
lock -1- from rear lid -arrow c-.
2. Rear lid 63
Passat 2015 ➤
Installing
Note
The Bowden cable -2- is only fitted on vehicles with power latching system.
lkswage es n
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Insert lid lock -1- in rear lid -arrow a- and tighten hexagon nuts
l purpos
-3-.
– Attach connector to lid lock.
nform
ercia
– Slide on anti-theft protection device -4- -arrow b-.

m
at
om
ion
c
• Before closing rear lid, check function of lid release compo‐

in t
or
nents.
his
ate
do
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Specified torques
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2.4.2 Removing and installing lid lock with
gh ht
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power latching system
by lksw
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Prote AG.

Passat 2015 ➤
Removing
AG. Volkswagen AG d
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es, in part or in w
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nform
mercia
at
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ion
c
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ate
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for
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Prote AG.
Note
If the rear lid does not open, it can be opened in an emergency by reaching through the rear lid trim and actuating
the emergency release by hand ⇒ Operating Manual .
2. Rear lid 65
Passat 2015 ➤

– Pull off anti-theft protection device -5- -arrow b-.
– Disconnect connector on lid lock.
– Press together retaining hooks -6- -arrows d- and remove lid
lock -1- from rear lid -arrow c-.
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mer
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– Lock latch -7- of lid lock -4-.

thi
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– Using a screwdriver -5-, push lever -6- to stop in

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-direction of arrow c-, and hold it in this position.

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– Detach Bowden cable -1- from retainer by turning it C py
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-arrow b-.
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– Guide Bowden cable -1- out of lever -2- -arrow c-. cted agen
Prote AG.
Installing

Passat 2015 ➤
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– Using a screwdriver -5-, push lever -6- to stop in

-direction of arrow c-, and hold it in this position.
– Guide Bowden cable -1- into lever -2- -arrow a-.
– Attach Bowden cable -3- to retainer by turning it -arrow b-.
– Release lever -6-, and operate release mechanism -7-
-arrow d-.
2. Rear lid 67
Passat 2015 ➤
AG. Volkswagen AG d
agen oes
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es, in part or in w
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Prote AG.

Passat 2015 ➤
2.4.3 Installing new lid lock with power latching system
AG. Volkswagen AG d
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atio
– Push clip -3- to stop in -direction of arrow c-, and hold it in this
om
position.
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– Attach Bowden cable -2- to retainer by turning it -arrow b-.

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– Release clip -3- and remove from lid lock -4- -arrow d-. Cop py
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– Operate release mechanism -6- -arrows e-. p by
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Prote AG.
2. Rear lid 69
Passat 2015 ➤
AG. Volkswagen AG d
agen oes
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nents.
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Specified torques
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Passat 2015 ➤
n AGGeneral
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n AG drepairs, exterior - Edition 03.2019
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Prote AG.
Note
If the rear lid does not open, it can be opened in an emergency by reaching through the rear lid trim and actuating
the emergency release by hand ⇒ Operating Manual .

– Disconnect connector -5- on power latching system -1-.
– Slightly turn mounting -arrow a- so that Bowden cable is free
of stress.
– Lift Bowden cable retainer -4- out of power latching system
-1-.
– Lift Bowden cable ball head -3- out of mounting -arrow b-.
– Turn retaining clip -2- 90° -arrow c-.
– Pull power latching system -1- off retaining clips -2-.
2. Rear lid 71
Passat 2015 ➤
Note
♦ The retaining clips -2- remain installed.

♦ If a new power latching system -1- is installed ⇒ page 73 , the retaining clips -2- must be removed.
Installing
AG. Volkswagen AG d
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– Fit power latching system -1- onto retaining clips -2-. C py
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– Turn retaining clips -2- 90° -arrow c-.
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– Fit Bowden cable ball head -4- onto mounting -arrow b-.
Prote AG.
– Slightly turn mounting so that Bowden cable -4- is free of

stress.
– Insert Bowden cable retainer -3- in power latching system
-1- -arrow a-.
– Connect connector -5- to power latching system -1-.
nents.

Passat 2015 ➤
2.4.5 Installing new power latching motor
Note
The existing retaining clips -2- must be removed.
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– Push retaining clips -2- installed on new power latching system

into holes in rear lid -arrows c-.
rrectne
– Fit Bowden cable ball head -3- onto mounting -arrow a-.
– Slightly turn mounting so that Bowden cable -4- is free of
ss
stress.
o
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– Insert Bowden cable retainer -4- in power latching system

mer
-1- -arrow b-.

atio
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– Connect connector -5- to power latching system -1-.

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Prote AG.
2. Rear lid 73
Passat 2015 ➤
2.5 Removing and installing operating

mechanism
⇒ “2.5.1 Removing and installing handle, without reversing cam‐
era”, page 74
⇒ “2.5.2 Removing and installing handle, with reversing camera”,
page 76
2.5.1 Removing and installing handle, without

reversing camera
Note AG. Volkswagen AG d

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The brand badge can be renewed individually ⇒ page ise
d b 413 .
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AG. Volkswagen AG d Passat 2015 ➤
agen o
Volksw General bodyesrepairs,
not
gu
exterior - Edition 03.2019
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Prote AG.
Removing
– Detach connector -4- from handle connection -1-.
– Slightly turn handle -1- -arrow a- and remove from rear lid
-arrow b-.
In case of electrical malfunction, rear lid can be opened using lock
emergency release. Emergency release is accessible through an
aperture in rear lid trim.
Installing
2. Rear lid 75
Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
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rise nte
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nl
pt
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– Insert handle -1- into rear lid -2- -arrow a-, and turn it slightly
thi
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-arrow b-.
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– Tighten bolts -3-.

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– Attach connector -4- to handle. C py
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• Before closing rear lid -2-, check function of lid release com‐ cop Vo
by lksw
ponents. cted agen
Prote AG.
Specified torques
2.5.2 Removing and installing handle, with re‐

versing camera

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
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au ra
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Note
t to the co
The brand badge can be renewed individually ⇒ page 413 .
rrectness o
cial p
f inform
mer
atio
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Cop py
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by
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Prote AG.
2. Rear lid 77
Passat 2015 ➤
Removing
– Separate electrical connectors -1 and 7-.
– Slightly turn handle -2- -arrows a-, and remove it from rear lid
-arrow b-.
– Pull water drain hose -6- off handle -arrow c-.
AG. Volkswagen n AG do
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In case of electrical malfunction,
Vol rear lid can be openednousing
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For general information
s
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nl
camera -4- and the gear unit -3- refer to⇒ Communication; Rep.
pt
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gr. 91 ; Reversing camera system .
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Installing
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– Insert handle -2- into rear lid -5- -arrow a-, and turn it slightly
-arrows b-.

lkswage es n
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Passat
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ran
ir General
se body repairs, exterior - Edition 03.2019
tee
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– Attach water drain hose -6- to handle -arrow c-.
ce
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– Secure connectors -1 and 7-.
an
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Specified torques
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2.6 Removing and installing hinges
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Prote AG.
Removing
Note
♦ Removal and installation is described for the left-hand hinge.

Removal and installation of the right hinge are similar.
♦ For clarity the rear window is not shown in the figure.
2. Rear lid 79
Passat 2015 ➤
AG. Volkswagen AG d
agen oes
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– Remove rear shelf -4- ⇒ General body repairs, interior; Rep.

ility
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gr. 70 ; Trims, interior; Removing and installing rear shelf .

wit
is n
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– Remove luggage compartment trim ⇒ General body repairs,

ole,
spec
interior; Rep. gr. 70 ; Luggage compartment trims .

t to the co
– Removing rear lid -3- ⇒ page 53 .

– Guide wires -2- out of hinge -arrow a-.
rrectne
– Remove gas strut and spring ⇒ page 84 , or remove drive

⇒ page 87 .
ss o
Further removal requires the help of a second mechanic.

cial p
f inform
– Unscrew bolts -5- in interior.

mer
atio
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– The second mechanic removes the hinge -1- through the lug‐
o
n
c
gage compartment.
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Cop py
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Passat 2015 ➤
AG. Volkswagen AG d
agen oes
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nl
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Hinge -1- installation is carried out in reverse order of removal.

sd
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Specified torques t. Cop py
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♦ Hinge ⇒ “2.1 Assembly overview - rear lid”, page 51 pyri by
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Prote AG.

2. Rear lid 81
Passat 2015 ➤
AG. Volkswagen AG d
agen oes
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cial p
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Cop py
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pyri by
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by
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Prote AG.
Removing
– Remove trim for rear lid lock ⇒ General body repairs, interior;
Rep. gr. 70 ; Luggage compartment trims; Removing and in‐
stalling trim for rear lid lock .
– Unscrew bolts -1- and remove striker pin -2- from lock carrier.
Installing
– Mount striker pin -2- with bolts -1- on lock carrier.
Specified torques
♦ Hexagon nut ⇒ “2.1 Assembly overview - rear lid”, page 51
2.8 Removing and installing rear lid seal

In the factory a sealant is applied to the rear lid seal, the seal is
fitted to the body flange and then rolled on.

Passat 2015 ➤
AG. Volkswagen AG d
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Note orise nte
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♦ When the seal is removed, the sealant on the inside of the seal s
ce
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will be spread and the flanks will be bent out slightly. If the seal
un
pt
an
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is then refitted, sealing and firm seating are no longer guar‐
itte
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placed with a seal known as a “tap-on seal”.
h re
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spec
♦ If a seal has been partially removed, squeeze sides of seal
es, in part or in w
together before installing.
t to the co
rrectness of i
l purpos
nform
mercia
a
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tion in
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te o
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Cop py
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by c lksw
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Prote AG.
Removing
– Pull seal -1- off body flange -2-.
Installing
– Align vulcanised point -3- of seal -1- in area of tail light -4-.
– Press seal -1- evenly onto body flange -2- by hand.
2. Rear lid 83
Passat 2015 ➤
2.9 Removing and installing gas strut

Removing
Note
♦ The rear lid must be supported when a gas strut or spring is removed. One gas strut or spring alone cannot
support an open rear lid.
♦ The ball-head pins -3 and 7- are part of the body and the hinge.
♦ The gas strut -1- is installed only on the left side.
♦ The spring -5- is installed on the left and right side.
AG. Volkswagen AG d
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rrectness of i
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nform
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at
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ion
c
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Prote AG.
Gas strut
– Remove luggage compartment trim ⇒ General body repairs,
interior; Rep. gr. 70 ; Luggage compartment trims .
– Open rear lid and brace it open.

Passat 2015 ➤
NOTICE
Risk of damage to spring clip caused by levering it out too far.
The spring clip may break.
– Never lever spring clip completely out of ball socket.
– Position a small screwdriver -4- beneath spring clips -2-.

– Lift spring clips -2- just enough that they can be moved over
ball sockets -arrows a-.
– Pull gas strut -1- off ball-head pins -3- -arrows b-.
After removing gas strut, slide spring clips -2- back immediately.
– When the gas strut is disposed, gas needs to be released from
gas strut ⇒ page 87 .
Spring
AG. Volkswagen AG d
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– Open and support rear lid. Volksw not
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– Lift spring -5- out of mounting -7-. orise nte
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– Mark mounting -6- of spring -arrow c-. ss a c
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nl
– Now remove spring from mounting -6-.
pt
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The spring -5- will immediately contract on prising out of mounting.
hole
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Installing
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nf
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m
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Cop py
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Prote AG.
2. Rear lid 85
Passat 2015 ➤
lkswage es n
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t to the co
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mer
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n
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Installing gas strut
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• The spring clips -2- are pushed onto the ball sockets of the gas
i
o
pr
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strut -1-.
fo
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– Push ball sockets of gas strut -1- onto ball-head pins -3- until Cop py
ball sockets engage audibly with the ball-head pins.
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– Twist spring -5- into marked mounting -6-.
– Pull on spring and attach it to mounting -7-.

agen
AG. Volkswagen AG d
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2.10 ss au Releasing gas from gas strut ra
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– Clamp gas strut in vice in area x = 50 mm.

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CAUTION
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Risk of eye injury caused by flying swarf.
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– Cover area of saw cut with a cloth.
rrectness of i
– Saw open strut cylinder in first third of total cylinder length,
starting from the reference edge on the piston rod side.
l purpos
– Feed oil and cleaning clothes into existing method of disposal.
nform
ercia
2.11 Removing and installing drive unit for

m
at
om
i
rear lid - VX69-
on
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Removing
at
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Note
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♦ The rear lid must be supported when the drive or the spring is
p by
co Vo
removed. The rear lid will not stay open if no drive or spring is
by lksw
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Prote
installed.
AG.
♦ Ball-head pin -9- is part of the hinge.

♦ The drive -1- is installed only on the left side.
♦ The spring -5- is installed only on the right side.
2. Rear lid 87
Passat 2015 ➤
lkswage es n
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– Remove luggage compartment trim ⇒ General body repairs, cop Vo
by lksw
interior; Rep. gr. 70 ; Luggage compartment trims . cted agen
Prote AG.
– Open and support rear lid.

– Disconnect connector -2-.
– Lift drive -1- off mounting -9- -arrow b-.
– Using long-nose pliers -8-, carefully push clip -7- slightly into
ball socket -6-.
– Pull drive -1- off ball-head pin -5-.
Spring
– Open and support rear lid.
– Lift spring -4- out of mounting -9-.
– Mark mounting -3- of spring -arrow a-.
– Now remove spring from mounting -3-.
Installing

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
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n
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Drive
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– Slightly pull back clip -7- in ball socket -6-.

ng
t.
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– Push drive -1- onto ball-head pin -5- and mounting -9-
. C rig
ht ht
rig
-arrow b-. py by
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Prote AG.
Spring
– Twist spring -4- into marked mounting -3-.
– Pull on spring and attach it to mounting -9-.
2. Rear lid 89
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General body repairs, exterior - Edition
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olks 03.2019 ot g
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th or
3 Tank flap unit ss
au ac
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nl
pt
⇒ “3.1 Assembly overview - tank flap unit”, page 90
du
an
itte
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⇒ “3.2 Removing and installing tank flap unit”, page 90
ab
ility
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⇒ “3.3 Removing and installing fuel tank flap”, page 93
wit
, is n
h re
3.1 Assembly overview - tank flap unit
hole
spec
es, in part or in w
t to the co
1 - Tank flap unit
rrectness of i
⇒ page 90
l purpos
2 - Tank flap
– Removing and installing
nf
ercia
⇒ page 90
orm
m
atio
m
3 - Water drain hose

o
n in
or c
❑ Routed between wheel
thi
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housing and wheel
iva
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housing liner
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4 - Bolt
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❑ 1.5 Nm
t. rig
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5 - Tank filler flap locking motor
c by lksw
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- V155- Prote AG.

⇒ page 159
6 - Electrical connector
3.2 Removing and installing tank flap unit


Passat 2015 ➤
♦ Radio release tool - T10057-
Removing
AG. Volkswagen AG d
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com
tion in
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s
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– Screw off tank cover. t. C rig
gh ht
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– Using radio release tool - T10057- , punch through tank flap
cop Vo
by lksw
cted
unit at markings -2- -arrows a-.
agen
Prote AG.
– Insert radio release tool - T10057- through these openings

-2- until the notch is reached.
Retaining hooks -3- -arrow b- are released.
3. Tank flap unit 91

Passat 2015 ➤
Note
Make sure that the tank flap unit does not strike the side panel -arrow c-.
AG. Volkswagen AG d
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un
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com
tion in
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s
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do
– Roll sleeve -2- off filler neck.

r
rp
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fo
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– Swing tank flap unit -1- out of side panel -4- -arrow a-.
n
t.
yi Co
Cop py
– Pull out tank flap unit -1- towards rear -arrow b-.
t. rig
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pyri by
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– Guide water drain hose -3- together with tank flap unit out of by c lksw
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side panel -4-.
Prote AG.
Installing
Note
Make sure that the tank flap unit does not strike the side panel -arrow c-.

AG. Volkswagen AG d
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aut
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ra Passat 2015 ➤
s c
s General body repairs, exterior - Edition 03.2019
ce
e
nl
pt
du
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
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nf
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n in
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.
– Insert water drain hose -3- through opening in tank flap unit
-1- and then pull it through as far as it will go.
– Push water drain hose -3- into side panel -4-.
– Insert tank flap unit -1- into side panel -arrow d-.
– Swing tank flap unit -1- into side panel -arrow e- until retaining
hooks engage.
– Pull sleeve over filler neck -2-.
• Check function of release components.
Specified torques
♦ Bolt ⇒ page 90
3.3 Removing and installing fuel tank flap

Removing

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
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V gu
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nl
pt
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es, in part or in w
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nf
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m
atio
– Push tank flap -1- out of catches of tank flap unit -2-
om
-arrow a-.
n in
or c
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e
– Remove tank flap -arrows b-.

t
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Installing
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Prote AG.

AG. Volkswagen AG d
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not Passat 2015 ➤
o
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V
Generalgu body repairs,
ara exterior - Edition 03.2019
ise nte
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aut ra
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nl
pt
du
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es, in part or in w
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t.
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t. rig
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by c lksw
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Prote AG.
– Position tank flap -1- on tank flap unit -2- -arrows a-.
– Push tank flap into catches of tank flap unit -arrow b-.

Passat 2015 ➤
57 – Front doors, door components, central locking

1 Door
⇒ “1.1 Assembly overview - door”, page 96
⇒ “1.2 Removing and installing inner door seal”, page 98
⇒ “1.3 Removing and installing outer door seal”, page 101
⇒ “1.4 Removing and installing door”, page 103
⇒ “1.5 Adjusting door”, page 105
⇒ “1.6 Adjusting striker pin”, page 108
⇒ “1.7 Removing and installing door arrester”, page 110
1.1 Assembly overview - door

AG. Volkswagen AG d
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♦ The illustrations show the left-hand side. The procedure
ut
ho for the right-hand side is basically the same. eo
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♦ After renewal of A-pillar, the specified torque for bolts -2 and 5- as well as for -14 and 17- changes.
s
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1 - Rear door
ility
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⇒ page 103
hole
spec
es, in part or in w
t to the co
2 - Bolt
❑ Loosening once to ad‐
just the door is permit‐
rrectness of i
ted. Always renew oth‐
l purpos
erwise.
❑ 50 Nm
nf
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or
Note
m
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♦ After renewal of A-pillar the n in

or c
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specified torque changes.

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♦ Specified tightening torque after

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renewal of A-pillar: 20 Nm + 90°

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t.
3 - Door hinge
rig
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❑ The hinge is split. Its up‐
o
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per and lower sections Prote AG.
can be renewed individ‐
ually, if necessary.
❑ Lower part is secured to
hinge upper part with
bolt -8-.
4 - Cover
❑ For bolt -8-
❑ Not installed in all mar‐
kets
5 - Bolt
❑ Installed from inside ve‐
hicle.
96 Rep. gr.57 - Front doors, door components, central locking

Passat 2015 ➤
❑ Loosening once to adjust the door is permitted. Always renew otherwise.
❑ For loosening and reattaching, the dash panel is not removed.
❑ To remove and install, the dash panel must be removed ⇒ General body repairs, interior; Rep. gr. 70 ;
Dash panel; Removing and installing dash panel .
❑ 50 Nm
Note
♦ After renewal of A-pillar the

renewal of A-pillar: 20 Nm + 90°. Volkswag
AG en AG
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6 - Cover db
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❑ For bolts -7 and t16-ho
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❑ Not installed in
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7 - Bolt
pt
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❑ 50 Nm
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8 - Bolt
h re
hole
spec
❑ Connects upper part of hinge -3- to bottom part of hinge -6-
es, in part or in w
❑ 23 Nm
t to the co
9 - Door hinge
❑ The hinge is split. Its upper and lower sections can be renewed individually, if necessary.
rrectness of i
❑ Upper part is secured to hinge lower part with bolt -5-.
l purpos
10 - Bolt
❑ 30 Nm nf
ercia
orm
m
11 - Bolt
atio
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❑ Qty. 2
n in
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❑ 9 Nm
t
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12 - Door arrester
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t.
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t.
13 - Door hinge
rig
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❑ Lower part is secured to hinge upper part with bolt -8-.
AG.
14 - Bolt
❑ Installed from inside vehicle.
❑ For removal and installation, A-pillar lower trim must be removed ⇒ General body repairs, interior; Rep.
gr. 70 ; Trims, interior; Removing and installing A-pillar gap cover .
❑ 50 Nm
Note

15 - Door hinge
1. Door 97
olkswagen AG
en AG. V
Passat 2015 ➤ ksw
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not
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by gu
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16 - Bolt ss
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❑ 50 Nm
itte
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17 - Bolt
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❑ 50 Nm
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
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nform
mercia
a
1.2 Removing and installing inner door seal
com
tion in
r
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thi
During production, a sealant is applied to the inner door seals,
s
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which are then placed on the door flange and rolled on.
do
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♦ When removing the seal, the sealant is distributed across the
co lksw
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cted agen
inside of the seal. The sides are bent upwards slightly when Prote AG.
this is being done. If the seal is then refitted, sealing and firm
seating are no longer guaranteed.
♦ Therefore, each seal that is completely removed must be re‐
newed with a so-called “tap-on seal”.
♦ If a seal has been partially removed, squeeze sides of seal
together before installing.
♦ Removal and installation are described only for the left door
inner seal. The procedure for the right-hand side is basically
the same.
♦ For reasons of clarity, the front door is shown in removed state.
Removing

Passat 2015 ➤
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mer
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n
c
i
or
n thi
te
sd
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pr
cum
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fo
en
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t.
– Remove sill panel moulding ⇒ General body repairs, interior;
yi Co
op py
Rep. gr. 70 ; Trims, interior; Removing and installing sill panel t. C rig
gh ht
moulding . yri
p by
co Vo
by lksw
cted
– To remove door seal, remove pillar trims as required ⇒ Gen‐
agen
Prote AG.
eral body repairs, interior; Rep. gr. 70 ; Trims, interior; Over‐
view of fitting locations - trims, interior .
– Pull door seal -1- off body flange -3-.
Installing
1. Door 99
Passat 2015 ➤
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mer
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n
c
i
or
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– Start installing door seal -1- at top radius of door aperture

t
sd
va
-arrow-.
i
o
pr
cum
r
fo
en
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– Align vulcanised point -2- above lower hinge.

t.
yi Co
op py
– Install pillar trims ⇒ General body repairs, interior; Rep. gr.
t. C rig
gh ht
yri
70 ; Trims, interior . p by
co Vo
by lksw
cted agen
– Install sill panel strip ⇒ General body repairs, interior; Rep. Prote AG.
gr. 70 ; Trims, interior; Removing and installing sill panel strip .

Passat 2015 ➤
1.3 Removing and installing outer door seal

⇒ “1.3.1 Removing and installing outer door seal”, page 101
⇒ “1.3.2 Removing and installing door seal”, page 102
1.3.1 Removing and installing outer door seal
Note
♦ Removal and installation are described only for the right door
outer seal. Removal and installation of the left door outer seal
are similar.
♦ Remove backing only immediately before installation. Working
temperature approx. 20°C. AG. Volkswagen AG d
agen oes
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es, in part or in w
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at
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ion
c
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ate
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for
en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
– Pull door seal -1- off door.
Installing
– Remove remaining adhesive residue with eraser disc for ad‐
hesive strip remover - VAS 6349- .
1. Door 101
Passat 2015 ➤
– Immediately before bonding outer door seal, clean bonding

surface thoroughly with adhesive remover D 002 000 10.
• Bonding surfaces must be free of dust and grease and there
should be no adhesive residues.
– Vulcanised point -2- of door seal must be in centre area of side
member.
– Pull off protective backing, and start fitting seal in upper rear
radius -arrow- of door. Do not pull door seal excessively to
avoid stretching seal.
– Press bonding surface of seal -1- firmly onto door -3- all around
using roller - 3356- .
1.3.2 Removing and installing door seal
Note
♦ Removal and installation are described only for the right door
outer seal. Removal and installation of the left door outer seal
are similar.
temperature approx. 20°C.
AG. Volkswagen AG d
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Cop py
t. rig
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by c lksw
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Prote AG.

Passat 2015 ➤
Removing
– Remove trim cover for door ⇒ page 353 .
– Pull door seal -1- off door -3-.
Installing
olkswagen AG
en AG. V
– Immediately before bonding outeroldoor
ksw seal, clean bonding es not
ag do
surface thoroughly with adhesive
ed
b remover D 002 000 10.
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• Bonding surfaces must abeut free of dust and grease and there
ho eo
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should be no adhesivess residues. c
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nl
– Pull off protective backing -2-, and centre seal on door. Fit seal,
pt
du
an
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and press it on.
y li
erm
ab
– Press bonding surface of seal -1- onto door -1- using roller -
ility
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3356- .
wit
, is n
h re
hole
1.4 Removing and installing door
spec
es, in part or in w
t to the co
♦ Key (for door alignment) - 3320-
rrectness of i
♦ Universal joint for 3320 - 3320/1-
l purpos
♦ Bit for 3320 - 3320/2-

♦ Bit for 3320 - 3320/3-
nform
ercia

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at
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io
♦ Hexagon bit, long reach - 3410-
n
c
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at
do
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♦ Removal wedge - 3409-

um
for
en
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t.
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Prote AG.
Note
The removal and installation sequence is for the rear left door.
Removal and installation of the rear right door are similar.
Removing
1. Door 103
Passat 2015 ➤ AG. Volkswagen AG d
agen
General body repairs, exterior - Edition 03.2019 oes
olksw not
V gu
by ara
ed nte
oris eo
th
au ra
c
ss
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Disconnect battery earth cable with ignition switched on ⇒

Electrical system; Rep. gr. 27 ; Battery; Connecting and dis‐
connecting battery .
– Press wedge - T10383/1- between bellows -3- and locking el‐
ement -arrow a-.
– Push locking element upwards -2- with wedge - T10383/1-
-arrow b- and separate electrical connector -3- from coupling
station -arrow c-.
– Undo screws -7- from hinges.
– Unscrew bolt -4- for door arrester -5-.
– Push door arrester -5- inwards -arrow d-.
– Lift front door -1- upwards -arrow f- so that hinge -6- is released
from hinges -7-.
Installing

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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ce
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nl
pt
du
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itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
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orm
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atio
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n in
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sd
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t.
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Cop py
t. rig
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Vo
co lksw
by
cted agen
Prote AG.
Installation is carried out in the reverse order of removal. To this

end, the following should be observed:
• Door arrester -5- must have been pushed inwards -arrow d-.
• After installing front door, the hinge arms must be flush one
above the other.
– Adjust front door -1- ⇒ page 105 .
– Observe front door shut lines -1- ⇒ Body Repairs; Rep. gr.
00 ; Body panel gaps/shut lines; Body - middle .
Specified torques
Door arrester and hinges
⇒ “1.1 Assembly overview - door”, page 96 .
1.5 Adjusting door

♦ Bit for 3320 - 3320/2-
♦ Bit for 3320 - 3320/3-
1. Door 105
Passat 2015 ➤ AG. Volkswagen AG d
agen
Vo03.2019
lksw
oes
not
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♦ Torque wrench - V.A.G 1331- tho
r eo
au ra
c
♦ Hexagon bit, long reach - 3410- ss
ce
e
nl
pt
du
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itte
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ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
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orm
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Cop py
t. rig
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Note by c lksw
cted agen
Prote AG.
♦ Only the adjustment for the left front door is described. The adjustment of the right front door is similar.
♦ Vehicle must be standing on its wheels when front door adjustment is performed.
♦ The front door is correctly adjusted when all shut lines are even when closed. it is not protruding too far
inwards or outwards, and when the contours are flush with each other.
♦ For checking gaps/shut lines refer to ⇒ Body Repairs; Rep. gr. 00 ; Body panel gaps/shut lines; Body -
middle .
♦ After installing or alignment, carry out corrosion protection measures on hinges and screws/bolts.

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
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au ra
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un
pt
an
d
itte
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ility
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wit
is n
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
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Adjusting shut lines

or
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te
sd
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To be able to adjust shut lines correctly, bolts -2-, -3-, -5- and
i
o
pr
cum
-6- in A-pillar must be loosened.

r
fo
en
ng
t.
yi
– In order to gain access to bolt -3- on driver side, detach fuse
Co
Cop py
box, and lower it ⇒ Electrical system; Rep. gr. 97 ; Relay
t. rig
gh ht
yri
carriers, fuse holders, E-boxes; Removing and installing relay
p by
co Vo
by lksw
and fuse holder behind dash panel on driver side . Prote
cted AG.
agen
– For bolt -3-, glove compartment on front passenger side must

be removed ⇒ General body repairs, interior; Rep. gr. 68 ;
Compartments/covers; Removing and installing glove com‐
partment .
– For loosening bolt -6-, lower A-pillar trim must be removed ⇒
General body repairs, interior; Rep. gr. 70 ; Trims, interior;
Removing and installing A-pillar gap cover .
Adjusting for flush fitting
In order to adjust flushness correctly, bolts -4- and -5- must be
loosened.
Use door alignment tool - 3320- with appropriate bit for this.
1. Door 107
Passat 2015 ➤
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Specified torques
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Hinges ⇒ “1.1 Assembly overview - door”, page 96
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1.6 Adjusting striker pin
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♦ Threaded plate -1- of striker pin is secured in pillar using a method which differs from the previous method.
♦ Bow outside of threaded plate is welded firmly to pillar. Webs to threaded plate are plastically deformable.
♦ Greater forced has to be applied so that position of striker pin -2- can be adjusted when bolts -3- are loos‐
ened.

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Note
♦ The front door must lock fully when closing without any additional force being required and must not have
any play.
♦ The front door must not be pushed up or down as a result of the striker pin adjustment.
By adjusting the striker pin the alignment of the front door with the
side panel or the rear door can be adjusted -arrow a- and
-arrow b- (wind noise).
– Loosen striker pin -2- by loosening bolts -3- in B-pillar.
Note
Greater forced has to be applied so that position of striker pin -2- can be adjusted when bolts -3- are loosened.
– Tighten bolts -3- of striker pin -2-.
1. Door 109
Passat 2015 ➤
Specified torques
Component Specified torques
Striker 20 Nm
1.7 Removing and installing door arrester

Note
The description of removal and installation only applies to the left

wing. The procedure for the right-hand side is basically the same.
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Passat 2015 ➤
AG. Volkswagen AG d
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– Remove front door trim ⇒ General body repairs, interior; Rep. cted agen
Prote AG.
gr. 70 ; Front door trims; Removing and installing front door
trim .
– Remove self-adhesive cover or front loudspeaker ⇒ Commu‐
nication; Rep. gr. 91 ; Sound system; Overview of fitting
locations - sound system .
– Unscrew bolt -2- in A-pillar.
– Unscrew bolts -3- and remove door arrester -1- through the
opening of the loudspeaker -arrow a-.
Installing
1. Door 111
Passat 2015 ➤
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Installation is carried out in the reverse order of removal.

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Specified torques
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Door arrester ⇒ “1.1 Assembly overview - door”, page 96

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Passat 2015 ➤
2 Door components
⇒ “2.1 Assembly overview - door components”, page 113
⇒ “2.2 Assembly overview - window regulator”, page 115
⇒ “2.3 Assembly overview - door handle and door lock”,
page 116
⇒ “2.4 Removing and installing window regulator motor”,
page 117
⇒ “2.5 Removing and installing window regulator”, page 119
⇒ “2.6 Removing and installing inner door cover”, page 122
⇒ “2.7 Removing and installing striker pin”, page 124 AG. Volkswagen AG d
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⇒ “2.12 Removing and installing door lock”, page 141
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⇒ “2.13 Removing and installing window channel”, page 146
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⇒ “2.14 Removing and installing window slot outer seal”,
page 149
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⇒ “2.15 Removing and installing window slot inner seal”,
page 151
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2. Door components 113

Passat 2015 ➤
1 - Rear door
⇒ page 103
2 - Stickers
❑ Diameter 28 mm
❑ If necessary, manufac‐
ture using commercially
available textile adhe‐
sive tape.
❑ Stickers must cover the
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200 mm x 100 mm Po‐
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tration.
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– Warm using hot air
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blower - V.A.G 1416-

and push on to outer
door panel with force.
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5 - Inner door cover
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❑ Stickers must cover the openings completely
8 - Dampers
❑ Self-adhesive
❑ Installing:
– Cut to size if required, 250 mm x 160 mm Position as shown in illustration. Distance to next insulation
10 mm.
– Warm using hot air blower - V.A.G 1416- and push on to outer door panel with force.
9 - Dampers
❑ Self-adhesive
❑ Installing:
– Cut to size if required, 250 mm x 160 mm Position as shown in illustration. Distance to next insulation
10 mm.

Passat 2015 ➤
10 - Stickers
❑ Diameter 19 mm
11 - Window slot inner seal
12 - Window slot outer seal
13 - Window channel
14 - Stickers
❑ Qty. 3
❑ 15 mm x 50 mm
2.2 Assembly overview - window regulator
1 - Window regulator
⇒ page 119
2 - Hexagon nut
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2.3 Assembly overview - door handle and door lock
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1 - Door lock
⇒ page 141
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2 - Bolt
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❑ 3 Nm
❑ For lock cylinder.
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3 - Mounting bracket
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⇒ page 139
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5 - Carrier
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6 - Cover
❑ Remove and install for
lock cylinder
⇒ page 126
without lock cylinder
⇒ page 128 .
7 - Door handle
⇒ page 135
8 - Bolt
❑ 1.5 Nm
❑ Bearing plate is loos‐
ened from door when
this bolt is loosened
9 - Bowden cable
❑ From door lock -1- to mounting bracket -3-
10 - Bowden cable
❑ From inner door handle to door lock -1-
❑ With grommet to passage on cover.
11 - Bolt
❑ Qty. 2
❑ 18 Nm
Note
The bolts are microencapsulated

and must be renewed each time
they are loosened.

Passat 2015 ➤
12 - Cover
2.4 Removing and installing window regula‐

tor motor
Note
♦ Removal and installation are described only for the left motor.
Removal and installation of the right motor are similar.
♦ The door control unit - J386/J387- -5- is separated from win‐
dow regulator motor - V14/V15- -1-.
♦ The door control unit - J386/J387- is clipped into door.
Removing
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Passat 2015 ➤
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– Remove front door trim ⇒ General body repairs, interior; Rep.

spec

es, in part or in w
t to the co
trim .
– Tape up door window to prevent it from sliding down.
rrectness of i
– Switch off ignition and all electrical consumers. Withdraw ig‐

nition key.
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– Remove bolts -2- (qty. 3).

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– Remove window regulator motor -1- from mounting brackets

com
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of cable drum.
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Passat 2015 ➤
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– Position window regulator motor -1- on mounting brackets of

cable drum. Move door window up and down slightly so that
the splines between window regulator motor and cable drum
engage more easily.
– Connect connector -3-.
– The work procedure and notes on the automatic window rais‐
ing and lowering system as well as on the excess-force limi‐
tation feature can be found in ⇒ Maintenance ; Booklet .
quence of removal.
Specified torques
♦ Bolts

tor

Passat 2015 ➤
♦ Torque wrench - V.A.G 1783- n AG. Volkswagen AG do

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Removal and installation are described only for the left window
regulator. Removal and installation of the right window lifter mech‐
anism are similar.
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Passat 2015 ➤

trim .
– If present, remove loudspeaker ⇒ Rep. gr. 91 ; Sound system;
Overview of fitting locations - sound system
– Remove door window ⇒ page 334 .
– Remove window regulator motor ⇒ page 117 .
– Release locking hook of cable drum -4- and insert into door.
– Unscrew hexagon nuts -3- and insert studs of window regula‐
tor into door.
– Loosen hexagon nuts -2-, do not remove.
– Slightly push window regulator upwards in door -arrow a-, and
guide it into door.
– Turn window regulator -1- 90° -arrows b-, and remove it
through opening in door -arrow c-.
Installing
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121
AG.
2. Door components
Passat 2015 ➤
– Insert studs of window regulator into inner door panel, and

guide them downwards -arrow c-.
– Tighten hexagon nuts -2 and 3-.
– Press cable drum against door inner part until locking devices
-4- engage audibly.
– Install window regulator motor ⇒ page 117
– Install door window ⇒ page 334
Specified torques
♦ Hexagon nuts
2.6 Removing and installing inner door cov‐

er
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Removal and installation are described only for the left cover. The
hole
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procedure for the right-hand side is basically the same.
es, in part or in w
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Passat 2015 ➤
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– Lift lower end of cover -1- -arrow a-.

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– Pull cover -1- out of door -arrow b-.

rrectne
Note
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Passat 2015 ➤
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– Fit cable -3- together with grommet -2- into cover -1-.
– Attach grommet -2- to cover -1-.
– Insert cover -1- in door -arrow a-.
– Engage cover -1- around circumference -arrow b-.
Note
♦ Check proper seating of cover by pressing with fingers around circumference.

♦ If fitted, join electrical connector at grommet.


AG. Volkswagen AG d
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♦ Torque wrench -ssV.A.G 1331-
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Note
Removal and installation are described only for the right door
striker pin. The procedure for the right-hand side is basically the
same.
Removing
– Unscrew bolts -2- and remove striker pin -1-.
Installing
Note
A bent striker pin (square U-shape) must be installed.
– Position striker pin -1- on B-pillar -3- with the U-shape facing
inwards. Tighten bolts -2-.
Specified torques
Striker 20 Nm

Passat 2015 ➤
2.8 Removing and installing cap for door

handle
⇒ “2.8.1 Removing and installing cap for door handle, with lock
cylinder”, page 126
⇒ “2.8.2 Removing and installing cap for door handle, without lock
cylinder”, page 128
2.8.1 Removing and installing cap for door

handle, with lock cylinder
Note
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o cap, the screwdriver
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Passat 2015 ➤
– Pull door handle away from door.

– Push a small screwdriver -3- slightly -arrow a- into opening on
underside of lock cylinder cover cap.
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– Pull lock cylinderVolhousing cover cap -1-, together
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– Push cap
au upwards off lock cylinder.
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
r
fo
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ng
t.
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Cop py
t. rig
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co lksw
by
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Prote AG.
– Pull door handle -1- away from door.

– Push lock cylinder cover cap -2- at a slight angle from above
-arrow a- onto lock cylinder.
– Push lock cylinder cover cap -2- onto door -arrow b- until cover
cap engages in lock cylinder.

Passat 2015 ➤
2.8.2 Removing and installing cap for door

handle, without lock cylinder
Note
The cover cap is installed when no lock cylinder is fitted.

AG. Volkswagen AG d
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Removing olksw
oes
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Special tools and workshop equipment required orise nte
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♦ Disassembly and assembly tool - T10539- ss a c
ce
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nl
pt
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erm
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ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
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t.
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Cop py
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rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Remove plugs -3-.

– Insert disassembly and assembly tool - T10539- with marking
facing upwards up to locking hook of door handle bracket.
– Pull door handle -2- off door -arrow b-.
– Push disassembly and assembly tool - T10539- approx. 5 mm
towards front -arrow b- until hook is released.

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
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le
un
pt
an
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rm
ab
pe
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wit
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hole
spec
es, in part or in w
t to the co
There must be a gap -arrow a- between door handle -2- and door. rrectness of i
l purpos
Note
Do not push the door handle into the door. Otherwise the door handle bracket will be damaged.
nform
mercia
– Pull cover cap -1- out of mounting bracket -arrow b-.

com
tion in
r
Installing
te o
thi
s
iva
do
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cum
fo
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
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erm
ab
ility
ot p
wit
is n
h re
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
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n
c
i
or
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pr
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fo
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t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
• There is a gap between door handle -2- and door -arrow a-.
– Push cover cap -1- into mounting bracket -arrow b-.

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
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tho eo
au ra
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un
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pe
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wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Slightly press cover cap -1- onto door.
l purpos

nform
ercia
– Turn disassembly and assembly tool - T10539- in locking hook

m
by 90° -arrow a-, and pull it out by approx. 5 mm -arrow b- until

com
tio
hook engages.
n in
r
te o
thi
Door handle -2- folds down onto door automatically -arrow c-.
s
iva
do
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rp

um
fo
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by 90° -arrow a-, and pull it out of door.

n
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– Secure plug -3-.
t. C rig
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Vo
o
2.9 Removing and installing lock cylinder
c by lksw
cted agen
Prote AG.

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
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tho eo
au ra
s c
Note s
ce
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un
pt
an
d
itte
♦ The removal and installation sequence is only for the left lock
y li
rm
ab
cylinder. The procedure for the right-hand side is basically the
pe
ility
same.
ot
wit
, is n
h re
♦ Door handle stops in “open” state. Do not push in the door
hole
handle as otherwise the retaining lug on the mounting bracket
spec
will break off and it will no longer be possible to reinstall a re‐
es, in part or in w
t to the co
moved door handle.
Removing
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
en
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
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Prote AG.

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
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y V gu
d b ara
rise nte
tho eo
au ra
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le
un
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an
d
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ab
ility
ot p
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is n
– Remove cap for lock cylinder ⇒ page 126 .

h re
ole,
spec
– Raise cover -5-.

t to the co
– Pull out door handle -2- as far as it will go.

– Unscrew bolt -4- onto stop.
rrectne
– Press in bolt -4- with locking element -6- -arrow a-. Only then
is the lock cylinder released.
ss o
– Pull door handle -2- away from door.

cial p
f inform
– Pull out lock cylinder housing -1- perpendicular to door

mer
atio
-arrow b- from mounting bracket -3-.

om
n
c
Installing
or
n thi
te
sd
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pr
cum
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fo
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Push lock cylinder housing -1- into mounting bracket -3- at a
right-angle -arrow a-.
l purpos
– Screw bolts -4- into door handle bracket. While doing this, the
locking mechanism -6- is pulled automatically in installation
nform
ercia
position -arrow b-.

m
at
Door handle -2- folds down onto door automatically.

om
ion
c
in t
or
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ate
Note
do
priv
cum
for
en
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During installation, lock cylinder housing must be pressed against outer door panel.
n
t.
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Cop py
t. rig
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The remaining installation steps are carried out in the reverse se‐ pyri by
Vo
co
quence of removal.
by lksw
cted agen
Prote AG.
• It is essential that a functional check is then performed with
the door open.
Specified torques
♦ Bolts
⇒ “2.3 Assembly overview - door handle and door lock”, page
116

Passat 2015 ➤
2.10 Removing and installing door handle

⇒ “2.10.1 Removing and installing door handle”, page 135
⇒ “2.10.2 Removing and installing door handle with keyless entry
system”, page 137
2.10.1 Removing and installing door handle

Removing
Note
The removal and installation sequence is only for the left door
handle. The procedure for the right-hand side is basically the
same.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
– Depending on version, remove lock cylinder cap ⇒ page 126

om
ion
and lock cylinder ⇒ page 131 .

c
in t
or
his
te
– Or just remove cap (without lock cylinder) ⇒ page 128 .

a
do
priv
cum
or
– Pull door handle -1- towards rear slightly -arrow a- until it

f
en
ng
comes out of support for mounting bracket -2-.

t.
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Cop py
t. rig
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pyri by
Vo
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135
by c lksw
cted
2. Door components
agen
Prote AG.
Passat 2015 ➤
– Swivel door handle in direction of -arrow b-.

– Remove door handle from mounting bracket -2-, keeping door
handle at right angles to mounting bracket -arrow c-.
Installing
AG. Volkswagen AG d
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nl
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du
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– Insert door handle -1- at right angle -arrow a- in mounting

es, in part or in w
t to the co
bracket.
– Swing door handle -1- towards door -arrow b-.
rrectness of i
– Press door handle forwards -arrow c- into support for door

handle bracket -2-.
l purpos
– It is essential that a functional check is then performed with

the door open.
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Passat 2015 ➤

with keyless entry system
Removing
Note
AG. Volkswagen AG d
agen oes
lksw not
The removal and installation sequence is only for the left door by Vo gu
ara
handle. The procedure for the right-hand side is basicallyorthe
d
ise nte
same. auth eo
ra
ss c
ce
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un
pt
an
d
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erm
ab
ility
ot p
wit
is n
h re
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
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te
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pr
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fo
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
For general information and work instructions for the door handle
with keyless entry system refer to ⇒ Electrical system; Rep. gr.
94 ; Entry and start authorisation system .

Passat 2015 ➤
– Open locking mechanism on connector -4- using a screwdriver

-3- -arrow d-.
n AG. Volkswagen A
– Remove door handle from mountingolks
wagbracket
e
-2-, keeping
G do
edoor
s no
handle at right angles to mounting
db
y V bracket -arrow c-. t gu
ar
e an
ris tee
Installing tho or
au ac
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d
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pe
ility
ot
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
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t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
bracket.
The connector for the keyless entry system is connected when
the door handle is being inserted.
– Swing door handle -1- towards door -arrow b-.
handle bracket -2-.
the door open.

Passat 2015 ➤
2.11 Removing and installing mounting

bracket
Removing
Note
agen
AG. Volkswagen AG d
oes
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ara
Removal and installation
orised
are described only for the left mounting
nte
bracket. The procedure
aut
h for the right-hand side is basically thee or a
same. ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Passat 2015 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
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un
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an
d
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

trim .
– Remove door handle ⇒ page 135 .
– Remove inner door cover ⇒ page 122 .
– Unscrew bolt -4-.
– Remove mounting bracket -1- from door.
Detach cable
– Slightly swing aside retainer -3- -arrow a-.
– Lift pin of cable -2- out of mounting.
Installing

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
Attaching cable
do
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t.
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t. rig
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Make sure the connector -5- for the keyless entry system is firmly seated.
o Vo
by c lksw
cted agen
Prote AG.
– Push pin of cable -2- into mounting -arrow b-.
– Guide door handle bracket -1- into door -arrow c-.
– Tighten bolt -4-.
Specified torques
♦ Bolts
116
2.12 Removing and installing door lock


Passat 2015 ➤
♦ Hexagon bit, long reach - T10054-

agen oes
olksw not
yV gu
♦ Removal and installation areisdescribed
ed b only for the left door ara
nte
lock. The procedure for the horight-hand
r
side is basically the eo
ut
same. ss a ra
c
ce
le
♦ The door window must be closed for subsequent work.

un
pt
an
d
itte
y li
♦ The bolts are microencapsulated and must be renewed each

erm
ab
time they are loosened.

ility
ot p
wit
is n
h re
Removing
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes Passat 2015 ➤
olksw not
dGeneral
byV body repairs, exterior - Edition
gu
ara 03.2019
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

trim .
– If fitted, disconnect connector.
– Remove door lock -1- from door -arrow-.
Note
Cables can be detached if this is necessary for subsequent work.
Detach cable from mounting bracket

– Remove cover ⇒ page 144 .
– Turn cable -5- through 90° -arrow a- and take out of holder.
– Swivel cable -arrow b- upwards until cable can be threaded
out of eye in door lock -1- -arrow c-.

Passat 2015 ➤
Detach cable from interior door handle

– Turn cable -4- by 90° and take it out of holding device.
– Swivel cable -arrow d- so far until cable can be threaded out
of eye in door lock -1- -arrow e-.
Removing cover
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Disengage hook -3- in -direction of arrow a-.

– Use the hook to pull cover -1- out of door lock -2- -arrow b-.
– Pull cover -1- upwards -arrow c- from door lock -2-.
Installing
Note
The bolts are microencapsulated and must be renewed each time they are loosened.

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Attach removed cables -4- and -5- to door lock -1-.

– Install cover ⇒ page 145 .
– Insert door lock -1- into door.
– If fitted, connect connector.
– Clip cap -3- in.
quence of removal.
the door open.
Only if the cables are adjusted and locked correctly, the door lock
can be unlocked and opened properly.
Specified torques
♦ Bolts
116
Fitting cover

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
o eo
Passat 2015 ➤ aut
h
ra
s c
General body repairs, exterior - Edition 03.2019 s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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o
m
f
en
ng
t.
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rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Push cover -1- onto retainer -3- on door lock -2- -arrow a-.
– Engage hook -4- with door lock -2- -arrow b-.
2.13 Removing and installing window chan‐

nel
Note
♦ The removal and installation sequence is only for the left win‐
dow channel. Removal and installation of the right window
channel are similar.
♦ Do not bend window channel when removing!
Removing

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op py
– Remove window slot inner seal ⇒ page 149 . t. C rig
gh ht
pyri by
– Remove window slot outer seal ⇒ page 149 .
co Vo
by lksw
cted agen
Prote AG.
– Remove B-pillar trim ⇒ page 360 .
– Fixed door window ⇒ page 339
– Peel sealing lip of window channel -1- off the door flange from
the inside.
– Pull window channel -1- out of mountings on door
-arrows a and b-.
– Pull window channel -1- -arrows c- off flange -2- uniformly all
around it.
Installing

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Spray window channel with soapy water to facilitate installa‐

tion.
nform
ercia
– Insert window channel -1- into mountings on door

m
-arrows c and b-.

a
com
tion in
– Fit window channel -1- from rear towards front onto door flange
r
te o
thi
-arrows a-.
s
iva
do
r
rp
– Fold sealing lip of window channel onto door flange -2- from
um
fo
the inside -arrows-.

en
ng
t.
yi Co
Cop py
t. rig
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yri by
Note op Vo
by c lksw
cted agen
Prote AG.
To prevent wind noise, ensure window channel -1- seats evenly when installing.
quence of removal.

Passat 2015 ➤
2.14 Removing and installing window slot

outer seal
Removing
Note
♦ The core of the window slot outer seal is a metal insert.

♦ If it is bent or distorted, the window slot outer seal can no lon‐
ger be straightened out. It will remain “wavy”.
♦ Therefore, the window slot outer seal must be pulled off and
pressed on evenly, without bending or distorting it.
♦ Removal and installation are only described for the left window
slot outer seal. Removal and installation of the right window
slot outer seal are similar.
AG. Volkswagen AG d
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olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Slightly detach window slot outer seal -1- evenly from door
flange -2- using wedge - T10039/1- -arrows a-. Make sure not
to bend the side strip.

Passat 2015 ➤
– Pull out window slot outer seal -1- behind exterior mirror -3-
-arrow b-.
Installing
AG. Volkswagen AG d
agen oes
olksw not
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♦ The use of striking tools is not allowed for installing the window slot outer seal.
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– Push window slot outer seal -1- behind exterior mirror -3-
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– Align window slot outer seal -1- with B-pillar and press it uni‐
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Passat 2015 ➤
2.15 Removing and installing window slot in‐

ner seal
Note
Removal and installation are only described for the left window
slot inner seal. Removal and installation of the right window slot
outer seal are similar.
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Removing
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– Lift window slot inner seal -1- uniformly off flange -2- without
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2. Door components
Passat 2015 ➤
3 Central locking
⇒ “3.1 Overview of fitting locations - central locking”, page 152
⇒ “3.2 Assembly overview - ignition key”, page 154
⇒ “3.3 Removing and installing bonnet contact switch F266 ”,
page 154
⇒ “3.4 Removing and installing driver door control unit J386 and
front passenger door control unit J387 ”, page 156
⇒ “3.5 Removing and installing rear left door control unit J926 and
rear right door control unit J927 ”, page 158
⇒ “3.6 Removing and installing tank filler flap locking motor V155
”, page 159
⇒ “3.7 Removing and installing ignition key battery”,
gen A page
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⇒ “3.8 Removing and installing dcap
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❑ Removing ⇒ Electrical
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system; Rep. gr. 96 ;
wit
Anti-theft alarm system;
, is n
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Removing and installing
hole
spec
alarm horn H12 .
es, in part or in w
t to the co
2 - Front passenger door con‐
trol unit - J387-
❑ Installed in door separa‐ rrectness of i
ted from window regula‐
tor motor.
l purpos

⇒ page 156
nf
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or
3 - Aerial for interface for entry

m
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atio
and start system

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❑ Integrated in door han‐

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⇒ page 137
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agen
inner part of door.
❑ Electric central locking
is integrated into door
lock.
❑ Removing ⇒ page 141
5 - Rear right door control unit
- J389-
❑ Installed in door separa‐
ted from window regula‐
tor motor.
⇒ page 158
6 - Rear right door lock
❑ Door lock is secured to inner part of door.
❑ Electric central locking is integrated into door lock.

Passat 2015 ➤
7 - Aerial for interface for entry and start system
❑ Integrated in door handle
❑ Door handle removed and installed ⇒ page 198
8 - Tank filler flap locking motor - V155-
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❑ Location: Bolted to rear lid. byV gu
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❑ Removing ⇒ page 74 ut
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10 - Rear lid lock s
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❑ Location: bolted to rear lid
du
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❑ Installed behind bumper cover
hole
spec
es, in part or in w
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13 - Rear left door lock
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❑ Electric central locking is integrated into door lock.
nf
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14 - Rear left door control unit - J388-
atio
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❑ Installed in door separated from window regulator motor.
or c
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15 - Front left door lock
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17 - Central switch for window regulators
❑ Location: installed in door panel
❑ Remove and install central switch for window regulator ⇒ Electrical system; Rep. gr. 96 ; Controls;
Overview of fitting locations - controls in front doors .
18 - Central locking button
❑ Location: installed in door panel
❑ Remove and install button for central closing ⇒ Electrical system; Rep. gr. 96 ; Controls; Overview of
fitting locations - controls in front doors .
19 - Driver door control unit - J386-
❑ Installed in door separated from window regulator motor.
20 - Onboard supply control unit - J519-
❑ Location: Under dash panel on driver side.
❑ Removing ⇒ Electrical system; Rep. gr. 97 ; Control units; Overview of fitting locations - control units .
21 - Bonnet contact switch - F266-
❑ Contact switch for anti-theft alarm.
3. Central locking 153

Passat 2015 ➤
❑ Location: on lid lock.
3.2 Assembly overview - ignition key
1 - Transmitter unit
❑ Adaptation ⇒ page 160
2 - Release mechanism
3 - Emergency key
4 - Cover
⇒ page 161
5 - Bolt
❑ 1 Nm
6 - Battery
⇒ page 160
7 - Cover for battery compart‐
ment
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3.3 Removing and installing bonnet contact

spec
es, in part or in w
switch - F266-
t to the co
Removing
rrectness of i
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nf
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154
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Rep. gr.57 - Front doors, door components, central locking Prote AG.
Passat 2015 ➤
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– Remove lid lock -1- and separate electrical connector -3-
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⇒ page 32 . p by
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– Release locking hooks -arrow a-. Prote AG.
– Push contact switch -1- in elongated holes -arrow b-.

– Remove contact switch -1- from lid lock -2-.
Installing

Passat 2015 ➤
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– Insert contact switch -1- in elongated holes -arrow a-.

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– Push contact switch -1- in elongated holes onto stop

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-arrow b-.
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– Install contact switch and attach electrical connector Cop py
⇒ page 32 .
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3.4 Removing and installing driver door con‐
by lksw
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Prote AG.
trol unit - J386- and front passenger door

control unit - J387-
Note
If a new door control unit is installed, the additional functions and

the excess force limitation feature have to be coded!

Passat 2015 ➤
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Removing ss
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– Separate electrical connectors -3-.

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– Release retaining hook from outside -arrow A-.

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, is n
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door -arrow B-.

hole
spec
Installing
es, in part or in w
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– Check seals -2- for damage, and renew them as necessary.

– Place control unit -1- in mounting holes and push upwards.
rrectness of i
– Push retaining hook -4- into hole until it engages.

l purpos
– Attach connectors -3-.

nform
ercia
– A new control unit -1- must be coded using ⇒ Vehicle diag‐

nostic tester.
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Passat 2015 ➤
3.5 Removing and installing rear left door

control unit - J926- and rear right door
control unit - J927-
Note
If a new door control unit is installed, the additional functions and

the excess force limitation feature have to be coded!
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Removing
n in
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– Separate electrical connectors -3-.

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– Check seals -2- for damage, and renew them as necessary.
– Place control unit -1- in mounting holes and push upwards.

Passat 2015 ➤
– Push retaining hook -4- into hole until it engages.

– Attach connectors -3-.
– A new control unit -1- must be coded using ⇒ Vehicle diag‐
nostic tester.
3.6 Removing and installing tank filler flap locking motor - V155-
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Removing
– Remove fuel tank flap unit ⇒ page 90 .
– Separate connector -3-.
– Remove tank flap locking motor -1- from tank flap unit.
Installing
Install in reverse order of removal, observing the following:
– Attach electrical connector -3-.
– Place tank flap locking motor -1- on tank flap unit.

Passat 2015 ➤
– Installing tank flap unit ⇒ page 90

Specified torques
♦ Bolt ⇒ “3.1 Assembly overview - tank flap unit”, page 90
3.7 Removing and installing ignition key bat‐

tery
Removing
– Remove emergency key.
– Insert a small screwdriver -2- into the emergency key slot
-arrow a-.
– Turn screwdriver -2- -arrowAb- to open catch -3-.
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– Lift off cover. Volks ot g
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– Use a small screwdriver -3- to lift battery -1- -arrow a-. spec
– Pull battery -1- out of battery compartment -2- -arrow b-.

t to the co
Installing
rrectne
Note
ss o
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♦ Before installing battery, always press any key once.

inform
mer
♦ This resets the transmitter unit so that it can detect a new bat‐
atio
tery.
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Ensure correct polarity and mounting position when installing bat‐

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– Insert battery -2- into battery compartment by pressing slightly
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-arrow a-.
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– Assemble cover of battery compartment -1- and transmitter by c lksw
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unit -3- -arrow b-. Prote AG.
Adapting ignition key
Note
A new ignition key must be coded using ⇒ Vehicle diagnostic

tester.

Passat 2015 ➤
3.8 Removing and installing cap on ignition

key
Removing
– Lift off cover for battery compartment ⇒ page 160 .
– Pull cap -1- off transmitter unit -3- -arrow-.
Installing
Note
Use the screw -2- to cut the thread in on a new cap.
– Push cap -1- onto transmitter unit -3- -arrow-.

– Install screw -2-.
– Press cover onto battery compartment
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Passat 2015 ➤
58 – Rear doors, door components

1 Door
⇒ “1.1 Assembly overview - door”, page 162
⇒ “1.2 Removing and installing door”, page 164
⇒ “1.3 Adjusting door”, page 166
⇒ “1.4 Adjusting striker pin”, page 169
⇒ “1.5 Removing and installing door arrester”, page 171
⇒ “1.6 Removing and installing inner door seal”, page 173
⇒ “1.7 Removing and installing outer door seal”, page 176
1.1 Assembly overview - door
Note
♦ The illustrations show the left-hand side. The procedure for the right-hand side is basically the same.
♦ After renewal of B-pillar, the specified torque for bolts -2 and 5- as well as for -14 and 17- changes.
1 - Rear door
⇒ page 164
❑ Adjusting ⇒ page 166 AG. Volkswagen AG d
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❑ Loosening once to ad‐ horis nte
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just the door is permit‐ aut ra
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ted. Always renew oth‐ s
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erwise.
un
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❑ Installed from inside ve‐

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❑ To remove and install,

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B-pillar lower trim must

h re
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be removed first.
spec
❑ 50 Nm
t to the co
Note
rrectne

ss

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f i

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3 - Door hinge
om
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❑ The hinge is split.

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❑ Lower part is secured to

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hinge upper part with

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bolt -8-.
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❑ For bolt -8-.
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5 - Bolt
Prote AG.
❑ Loosening once to ad‐

just the door is permit‐
162 Rep. gr.58 - Rear doors, door components

Passat 2015 ➤
AG. VGeneral
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❑ To remove and install,sB-pillar
s
lower trim must be removed first.
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❑ 50 Nm
pt
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ility
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6 - Cover
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❑ For bolt -7-.
ss
7 - Bolt
o
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❑ Always renew, loosening it once to adjust door is allowed.
nform
mer
❑ 50 Nm
atio
om
8 - Bolt
n
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❑ Connects upper part of hinge to bottom part of hinge.

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❑ 23 Nm
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9 - Door hinge
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10 - Bolt
AG.
❑ 30 Nm
11 - Bolt
❑ Qty. 2
❑ 9 Nm
12 - Door arrester
13 - Door hinge
❑ Lower part is secured to hinge upper part with bolt -8-.
14 - Bolt
❑ To remove and install, B-pillar lower trim must be removed first.
❑ 50 Nm
Note

15 - Door hinge
16 - Bolt
❑ Always renew, loosening it once to adjust door is allowed.
1. Door 163
Passat 2015 ➤
❑ 50 Nm
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17 - Bolt olks
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❑ Looseningriseonce
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to adjust the door is permitted. Always
ara
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o eo
❑ Installedau from inside vehicle.
th
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❑ To remove and install, B-pillar lower trim must be removed first.
ce
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❑ 50 Nm
an
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1.2 Removing and installing door
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♦ Bit for 3320 - 3320/2- thi

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♦ Setting gauge - 3371- Prote
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agen
Note
The removal and installation sequence is described for the rear

left door only. Removal and installation of the rear right door are
similar.
Removing

Passat 2015 ➤
AG. Volkswagen AG d
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Prote AG.
– Press wedge - T10383/1- between bellows -3- and locking el‐

ement -2- -arrow a-.
– Press locking mechanism -2- upwards using the wedge -
T10383/1- -arrow b-. Separate electrical connector -3- from
coupling station -arrow c-.
– If fitted, remove covers of bolts -7-.
– Loosen bolts -7- at hinges -arrow e-, but do not remove them.
– Unscrew bolt -4- for door arrester -5-.
– Push door retaining strip -5- inwards -arrow d-.
– Lift front door -1- with upper parts of hinges -6- upwards
-arrow f- out of lower parts of hinges.
Installing
1. Door 165
Passat 2015 ➤
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Installation is carried out in the reverse order of removal. To this
end, the following should be observed:
• The door retaining strap -5- must have been pushed inwards
-arrow d-.
• After installing rear door, the hinge arms must be flush one
above the other.
– Adjust rear door -1- ⇒ page 166 .
– Observe front door shut lines -1- ⇒ Body Repairs; Rep. gr.
00 ; Body panel gaps/shut lines; Body - middle .
Specified torques
♦ ⇒ “1.1 Assembly overview - door”, page 162
1.3 Adjusting door

♦ Bit for 3320 - 3320/2-
♦ Bit for 3320 - 3320/3-

Passat 2015 ➤
♦ Torque wrench - w
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♦ Vehicle must be standing on its wheels when front door adjustment is performed.
Prote AG.
♦ The rear door is correctly adjusted when all shut lines are even when closed. it is not protruding too far
inwards or outwards, and when the contours are flush with each other.
♦ For checking gaps/shut lines refer to ⇒ Body Repairs; Rep. gr. 00 ; Body panel gaps/shut lines; Body -
middle .
♦ After installing or alignment, carry out corrosion protection measures on hinges and screws/bolts.
1. Door 167
Passat 2015 ➤
AG. Volkswagen AG d
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Adjusting shut lines t. C rig
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To be able to adjust gaps correctly, bolts -2-, -3-, -6- and -7- on
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B-pillar must be loosened.
agen
Prote AG.
– The B-pillar lower trim must be removed for bolts -3 and 7-.
Adjusting for flush fitting
In order to adjust flushness correctly, bolts -5- and -9- must be
loosened.
Use door alignment tool - 3320- with appropriate bit for this.
Note
Other measures, such as raising the rear door, will prove pointless. Subsequent pressure from above will cause
the door to sink again at the back.

Specified torques

Passat 2015 ➤
1.4 Adjusting striker pin

AG. Volkswagen AG d
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♦ Hexagon bit, long reach - 3410- orise nte
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Note
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♦ Threaded plate -1- of striker pin is secured in pillar using a method which differs from the previous method.
m
at
♦ Bow outside of threaded plate is welded firmly to pillar. Webs to threaded plate are plastically deformable.
om
ion
c
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♦ Greater forced has to be applied so that position of striker pin -2- can be adjusted when bolts -3- are loos‐
o
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ened.
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1. Door 169
Passat 2015 ➤
AG. Volkswagen AG d
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Note s
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♦ The rear door must lock fully when closing without any additional force being required and must not have
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♦ The rear door must not be pushed up or down as a result of the striker pin adjustment.
spec
t to the co
Striker pin can be used to align rear door flush with side panel (to
prevent wind noise) -arrows-.
rrectne
– Loosen striker -2- by loosening bolts -3- in C-pillar.

ss
Note
o
cial p
f inform
Greater forced has to be applied so that position of striker pin -2- can be adjusted when bolts -3- are loosened.
mer
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n
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– Tighten bolts -23- of striker pin -2-.

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Striker 20 Nm
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170
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Rep. gr.58 - Rear doors, door components
agen
Prote AG.
Passat 2015 ➤
1.5 Removing and installing door arrester

AG. Volkswagen AG d
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Note
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nl
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Removal and installation are described only for the left door ar‐
y li
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ab
rester. The procedure for the right-hand side is basically the
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Removing
spec
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1. Door 171
Passat 2015 ➤
AG. Volkswagen AG d
agen oes
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rise nte
tho eo
au ra
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un
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cial p
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mer
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c
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Prote AG.
– Remove rear door trim ⇒ General body repairs, interior; Rep.

gr. 70 ; Rear door trims; Removing and installing rear door
trim .
– Pull off self-adhesive cover.
♦ For models without loudspeaker pull off self-adhesive cover
and remove door retaining strap through opening for loud‐
speaker -arrow c-.
♦ For models with loudspeaker detach inner door cover
⇒ page 188 and remove through this opening.
– Unscrew bolt -2- in B-pillar.
– Remove screws -3- and remove door retaining strap -1-.
Installing

Passat 2015 ➤
AG. Volkswagen AG d
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Installation is carried out in the reverse order of removal.

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Specified torques
ole,
spec

t to the co
1.6 Removing and installing inner door seal

rrectne
During production, a sealant is applied to the inner door seals,

which are then placed on the door flange and rolled on.
ss o
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Prote AG.
1. Door 173
Passat 2015 ➤
Note
♦ When removing the door seal, the sealant is distributed across

the inside of the door seal. The sides are bent upwards slightly
when this is being done. If the door seal is then refitted, sealing
and firm seating are no longer guaranteed.
♦ Therefore, each door seal which has been removed complete‐
ly must be replaced by a “tap-on seal”. agen
AG. Volkswagen AG d
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♦ If a door seal has been partially removed, d bsqueeze sides of
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door seal together before installing. thor nte
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♦ Removal and installation are described
ss only for the left door c
ce
le
seal. The procedure for the right-hand side is basically the

un
pt
same.
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♦ For reasons of clarity, the rear door is shown removed.
pe
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Removing
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Prote AG.
– Remove sill panel moulding ⇒ General body repairs, interior;

Rep. gr. 70 ; Trims, interior; Removing and installing sill panel
moulding .

Passat 2015 ➤
– To remove door seal, remove pillar trims as required ⇒ Gen‐

eral body repairs, interior; Rep. gr. 70 ; Trims, interior; Over‐
view of fitting locations - trims, interior .
– Pull door seal -1- off body flange -2-.
Installing lkswage es n
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Do not kink vulcanised point -3-.
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Prote AG.
– Start installing door seal -1- at top radius of door aperture

-arrows-.
– Align vulcanised point -3- between hinges.
– Press door seal -1- onto body flange -2-.
– Install pillar trims ⇒ General body repairs, interior; Rep. gr.
70 ; Trims, interior .
– Install sill panel strip ⇒ General body repairs, interior; Rep.
gr. 70 ; Trims, interior; Removing and installing sill panel strip .
1. Door 175
Passat 2015 ➤
1.7 Removing and installing outer door seal

⇒ “1.7.1 Removing and installing outer door seal”, page 176
⇒ “1.7.2 Removing and installing door seal”, page 177
1.7.1 Removing and installing outer door seal

AG. Volkswagen AG d
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Note ed by ara
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♦ The removal
ss a and installation sequence is described only forc
the right door seal. The removal and installation of the left door
ce
le
un
pt
seal are similar.
an
d
itte
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ab
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temperature about 20°C.
ot p
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spec
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cial p
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mer
atio
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n
c
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Removing
Installing

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auth General body repairs, exterior - eEdition
or
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ss
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– Immediately before bonding door seal, clean bonding surface
nl
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thoroughly with adhesive remover D 002 000 10.
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– Vulcanised point -2- of door seal must be in centre area of side
hole
spec
member.
es, in part or in w
t to the co
– Pull off protective backing, and start fitting door seal in upper
rear radius -arrow- of door. Do not pull door seal excessively
to avoid stretching seal.
rrectness of i
– Press bonding surface of seal -1- firmly onto door -3- all around
l purpos
using roller - 3356- .
1.7.2 Removing and installing door seal
nform
mercia
at
om
io
Note
n
c
in t
or
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ate
♦ The removal and installation sequence is described only for
do
riv
the right door seal. The removal and installation of the left door
p
cum
for
seal are similar.
en
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t.
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C py
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temperature about 20°C.
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Prote AG.
1. Door 177
Passat 2015 ➤
Removing
– Remove trim cover for door ⇒ page 353 .
Installing
– Remove remaining adhesive residue -3- with eraser disc for
adhesive strip remover - VAS 6349- .
– Immediately before bonding door seal, clean bonding surface
thoroughly with adhesive remover D 002 000 10.
– Centre door seal -2- on door -1-.
– Pull off protective backing, and fit door seal to door.
– Press bonding surface of seal -3- onto door -1- using roller -
3356- .
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by
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Prote AG.

Passat 2015 ➤
2 Door components
⇒ “2.1 Assembly overview - door components”, page 179
⇒ “2.3 Assembly overview - door handle and door lock”,
page 182
⇒ “2.4 Removing and installing window regulator motor”,
page 182
olkswagen AG
en AG. V
⇒ “2.5 Removing and installing window regulator”,
olks page 185
wag does
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⇒ “2.6 Removing and installing inner door ris cover”, page 188
e d
nte
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⇒ “2.7 Removing and installing striker
ss a pin”, page 190 ra
c
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⇒ “2.8 Removing and installing cap on door handle”, page 192

un
pt
an
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⇒ “2.9 Removing and installing door handle”, page 197
rm
ab
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ility
⇒ “2.10 Removing and installing mounting bracket”, page 200
ot
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h re
⇒ “2.11 Removing and installing door lock”, page 203
hole
spec
⇒ “2.12 Removing and installing window channel”, page 207
es, in part or in w
t to the co
⇒ “2.13 Removing and installing window slot outer seal”,
page 210
rrectness of i
⇒ “2.14 Removing and installing window slot inner seal”,
page 212
l purpos
2.1 Assembly overview - door components
nform
mercia
a
com
Note
tion in
r
te o
thi
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do
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Prote AG.

Passat 2015 ➤
1 - Rear door
⇒ page 164
2 - Window slot inner seal
⇒ page 212
3 - Stickers
❑ Qty. 1
❑ Diameter 28 mm
sive tape.
4 - Dampers
❑ Self-adhesive AG. Volkswagen AG d
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❑ Installing: olksw not
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– Cut to size if required, horis
eo
250 mm x 160 mm Po‐ aut ra
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sition as shown in illus‐ s
ce
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tration.
un
pt
an
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– Warm using hot air
rm
ab
pe
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blower - V.A.G 1416-
ot
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and push on to outer
, is n
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door panel with force.
hole
spec
es, in part or in w
5 - Stickers
t to the co
❑ Qty. 1
❑ Diameter 32 mm
rrectness of i
l purpos

sive tape.
nform
ercia
6 - Inner door cover

m

com
tion in
r
7 - Door seal
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8 - Stickers
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❑ Qty. 1 Cop py
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❑ Diameter 42 mm
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❑ If necessary, manufacture using commercially available textile adhesive tape. Prote
cted AG.
agen
9 - Dampers
❑ Self-adhesive
❑ Installing:
– Cut to size if required, 250 mm x 160 mm Position as shown in illustration.
10 - Stickers
❑ Qty. 2
❑ Diameter 28 mm

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
lksw not
11 - Window slotd bouter
yV
o
seal gu
ara
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❑ Removing horis
and installing ⇒ page 210 eo
aut ra
12 - Window
ss channel c
ce
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un
pt
an
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13 - Stickers
erm
ab
ility
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❑ Qty. 2
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❑ 15 mm x 50 mm
h re
ole,
spec
t to the co
2.2 Assembly overview - window regulator
rrectne
ss o
cial p
f in
⇒ page 185
form
mer
atio
2 - Hexagon nut
om
n
c
❑ Qty. 1 top
i
or
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e
❑ 6 Nm
t
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3 - Hexagon nut
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❑ Qty. 1 bottom
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4 - Retaining hooks for cable
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drum
AG.
❑ Qty. 3
❑ Mounting for window
regulator motor
❑ Specified torque of win‐
dow regulator motor
bolts: 3 Nm

Passat 2015 ➤
2.3 Assembly overview - door handle and door lock
Note
1 - Door lock
⇒ page 203
2 - Bolt
❑ 1.5 Nm
❑ For locking bar in
mounting bracket.
3 - Mounting bracket
⇒ page 200
4 - Carrier
5 - Cover
⇒ page 192
6 - Door handle
⇒ page 197
7 - Bolt
❑ 1.5 Nm
❑ Bearing plate is loos‐ AG. Volkswagen AG d
agen
ened from door when Volksw
oes
not
this bolt is loosened ed by gu
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8 - Bowden cable aut
h
ra
s c
❑ From door lock -1- to s
ce
le
mounting bracket -3-

un
pt
an
d
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9 - Bowden cable
rm
ab
pe
❑ From inner door handle ility

ot
to door lock -1- wit

, is n
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❑ With grommet to pas‐
hole
spec
sage on cover.
es, in part or in w
t to the co
10 - Cover
11 - Bolt
rrectness of i
❑ Qty. 2
l purpos
❑ 18 Nm
Note
nform
mercia
The bolts are microencapsulated

com
tio
and must be renewed each time

n in
r
they are loosened.

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Special tools and workshop equipment required cted agen
Prote AG.

Passat 2015 ➤
lkswage es n
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nl
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Note
es, in part or in w
t to the co
♦ Removal and installation are described only for the left window
regulator motor. Removal and installation of the right window
rrectness of i
regulator motor are similar.
l purpos
♦ The door control unit -6- is clipped into door separated from
window regulator motor.
nform
ercia
Removing
m
at
om
ion
c
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or
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ate
do
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for
en
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co lksw
by
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Prote AG.

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
ce
e
nl
pt
du
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es, in part or in w
t to the co
rrectness of i
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nf
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or c
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Prote AG.

trim .
– Tape up door window to prevent it from sliding down.
– Switch off ignition and all electrical consumers. Withdraw ig‐
nition key.
– Remove bolts -4- (qty. 3).
– Remove window regulator motor -1- from mounting brackets
of cable drum -3-.
Installing

lkswage es n
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d Passat 2015 ran ➤
tee
t o
hGeneral body repairs, exterior - Edition 03.2019
u or
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es, in part or in w
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nform
mercia
a
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tion in
r
te o
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t.
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by
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Prote AG.
– Fit window regulator motor -1- onto mounting brackets of cable

drum -3-. Move door window up and down slightly so that the
splines between window regulator motor and cable drum en‐
gage more easily.
– Connect connector -2-.
– The work procedure and notes on the automatic window rais‐
ing and lowering system as well as on the excess-force limi‐
tation feature can be found in ⇒ Maintenance ; Booklet .
quence of removal.
Specified torques
♦ Mounting bracket

tor

Passat 2015 ➤
AG. Volkswagen AG d
♦ Torque wrench - V.A.G 1783- agen oes
olksw not
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hole
spec
es, in part or in w
t to the co
rrectness of i
Note
l purpos
Removal and installation are described only for the left window
regulator. Removal and installation of the right window lifter mech‐
nform
ercia
anism are similar.

m
at
om
ion
Removing
c
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or
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ate
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Prote AG.

Passat 2015 ➤

trim .
– Detach door window from window regulator. Do not remove it
⇒ page 337 .
– Move door window upwards, and secure it in place.
– Remove window regulator motor ⇒ page 182 .
– Release locking hook of cable drum -4- and insert into door.
– Unscrew lower hexagon nut -3- and insert threaded studs of
window regulator into door.
– Loosen upper hexagon nuts -2-, do not remove.
– Slightly push window regulator upwards in door -arrow a-, and
guide it into door.
– Turn window regulator -1- 90° -arrow b-, and remove it through
opening in door -arrow c-.
Installing
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– Insert window regulator -1- through opening in door p by
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-arrow a-, and swing it to installation position -arrow b-.
by lksw
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Prote AG.

Passat 2015 ➤
– Insert studs of window regulator into inner door panel, and

guide them downwards -arrow c-.
– Tighten hexagon nuts -2 and 3-.
AG . Volkswagen AG
– Press cable drum against door inner part until
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locking
agen devices does
not
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-4- engage audibly. by Vo gu
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– Install window regulator motor ⇒s aupage
t
182 ra
c
s
– Install door window ⇒ page 337
ce
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Specified torques
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♦ Window regulator
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2.6 Removing and installing inner door cov‐
spec
es, in part or in w
er
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Note
Removal and installation are described only for the left cover. The
procedure for the right-hand side is basically the same.
Removing

Passat 2015 ➤
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trim .
– Lift cover -1- at front -arrow a-.
– Pull cover -1- downwards out of door -arrow b-.
Note
If required for subsequent work, pull cable -3- with grommet -2- out of cover -1-. Separate connector at grommet
(if there is one).
Installing

Passat 2015 ➤
AG. Volkswagen AG d
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– Fit cable -3- together with grommet -2- into cover -1-.
agen
Prote AG.
– Attach grommet -2- to cover -1-.

– Insert cover -1- into door -2- -arrow a-.
– Engage cover -1- around circumference -arrow b-.
Note
♦ Check proper seating of cover by pressing with fingers around circumference.

♦ If fitted, join electrical connector at grommet.


Passat 2015 ➤
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Removal and sinstallation
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are described only for the right door or ac
striker pin. The procedure for the right-hand side is basically the
s
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Passat 2015 ➤
AG. Volkswagen AG d
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Removing
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– Unscrew bolts -2- and remove striker pin -1-.

rrectness of i
Installing
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– Fit striker pin -1- to C-pillar and tighten bolts -2-.

nform
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Striker 20 Nm
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2.8 Removing and installing cap on door

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♦ Disassembly and assembly tool - T10539-
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Removing

Passat 2015 ➤
AG. Volkswagen AG d
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cial p
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Prote AG.
– Remove plugs -3-.

– Pull door handle -2- off door -arrow b-.
– Push disassembly and assembly tool - T10539- approx. 5 mm
towards front -arrow b- until hook is released.

Passat 2015 ➤
AG. Volkswagen AG d
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Prote AG.
– There must be a gap -arrow a- between door handle -2- and

door.
Note
Do not push the door handle into the door. Otherwise the door handle bracket will be damaged.
– Pull cover cap -1- out of mounting bracket -arrow b-.

Installing

Passat 2015 ➤
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lkswagen Abody
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– There is a gap between door handle -2- and door -arrow a-.
– Push cover cap -1- into mounting bracket -arrow b-.

Passat 2015 ➤
lkswage es n
o ot g
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– Slightly press cover cap -1- onto door.

nform
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ion
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by 90° -arrow a-, and pull it out by approx. 5 mm -arrow b- until

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– Secure plug -3-.

Passat 2015 ➤
2.9 Removing and installing door handle

⇒ “2.9.1 Removing and installing door handle”, page 197
⇒ “2.9.2 Removing and installing door handle with keyless entry
system”, page 198
2.9.1 Removing and installingoldoor

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Removing
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cial p
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– Remove cap ⇒ page 192 .

– Pull out door handle -1- backwards slightly -arrow a- from sup‐
port for mounting bracket.
– Pull door handle -1- out of door handle bracket -2- -arrow c-.

Passat 2015 ➤
Installing
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bracket.
– Swing door handle -1- into door -arrow b-.
handle bracket -2-.
Installing cover cap ⇒ page 192
the door open.

with keyless entry system
Note
same.

Passat 2015 ➤
Removing
AG. Volkswagen AG d
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– Remove cap ⇒ page 192 .

nform
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c
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– Open locking mechanism on connector -4- using a screwdriver

a
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-3- -arrow d-.

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Passat 2015 ➤
AG. Volkswagen AG d
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nl
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For general information and work instructions for the door handle Prote AG.
bracket.
The connector for the keyless entry system is connected when
the door handle is being inserted.
– Swing door handle -1- into door -arrow b-.
handle bracket -2-.
Installing cover cap ⇒ page 197
the door open.
2.10 Removing and installing mounting

bracket

Passat 2015 ➤
Note
Removal and installation are described only for the right mounting
bracket. The procedure for the right-hand side is basically the
same.
Removing
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Prote AG.

Passat 2015 ➤

trim .
– Push door handle bracket -1- slightly towards rear, and re‐
move it from door.
Detach cable
– Lift pin of cable -2- out of mounting.
Installing
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Make sure the connector -5- for the keyless entry system is firmly seated.

Passat 2015 ➤
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– Slightly swing aside retainer th-3-ise
or -arrow a-. tee
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– Push pin of cable -2- into smounting -arrow b-.
ce
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– Guide door handle bracket -1- into door -arrow c-. du
an
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– Tighten bolt -4-.
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Specified torques
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♦ Mounting bracket
182
rrectness of i
2.11 Removing and installing door lock
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♦ Hexagon bit, long reach - T10054-
Note
♦ Removal and installation are described only for the left door
lock. The procedure for the right-hand side is basically the
same.
♦ The door window must be closed for subsequent work.
♦ The bolts are microencapsulated and must be renewed each
time they are loosened.
Removing

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
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– Remove rear door trim ⇒ General
ss body repairs, interior; Rep. c
ce

le
un
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trim .
an
d
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– If fitted, disconnect connector.

, is n
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spec
es, in part or in w
– Remove door lock -1- from door -arrow-.

t to the co
Note
rrectness of i
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Cables can be detached if this is necessary for subsequent work.

nform
ercia
Detach cable from mounting bracket

m
– Remove cover ⇒ page 205 .

a
com
tion in
– Turn cable -5- 90° and take out of holder -arrow a-.
r
te o
thi
s
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– Swivel cable -arrow b- so far until cable can be threaded out

do
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of eye in door lock -1- -arrow c-.

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Detach cable from interior door handle
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py by
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204
Prote AG.
Rep. gr.58 - Rear doors, door components
Passat 2015 ➤
– Swivel cable -arrow d- so far until cable can be threaded out

of eye in door lock -1- -arrow e-.
Removing cover
AG. Volkswagen AG d
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– Disengage hook -3- in -direction of arrow a-.

es, in part or in w
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– Use the hook to pull cover -1- out of door lock -2- -arrow b-.
– Pull cover -1- upwards -arrow c- from door lock -2-.
rrectness of i
Installing
l purpos
Note
nform
mercia
The bolts are microencapsulated and must be renewed each time they are loosened.
com
tion in
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rig ht
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Passat 2015 ➤
AG. Volkswagen AG d
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nl
pt
du
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ab
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– Attach removed cables -4- and -5- to door lock -1-.

ot p
wit
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– Install cover ⇒ page 206 .

h re
hole
spec
– Insert door lock -1- into door -arrow f-.

es, in part or in w
t to the co
– If fitted, connect connector.

rrectness of i
– Clip cap -3- in.

l purpos
quence of removal.
nform
ercia
– Carry out functional test before closing door.

m
at
om
• Only if the cables are adjusted and locked correctly, the door
ion
c
lock can be unlocked and opened properly.

in t
or
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ate
Specified torques
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or
♦ ⇒ “2.3 Assembly overview - door handle and door lock”, page

f
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182
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Passat 2015 ➤
AG. Volkswagen AG d
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ce
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nl
pt
du
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es, in part or in w
t to the co
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– Push cover -1- onto retainer -3- on door lock -2- -arrow a-.
– Engage hook -4- with door lock -2- -arrow b-.
2.12 Removing and installing window chan‐

nel
Note
♦ The removal and installation sequence is only for the left win‐
dow channel. Removal and installation of the right window
channel are similar.
♦ Do not bend window channel when removing!
Removing

Passat 2015 ➤
AG. Volkswagen AG d
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– Remove window slot inner seal ⇒ page 210 .

f inform
mer

atio
m
– Detach window channel -1- at rear end from door -arrow a-.
o
n
c
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– Peel sealing lip of window channel -1- off the door flange -2-
te
sd
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from the inside.

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– Pull window channel -1- out of mountings on door -arrows c-.

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– Pull window channel -1- -arrows b- evenly all around off door t. C rig
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flange -2-. yri
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Installing
agen
Prote AG.

Passat 2015 ➤
lkswage General body repairs,es n exterior - Edition 03.2019
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es, in part or in w
t to the co
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l purpos
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Prote AG.
– Spray window channel with soapy water to facilitate installa‐

tion.
– Push window channel -1- into mountings on door -arrows a-.
– Attach window channel at rear end to door -arrow c-.
– Fit window channel -1- all around onto door flange -2-
-arrows b-, and press it on.
– Fold sealing lip of window channel onto door flange from the
inside.
Note
To prevent wind noise, ensure window channel -1- seats evenly when installing.
quence of removal.

Passat 2015 ➤
2.13 Removing and installing window slot

outer seal
Note
♦ The core of the window slot outer seal is a metal insert.

♦ If it is bent or distorted, the window slot outer seal can no lon‐
ger be straightened out. It will remain “wavy”.
♦ Therefore, the window slot outer seal must be pulled off and
pressed on evenly, without bending or distorting it.
♦ Removal and installation are only described for the left window
slot outer seal. Removal and installation of the right window
slot outer seal are similar. en AG. V
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– Slightly detach window slot outer seal -1- evenly from door
flange -2- using wedge - T10039/1- -arrows a-. Make sure not
to bend the side strip.

Passat 2015 ➤
– Push window slot outer seal -1- towards front out of door
-arrow b-.
Installing
AG. Volkswagen AG d
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Note
♦ The use of assembly aid is allowed.

♦ The use of striking tools is not allowed for installing outer window slot seal.
– Push window slot outer seal -1- at front end into door
-arrow a-.
– Press window slot outer seal -1- evenly onto door flange -2-
by hand.

Passat 2015 ➤
2.14 Removing and installing window slot in‐

ner seal
Note
Removal and installation are only described for the left window
slot inner seal. Removal and installation of the right window slot
outer seal are similar.
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es, in part or in w
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ion
c
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ate
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Removing
trim .
– Lift window slot inner seal -1- evenly off flange -2- without
bending or distorting it -arrows-.
Installing
– Centre window slot inner seal -1- and press it evenly onto front
door flange -2- by hand.

Passat 2015 ➤
60 – Sunroof
1 Sliding sunroof
⇒ “1.1 Assembly overview - sliding sunroof”, page 213
⇒ “1.2 Assembly overview - sunroof roller blind”, page 215
⇒ “1.3 Removing and installing sliding sunroof frame”,
page 216
⇒ “1.4 Removing and installing wind deflector”, page 225
⇒ “1.5 Removing and installing glass panel”, page 226
⇒ “1.5.2 Removing glass panel when drive is defective”,
page 231
⇒ “1.6 Adjusting sunroof panel”, page 232
⇒ “1.7 Removing and installing guide plate”, page 234
⇒ “1.8 Removing and installing front trim for sliding sunroof”, page
239
⇒ “1.9 Removing and installing sliding sunroof motor V1 ”,
page 248
⇒ “1.10 Removing and installing sliding sunroof adjustment con‐
trol unit J245 ”, page 252
⇒ “1.11 Operating without current”, page 257
⇒ “1.12 Removing and installing sliding sunroof seals”,
page 259
⇒ “1.13 Removing and installing sunroof roller blind”, page 260
⇒ “1.14 Programming sliding sunroof adjustment control unit J245
”, page 270
1.1 Assembly overview -nsliding

wage
sunroof
AG. Volkswagen AG
doe
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1. Sliding sunroof
agen
Prote AG.
Passat 2015 ➤
1 - Glass panel for panorama

tilting sunroof (single pane
safety glass)
❑ Removing glass panel
⇒ page 226 .
❑ If drive defective, re‐
move glass panel
⇒ page 231
❑ Adjusting glass panel
⇒ page 232
2 - Bolt
❑ Bolts are microencap‐
sulated and must al‐
ways be renewed after
loosening.
❑ Qty. 6
❑ 5.5 Nm
3 - Seal of sliding sunroof
frame
⇒ page 259
4 - Sunroof roller blind
❑ Removing and installing agen
AG. Volkswagen AG d
oes
⇒ page 260 Volksw not
gu
d by ara
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5 - Sliding roof frame horis nte
eo
ut
❑ Removing and installing ss a ra
c
sliding sunroof frame
ce
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un
⇒ page 216 .
pt
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❑ Guide channels are to
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be greased, if required,
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with special grease G
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060 751 A2 only other‐
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wise correct operation

spec
cannot be guaranteed.
es, in part or in w
6 - Bolt t to the co
❑ For sliding sunroof motor.

rrectness of i
❑ Qty. 1
l purpos
❑ 4 Nm
7 - Bolt
nform
ercia
❑ For sliding sunroof motor.

m
❑ Qty. 1
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tion in
❑ 4 Nm
r
te o
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s
8 - Sliding sunroof motor - V1-

iva
do
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❑ With separate sliding sunroof adjustment control unit - J245-

um
fo
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t.
❑ Removing and installing sliding sunroof motor - V1- ⇒ page 270
yi Co
Cop py
❑ Sliding sunroof adjustment control unit - J245-
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❑ Adapting sliding sunroof adjustment control unit - J245- ⇒ page 270
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Prote AG.
9 - Bolt
❑ For the cover
❑ Qty. 5
❑ 2.5 Nm
214 Rep. gr.60 - Sunroof

Passat 2015 ➤
General
AG. Volksw body
agen repairs, exterior - Edition 03.2019
n AG do
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10 - Cover ed
by
V ua
ran
ris tee
11 - Bolt ut
ho
or
ac
sa
❑ Bolts are microencapsulated and must always
s be renewed after loosening.
ce
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nl
pt
❑ Qty. 13
du
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itte
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❑ 3 Nm
erm
ab
ility
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12 - Guide plate
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❑ With tilting mechanism and cables
h re
hole
spec
❑ Forms one component in conjunction with securing bracket of lift sun blind and control unit
es, in part or in w
t to the co
13 - Wind deflector
rrectness of i
14 - Bolt
l purpos
❑ For wind deflector.
nform
ercia
❑ Qty. 2
❑ 2 Nm
m
at
om
ion
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or
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ate
1.2 Assembly overview - sunroof roller blind
do
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1 - Sunroof roller blind C py
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❑ Removing and installing yri
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⇒ page 215
c by lksw
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Prote AG.
2 - Support
❑ For sunroof roller blind
fabric.
3 - Bolt
❑ Qty. 2
❑ 2 Nm
4 - Tension wire
❑ For securing the fabric
in the tension bow
5 - Follower
6 - Slide
7 - Tension bow
⇒ page 267
8 - Handle
9 - Bolt
❑ For the handle
❑ Qty. 2
❑ 1 Nm
10 - Slide
1. Sliding sunroof 215

Passat 2015 ➤
1.3 Removing and installing sliding sunroof

frame
⇒ “1.3.1 Minimum curing period”, page 216
⇒ “1.3.2 Fitting instructions”, page 217
⇒ “1.3.3 Cleaning in the event of dirt caused by adhesive sealant”,
page 217
⇒ “1.3.4 Touching up paint damage”, page 217
⇒ “1.3.5 Materials”, page 217
⇒ “1.3.6 Preparing body flange for bonding”, page 218
⇒ “1.3.7 Preparing sliding sunroof frame for installation”,
page 218
⇒ “1.3.8 Removing and installing sliding sunroof frame”,
page 219
1.3.1 Minimum curing period
Note
♦ There are special requirements for renewing bonded sliding

sunroof frames.
♦ The vehicle is safe to use only after the minimum curing period
has elapsed.
2-pack window adhesive n AG. Volkswagen AG do

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The minimum curing period for the 2-pack ed
window
byV adhesive is ua
ran
3 hours. horis tee
ut or
a ac
Minimum curing period is the timessfrom bonding the sliding sun‐
roof assembly frame until vehicle may be used. During this time,
ce
le
un
pt
the vehicle must be standing on a level surface at room temper‐

an
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ature (at least 15°C).

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1-pack window adhesive

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The minimum curing period for the 1-pack window adhesive is

hole
24 hours.
spec
es, in part or in w
Minimum curing period is the time from bonding the sliding sun‐
t to the co
roof assembly frame until vehicle may be used. During this time,
the vehicle must be standing on a level surface at room temper‐
ature (at least 15°C).
rrectness of i
l purpos
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tion in
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Prote AG.

Passat 2015 ➤
1.3.2 Fitting instructions

– Apply adhesive sealant in continuous bead, holding applicator
at right angle to sliding sunroof frame.
Note
♦ The sliding sunroof frame must be fitted within 10 minutes.

♦ Otherwise, the adhesive properties of the window adhesive
will be impaired.
♦ Insert sliding sunroof frame into aperture, align it centrally, and

press in onto spacer rib.
1.3.3 Cleaning in the event of dirt caused by

adhesive sealant
Note
♦ When cleaning freshly installed sliding sunroof assembly

frame from the inside in the vehicle, do not press assembly
frame outwards.
♦ Otherwise, the adhesive bead will be detached.
– Adhesive remover works well as a cleaning solution. Safety

precautions must
lkswbe
ageobserve for all work eprocedures.
sn
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– First, clean
ris
ed the painted surface roughly with a lint-free
ara
nte cloth.
Remove utho residue using adhesive remover . eo
r
sa ac
– Cleaning
s
plastic trim: Allow adhesive sealant to cure (approx.
ce
le
1 hour) and then peel off.

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pt
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1.3.4 Touching up paint damage

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If paintwork is damaged, paint structure must be restored accord‐

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ing to specifications in “Paint” workshop manual.

hole
spec
1.3.5 Materials
es, in part or in w
t to the co
Note
rrectness of i
The current material numbers for the chemical materials listed

l purpos
should be gleaned from the Electronic parts catalogue “ETKA”.

nform
ercia
♦ 2-pack window adhesive 1) 1 2) 2 3) 3

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tion in
♦ Activator 1) 1
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♦ Primer 1
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♦ Cleaning solution 1) 1
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217
cted agen
Prote
1. Sliding sunroof
AG.
Passat 2015 ➤
General body repairs, exterior - Edition 03.2019 n AG. Volkswagen AG do
lkswage es n
o ot g
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♦ Applicator ir se
d ran
tee
tho
u or
a ac
♦ Adhesive remover 1) 1 ss
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nl
pt
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♦ Cutting cord 357 853 999 4
an
4)
itte
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erm
ab
♦ Wire reel VAS 4
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4)
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6452/1
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♦ Cutting cord 4
spec
4)
6888/1 es, in part or in w
t to the co
1) 1 Observe manufacturer's instructions enclosed in the packaging.
rrectness of i
2) 2 Observe minimum curing period ⇒ page 216 .
l purpos
3) 3 Double cartridge gun - VAS 5237- must be used to apply these materials.
4) 4 The cutting cords stated above can be used alternatively to the cutting wires,
nf
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o
and vice versa. They are designated for single use.
rm
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atio
1.3.6 Preparing body flange for bonding
om
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♦ Cut back residual adhesive sealant to 1 to 2 m shortly before
te
sd
a
bonding window back in.

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♦ When doing this, take care not to damage the primer layer.
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♦ Keep bonding surface free of dirt and grease.
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♦ Do not treat bonding surface with activator, glass/paint primer cop Vo
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or cleaning solution immediately after cutting back.
agen
Prote AG.
♦ The remaining material is required as a base for better adhe‐

sion of the new adhesive sealing material to be applied.
– Cut back remaining material on body flange with U-shaped
blade - V.A.G 1561/3- , but do not remove completely.
Exception: If bonding is not performed immediately after cutting
back, the remaining residual material must be activated with ac‐
tivator .
– Apply activator evenly in one stroke using applicator .
NOTICE
Risk of damage to paintwork structure caused by activator.
– Apply activator precisely onto adhesive bead, and do not
spill any activator.
1.3.7 Preparing sliding sunroof frame for in‐

stallation
Work to be carried out on a new sliding sunroof frame:
Note
On a new sliding sunroof frame, the trim is already bonded.
Clean bonding surface -3- thoroughly, using cleaning solution .

– Lightly key the bonding surface -3- with fine emery paper.
– Clean around bonding surface -3- using cleaning solution .
– Then rub primer/bonding surfaces -3- using a lint-free cloth.

Passat 2015 ➤
– Using applicator -2-, apply primer evenly in one pass.

Drying time for primer is 10 minutes.
Work to be carried out on a cut out sliding sunroof frame:

AG. Volkswagen AG d
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olks
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ed
♦ Do not treat bonding surface with activator, glass/paint
horis primer nte
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t ra
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ss
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nl
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du
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erm
ab
– Cut back remaining material using scraper set - VAS 861 005-
ility
ot p
but do not remove completely.
wit
, is n
h re
• Exception: if bonding is performed later than one day after
hole
cutting back adhesive bead, the remaining residual material
spec
must be activated with activator .
es, in part or in w
t to the co
rrectness of i
NOTICE
l purpos

nf
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orm
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atio
om
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1.3.8 Removing and installing sliding sunroof

or c
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frame
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♦ Double cartridge gun - VAS 5237- C py
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Prote AG.

Passat 2015 ➤
♦ Electric cutter - V.A.G 1561A-
♦ Blade (L-shape 19 mm) - V.A.G 1561/21-
AG. Volkswagen AG d
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Prote AG.

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
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– Remove front trim ⇒ page 239 . s aut ra
c
s
– Remove glass panel ⇒ page 226 .
ce
le
un
pt
an
d
itte
– Remove moulded headliner ⇒ General body repairs, interior;

y li
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ab
Rep. gr. 70 ; Roof trims; Removing and installing moulded

pe
ility
headliner .
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– Mask off any surrounding components such as the roof edge

hole
-3- in order to protect them from being damaged.

spec
es, in part or in w
t to the co
– Stick electric cutter - V.A.G 1561A- -4- with L-shaped 19 mm

blade - V.A.G 1561/21- into rear adhesive bead -2-.
– Cut through adhesive bead -2- at right angle -arrow a- and
rrectness of i
sideways up to front -arrow b-.

l purpos
Note
nform
ercia
In the middle at the rear, there is a centring pin made of plastic.

m
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tion in
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221
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Prote AG.
1. Sliding sunroof
Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
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rise nte
tho eo
au ra
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ce
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un
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an
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erm
ab
ility
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wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
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or
n thi
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pr
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t.
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– Secure a handle from, for example, windscreen removal kit - t. C rig
gh ht
V.A.G 1755- to each end of the cord. pyri by
Vo
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cted agen
The cutting of the adhesive bead -2- is only possible with the help Prote AG.
of a second mechanic.
– One person pulls from the outside, the other pulls from the
inside.
Note
♦ There are 3 adhesive beads on the roof cross member and increased resistance will be encountered here.
♦ Keep the cord near the sliding sunroof frame to ensure that it cannot be cut by the surrounding edges.
– The adhesive bead -2- must be cut through, starting from the
rear -arrow a-, as far as the middle of the roof cross member
-3-.
– Move cord to other side.
– The adhesive bond is cut through, starting from the rear
-arrow b-, as far as the roof cross member.
– Remove sliding sunroof frame -3-.

Passat 2015 ➤
Note
♦ The exact position of the adhesive beads on the new sliding sunroof frame must be taken from the adhesive
beads on the removed sliding sunroof frame.
♦ The position of the adhesive bead on the metal flange must also be the same if a new roof is fitted.
Installing
AG. Volkswagen AG d
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ab
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is n
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spec
t to the co
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cial p
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mer
atio
om
n
c
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or
n thi
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sd
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– Prepare body flange for installation of sliding sunroof frame

iv
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pr
⇒ page 218 .
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fo
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ng
t.
– Prepare new sliding sunroof frame -1- for installation
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⇒ page 218 . t. C rig
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– Prepare cut out sliding sunroof frame -1- for installation
co Vo
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⇒ page 219 .
agen
Prote AG.
– Installation instructions ⇒ page 217

• The glass panel -1- has been built into the frame -4-.
• Sliding sunroof frame can also be installed without height
stops -3-.

Passat 2015 ➤
– Apply 2-component glass adhesive . Dimensions for adhesive

bead -5-: width = 12 mm; height = 10 mm
Note
Sliding sunroof frame must be installed within 10 minutes, or adhesive properties of glass adhesive will be
impaired.
AG. Volkswagen AG d
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un
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ab
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is n
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
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t.
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Cop py
t. rig
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pyri by
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Prote AG.
– Insert sliding sunroof frame with glass panel in roof aperture.

New sliding sunroof frame
– Centring lug -3- aligns sliding sunroof frame within aperture.
– Press sliding sunroof frame downwards as far as the stops,
check height setting in relation to roof ⇒ page 232 .
Existing sliding sunroof frame
– If the centring pin no longer exists, the sliding sunroof frame
is aligned in relation to the roof aperture -2-.
– Press sliding sunroof frame downwards as far as the stops,
check height setting in relation to roof ⇒ page 232 .
– Observe minimum drying time ⇒ page 216 .

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
lksw not
1.4 Removing and installing wind deflector
o
byV gu
ara
ed
ris nte
o eo
Removing aut
h
ra
ss c
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e
nl
pt
du
an
itte
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erm
ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
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at
om
ion
c
in t
or
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ate
do
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for
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t.
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rig ht
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Prote AG.
– Open front glass panel completely.

– Using a screwdriver -2-, lift out retaining hook from frame
-arrow a-.
– Push wind deflector -1- towards front as far as stop
-arrows b-.
– Lift out wind deflector from installation frame.
Installing

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
– Position wind deflector -1- with retaining hooks in holes.
an
d
itte
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erm
– Push wind deflector backwards until retaining hooks engage

ab
ility
audibly in frame.
ot p
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is n
1.5 Removing and installing glass panel h re

ole,
spec
⇒ “1.5.1 Removing and installing glass panel”, page 226

t to the co
⇒ “1.5.2 Removing glass panel when drive is defective”,

page 231
rrectne
1.5.1 Removing and installing glass panel

ss
Removing
o
cial p
f inform
mer
Note
atio
om
n
c
i
or
♦ For clarity, the moulded headliner is not shown in the illustration.

thi
te
sd
va
♦ The moulded headliner is not to be removed.

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Prote AG.

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
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itte
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erm
ab
ility
ot p
wit
, is n
h re
– Open sun blind completely.

hole
spec
– Open glass panel of panorama tilting roof by 150 mm

es, in part or in w
t to the co
-dimension a-.
– Push trim -1- slightly towards rear -arrow a-.
rrectness of i
– Remove trim -1- from sliding sunroof frame -2- -arrow b-.
l purpos
nf
ercia
orm
m
atio
om
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by c lksw
cted agen
Prote AG.

Passat 2015 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Undo rear securing bolts -2-.

l purpos
– Unscrew front securing bolts -3- on left and right.

– Loosen rear securing bolts -4- on left and right but do not undo
nform
ercia
completely.
m
– Lift out glass panel -1- upwards.

com
tion in
r
te o
thi
s
iva
Note
do
r
rp
cum
fo
en
g
In order to avoid damage during further work, close the mechanism with the push-button.
n
t.
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Installing
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Prote AG.

Passat 2015 ➤
♦ Torque wrench 210 Nm - V.A.G 1783-
Note
Bolts are microencapsulated and must always be renewed after they have been removed.
AG. Volkswagen AG d
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Cop py
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pyri by
Vo
co lksw
by
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Prote AG.
– Open mechanism by 150 mm -dimension a- with the push-

button.
– Place glass panel -1- on the tilting mechanism.

Passat 2015 ➤
– Lightly tighten securing bolts -2, 3 and 4- on left and right.

– Adjust panorama tilting sunroof glass panel (height adjust‐
ment): ⇒ page 232
Note
After adjusting panel height, tighten securing bolts -2, 3 and 4-.
Specified torques
♦ Glass panel ⇒ page 213
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Prote AG.
– Insert trim -1- into sliding sunroof frame -2- -arrow a-.
– Push trim -1- as far as stop towards front -arrow b-.

Passat 2015 ➤
1.5.2 Removing glass panel when drive

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Cop py
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pyri by
Vo
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by
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Prote AG.
– Open sun blind completely.

Rep. gr. 70 ; Roof trim; Removing and installing moulded
headliner .
– Push trim -1- slightly towards rear -arrow a-.
– Remove trim -1- from sliding sunroof frame -2- -arrow b-.

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
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y V gu
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rise nte
tho eo
au ra
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ce
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un
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d
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cial p
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mer
atio
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n
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i
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cum
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fo
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t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
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Prote AG.
– The rear securing bolts -2- must be unscrewed from inside the
vehicle.
– Loosen front securing bolts -4- on left and right but do not undo
completely.
– Undo rear securing bolts -3- on left and right.
– Lift out glass panel -1- upwards.
Note
In order to avoid damage during further work, close the mechanism with the push-button.
1.6 Adjusting sunroof panel


Passat 2015 ➤
Height-adjustment of glass panel
AG. Volkswagen AG d
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
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ion
c
in t
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ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Loosen securing bolts for glass panel.

– Operate glass panel of panorama tilting roof so that it moves
to “open” position.
– Operate glass panel of panorama tilting roof so that it moves
to “closed” position.

Passat 2015 ➤
– Adjust height of glass panel at front and rear on both sides as

follows:
Front panel adjustment:
-Dimension a- = 1 mm lower than roof assembly frame -3-.
– Press the inner seal to one side.
– Tighten the front inside bolts.
Rear panel adjustment:
-Dimension b- = 1 mm above roof profile -2-
– Tighten the rear inside bolts.
– Open panel and tighten the rear bolts.
Note
♦ To achieve the best possible optical appearance, ensure that adjustments on left and right are uniform
(symmetrical).
AG. Volkswagen AG d
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♦ The glass panel should not be higher than the roof
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Specified torques ss
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♦ Glass panel ⇒ page 213
du
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1.7 Removing and installing guide plate
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♦ The guide rails and the securing brackets are one component.
agen
Prote AG.
♦ The cables and the tilting mechanism are integrated in this component and cannot be replaced separately.

Passat 2015 ➤
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nform
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headliner .
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– Release wiring harness.

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– Mark position -4- of guide rails -1- on sliding sunroof frame

p
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-3-.
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– Unscrew bolts -2-. C py
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by
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Prote AG.

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
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– Low guide rails -1- at rear -arrow a-.
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– Pull guide rails -1- in parallel movement off sliding sunroof
fo
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frame -2- -arrow b-.

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Note
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Prote AG.
Do not twist or bend the guide rails and securing bracket as there is no strut in the front area.
Installing

Passat 2015 ➤
AG. Volkswagen AG d
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nl
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– Push guide rails -1- into sunroof panel -2-, keeping them par‐ cted agen
Prote AG.
allel to each other.
– Fit guide rails -1- on sunroof panel at rear.

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
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nl
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– Insert bolts -2- and tighten slightly.

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– Align guide rails -1- in accordance with the marking made pre‐
in t
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– The remaining installation steps are carried out in the reverse
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Specified torques
♦ Guide rails ⇒ page 213

agen
AG. Volkswagen AG d
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Passat 2015 ➤
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1.8 Removing and installing front trim for
h eo
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sliding sunroof
s
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nl
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⇒ “1.8.1 Minimum curing period”, page 239
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⇒ “1.8.3 Cleaning in the event of dirt caused by adhesive sealant”,
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t to the co
⇒ “1.8.5 Preparing front trim for installation”, page 240
⇒ “1.8.6 Preparing sliding sunroof frame for installation of front
rrectness of i
trim”, page 241
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⇒ “1.8.7 Removing and installing front trim for sliding sunroof”,

page 241
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1.8.1 Minimum curing period
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♦ There are special requirements for renewing bonded front
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trims.
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♦ The vehicle is safe to use only after the minimum curing period rig ht
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has elapsed.
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Prote AG.

The minimum curing period for the 1-pack window adhesive is
24 hours.
The minimum curing period is the time from bonding the wind‐
screen in until the vehicle may be used. During this time, the
vehicle must be standing on a level surface at room temperature
(at least 15°C).

– Apply adhesive sealing material in continuous bead, holding
applicator at right angle to front trim.
Note
♦ The front trim must be fitted within 10 minutes.

♦ Otherwise, the adhesive properties of the window adhesive
will be impaired.
♦ Fit front trim into aperture, align it, and press it in as far as
spacer rib.

Passat 2015 ➤
1.8.3 Cleaning in the event of dirt caused by

adhesive sealant
– Adhesive remover works well as a cleaning solution. Safety
precautions must be observe for all work procedures.
– First, clean the painted surface roughly with a lint-free cloth.
Remove residue using adhesive remover .
– Cleaning plastic trim: Allow adhesive sealant to cure (approx.
1.8.4 Materials
Note

♦ 1-pack win‐ 5) 1 6) 2
dow adhesive
♦ Primer 6) 1
♦ Cleaning solution 6) 1, 7) 3
♦ Applicator
♦ Adhesive remover 6) 1
♦ Cutting cord 8) 4
♦ Wire reel VAS AG. Volkswagen AG d

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♦ Cutting cord auth 8) 4 eo
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5) Observe manufacturer's instructions enclosed in the packaging.

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6) Observe minimum drying time ⇒ page 239 .

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7) Note drying time ⇒ page 241 .

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8) Cutting cords can be used alternatively to cutting wires, and vice versa. They
are designated for single use.

t to the co
1.8.5 Preparing front trim for installation

rrectne
Note
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♦ The area in which the adhesive bead is to be applied is marked

cial p
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on the front trim.

form
mer
♦ The application area for the adhesive bead is not precoated

atio
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or primed.
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– Clean around primer/bonding surface -3- using cleaning sol‐

iv
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pr
ution .
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– Then rub primer/bonding surfaces -3- using a lint-free cloth.
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rig ht
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by lksw
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Prote AG.

Passat 2015 ➤
– Using applicator -2-, apply primer evenly in one pass.

♦ Allow to air dry for approx. 10 minutes.
1.8.6 Preparing sliding sunroof frame for in‐

stallation of front trim
G. Volkswage
♦ Do not treat bonding surface with activator,
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♦ The remaining material is required
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or
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– Cut back remaining material using scraper set - VAS 861 005-
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NOTICE
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1.8.7 Removing and installing front trim for

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Prote AG.

Passat 2015 ➤
♦ Double cartridge gun - VAS 5237-
AG. Volkswagen AG d
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♦ Or hand cartridge gun - V.A.G 1628- horis nte
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♦ Electric cutter - V.A.G 1561A-
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♦ Saw blade, 80 mm in diameter - V.A.G 1561/26-
nf
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pyri by
Vo
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Prote AG.
♦ Either removal kit for flush bonded windows - V.A.G 1474 A-

♦ Or window removal set - VAS 6888- .
♦ Or wire reel - VAS 6452/1- .
♦ Scraper set - VAS 861 005-

Passat 2015 ➤
♦ Or scraper set - VAS 852 005-

AG. Volkswagen AG d
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Removing
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Note
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♦ The front trim is damaged when it is removed and cannot be

reused.
nform
ercia
♦ Protect any surrounding components against damage.

m
a
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♦ The glass panel is not to be removed. The installation position
n in
r
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of the glass panel is required as a reference for determining
thi
s
the height when installing the front trim.
iva
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Passat 2015 ➤ yV
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b ua
General body repairs, exterior - Editionrise03.2019
d ran
tee
tho
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a ac
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un
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d
itte
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ab
pe
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com
tion in
r
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Pull seal off front trim -1-.

– Bond windscreen seal to windscreen, and press it on firmly.
– Mark a line on the trims at a distance of -b- = 10 mm from the
edges.
– Mark a line on both sides at a distance -a- = 30 mm from the
rear edge.
Note
Due to the small clearance between the front trim and the frame, only make a cut with a max. depth of 5 mm.
– Using electric cutter - V.A.G 1561A- -5- and saw blade, 63 mm

in diameter - V.A.G 1561/25- -6-, separate front trim along
markings -3 and 4-.
– Make a cut with a width of approx. 5 mm along line -4- in front
area on left and right to allow for insertion of cutting cord.
– With front trim edges removed, the adhesive beads of the trim
are accessible.

lkswage es n Passat 2015 ➤
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byV General body repairs, ua exterior - Edition 03.2019
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rrectness of i
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
Seal -4- has been pulled off.

– Insert cutting cord -1- all round on one side, and secure it to
wire reel - VAS 6452/1- .
– Cut through adhesive bead -3-, and remove part of front trim
-2-.
– Fit wire reel - VAS 6452/1- on other side, and repeat the pro‐
cedure.

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
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d by ara
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– Secure a handle -1- from window removal kit - V.A.G 1755- to

nl
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each end of cord -2-.
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The cutting of the adhesive bead is only possible with the help of
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– Or work is carried out e.g. with wire reel - VAS 6452/1- -6-.
hole
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t to the co
Note
♦ There are 3 adhesive beads on the roof cross member and increased resistance will be encountered here.
rrectness of i
♦ If the handles are used, make even sawing movements -arrow-.

l purpos
– Now, cut through adhesive beads -5- on roof cross member at

nform
ercia
front as far as the middle -3- on one side.

m
at
om
– Then, cut through adhesive beads as far as the middle -3- on

ion
c
the other side.

in t
or
his
ate
– Remove front trim -4-.

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for
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pyri by
Vo
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by c lksw
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Prote AG.

Passat 2015 ➤
Note
See the markings on the front trim for the exact position of the adhesive beads.
Installing
AG. Volkswagen AG d
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• The glass panel has been built into the frame.

nform
ercia
– Prepare sliding sunroof frame for installation of front trim

m
at
⇒ page 241 .
om
ion
c
in t
– Prepare front trim -1- for installation ⇒ page 240 .

or
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for
– Clean around bonding surface -2- thoroughly, using cleaning

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t.
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solution .
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– Using applicator, apply primer evenly in one pass.
rig by
copy Vo
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– Note drying time for primer ⇒ page 241 .
agen
Prote AG.
– Apply adhesive.
Width of adhesive bead: 8 mm.

Passat 2015 ➤
Height of adhesive bead: 12 mm.

– Insert trim into roof aperture and centre it. Fix in place with
adhesive tape.
– Note minimum curing period for adhesive ⇒ page 239 .

motor -V1-
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Removing
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nf
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n in
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Cop py
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co lksw
by
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Prote AG.

Passat 2015 ➤
General
en AG. Vobody
lkswagrepairs,
en AG exterior - Edition 03.2019
ag does
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un
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d
itte
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is n
h re
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
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n
c
i
or
n thi
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sd
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pr
cum
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fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– If drive is defective, remove glass panel ⇒ page 231 .
– If fitted, pull off self-adhesive insulation -3-.
– Pull out cover upwards at an angle -arrows-.

Passat 2015 ➤
lkswage es n
o ot g
byV ua
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ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Switch off ignition, remove key, and open door.

• This situation must be maintained until drive has been instal‐
led.
• Remove and install drive for glass panel only when roof is
closed (zero position).
– Disconnect connector -2- at drive -1-.
– Unscrew bolts -3-, and pull off drive -1-.
Installing
Note
The bolts for the drive are microencapsulated and must always be renewed.

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
– Plug in connector -2- at drive -1-. Prote
cted AG.
agen
– Fit drive -1-, and tighten bolts -3-.

– After installation, the key can be inserted in ignition and starter
switch again.
– Then test for proper function.

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Push cover onto assembly frame.

rrectness of i

l purpos
– When pulled off beforehand, reattach self-adhesive insulation

-3-. If necessary, attach new insulation.
nform
ercia
Specified torques
m
♦ Sliding sunroof adjustment control unit - J245- ⇒ page 213

at
om
ion
c
♦ Cover ⇒ page 213

in t
or
his
ate

do
priv
cum
or
adjustment control unit - J245-

f
en
ng
t.
yi Co
op py
Special tools and workshop equipment required t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Passat 2015 ➤
Removing
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Pull self-adhesive insulation -3- off.

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
– Release retaining hooks -3- -arrows a-. s au ra
c
s
ce
e
– Slightly lift control unit -1-, and pull it out of bracket -2-
nl
pt
du
-arrows b-. an
itte
y li
erm
ab
– Disconnect connectors -4- from control unit -1-. ility
ot p
wit
Installing
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
254
cted agen
Prote AG.
Rep. gr.60 - Sunroof
Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
– Connect connectors -4- on control unit -1-.

rm
ab
pe
ility
– Push control unit -1- into mountings -2-.

ot
wit
, is n
h re
– Push control unit into retaining hooks -3- until retaining hooks
hole
spec
engage -arrows a-.

es, in part or in w
t to the co
– Code new control unit. ⇒ Vehicle diagnostic tester

rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co

rrectness of i
– Attach self-adhesive insulation -3-.

l purpos
Specified torques
nf
ercia

orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat 2015 ➤
1.11 Operating without current
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
Removing yri
p by
o Vo
by c lksw
cted
agen
Prote AG.

Installing
– Attach self-adhesive insulation -3-.
Specified torques

Passat 2015 ➤
Note
G. Volkswage
♦ In the event of power failure, the sliding/tilting
lksw
agen
A
sunroof with glass
n AG d
oes panel can be moved using a commercially
available hexagon key directly bon y V the drive.
o n ot g
d ua
ran
ise
♦ Considerable force mustubetho used to turn the key because
r
the drive is tnot
ee decoupled
or from the gears.
s a ac
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Insert hexagon key into the bolt -3- of the drive -1-.
– Turn the bolt -3- to close the glass panel.

Passat 2015 ➤

seals
⇒ “1.12.1 Removing and installing seal for sliding sunroof frame”,
page 259
⇒ “1.12.2 Removing and installing glass panel seal”, page 260
1.12.1 Removing and installing seal for sliding sunroof frame
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
Removing
gh ht
pyri by
Vo
o
by c lksw
– Remove glass panel ⇒ page 226 . cted agen
Prote AG.
– Pull seal -1- out of assembly frame -2-.

Installing
– Align interior seal -1- with vulcanisation point facing towards
curve on assembly frame -3- -arrows a-.
– Lip of seal -arrow b- must face outwards.
Press interior seal -1- uniformly into mounting slot of assembly
frame -2-.

Passat 2015 ➤
1.12.2 Removing and installing glass panel seal
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
Removing cted agen
Prote AG.
– Open glass panel.

– Pull seal -2- off glass panel -1-.
Installing
– Align seal -2- on outer edges of glass panel -1- -arrows-.
– Press seal -2- into mountings of glass panel -1-.
1.13 Removing and installing sunroof roller

blind

Passat 2015 ➤
♦ Torque wrench 210 Nm - VV.A.G

olkswa
1783-
n AG. gen AG
wage does
Volks not
gu
by ara
ed nte
oris eo
th
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Removing
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Undo screws -3- and remove handle -4-.
Note
♦ If the sun blind is to be reused, it is vital to ensure that the steel strips are not kinked.
♦ If a steel strip is kinked, a new sun blind has to be fitted.

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Lift sun blind -1- at rear left and right -arrow a- and push evenly
towards rear -arrow b-. Then pull out of guide rails -2-.
– Push slider -3- into rib -arrow c- and remove from guide
-arrow d-.
– Remove sun blind -1- from assembly frame.
If required for subsequent work, the tension bow can be removed
from sun blind ⇒ page 267 .
Installing
Note
♦ When installing the sun blind, it is vital to ensure that the steel strips are not kinked.
♦ If a steel strip is kinked, a new sun blind has to be fitted.

Passat 2015 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
o
• Tension bow is installed ⇒ page 267
au .
th or
ac
ss
– Insert right and left carriers -2- into guide rails -3- -arrow a-.
ce
le
un
pt
an
d
– Make sure that carriers are in correct position at top

itte
y li
erm
-arrow b- and bottom -arrow c- on guide rail -3-.

ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
264
by lksw
cted agen
Rep. gr.60 - Sunroof Prote AG.
Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Insert slide -2- into guides -arrows a-.

– Make sure that the sliders are in correct position in relation to
guide rails.

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co

rrectness of i
– Fit handle -4- and tighten screws -3-.

l purpos
Specified torques
nf
ercia
♦ Sunroof roller blind ⇒ page 215

orm
m
atio
m
♦ Handle ⇒ page 215

o
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
– Push cover onto assembly frame. t to the co

rrectness of i
l purpos
– When pulled off beforehand, reattach self-adhesive insulation

-3-. Use new insulation if necessary.
nf
ercia
Specified torques
rm
m
atio
m
♦ Cover
o
n in
or c
thi
Removing and installing tension bow

te
sd
iva
o
r
Removing:
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Removing sliding sunroof roller blind ⇒ page 260 .
– Pull slider -2- on left and right out of tension bow -4-
-arrows a-.
– Pull off tension bow from fabric of sliding sunroof roller blind
-6- -arrow b-.
Installing:

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
– Push tensioning wire -5- into sun blind fabric -6-. cted agen
Prote AG.
– Push tension bow -4- onto fabric of sun blind.

– Push slider -2- with spring -3- into tension bow.
quence of removal.

Passat 2015 ➤
1.14 Programming sliding sunroof adjustment control unit -J245-
Note
lkswage es n
ot g
If a glass panel, motor or tilt mechanism have been renewed, y V adaption needs to be performed.
o
♦ d b ua
ran
ir se tee
♦ Programming function is switched off when establishinguth reference points.
o
or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Establishing reference points of sliding sunroof motor

Ignition is switched on.
– Push button forwards -arrow b-, and hold in this position during
entire programming process (approx. 20 sec).
– When establishing reference points, glass panel first closes
and then moves approx. 200 mm towards the rear.
– Once panel has closed again, normalisation is finished and
button can be released.

Passat 2015 ➤
2 Water drain hoses

⇒ “2.1 Assembly overview - water drainage hoses”, page 271
⇒ “2.2 Cleaning water drainage hoses”, page 271
⇒ “2.3 Removing and installing water drain hoses”, page 273
2.1 Assembly overview - water drainage ho‐

ses
Note
In this vehicle, only the rear water drain hoses are fitted.
1 - Rear water drain hose

❑ Left and right
❑ Cleaning ⇒ page 271 .
⇒ page 273
2 - Clip
3 - Marking
❑ Hose must be pushed
up to the marking into
the drain grommet
4 - Rear drain grommet
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
e
2.2 Cleaning water drainage hoses

t
sd
iva
o
r
rp
cu
o

f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Water drain hoses 271

Passat 2015 ➤
♦ Cleaning and fitting tool - VAS 6620-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
Note
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
The rear water drainage hoses -1- run through the C-pillars and
end in the rear wheel housings.
– Remove rear wheel housing liners ⇒ page 403 .

Passat 2015 ➤
– Cleaning for all models is carried out from bottom drain grom‐
met -4- with the cleaning and pull-in cable - VAS 6620- .
2.3 Removing and installing water drain ho‐

ses
Note
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Remove C-pillar trim ⇒ General body repairs, interior; Rep.

gr. 70 ; Trims, interior; Removing and installing C-pillar trim .
m
at
om
io

n
c
in t
r

o
his
te
headliner .
a
do
priv
cum
or
– Pull rear water drain hose -1- out of clips -2- and out of drain
f
en
ng
grommets -4-.
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Water drain hoses 273

Passat 2015 ➤
63 – Bumpers y Volksw
agen
AG. Volkswagen AG d
oes
not
gu
d b ara
rise nte
1 Bumper, front tho eo
au ra
ss c
ce
le
⇒ “1.1 Assembly overview - bumper cover”, page 274
un
pt
an
d
itte
⇒ “1.2 Assembly overview - add-on parts”, page 276
y li
rm
ab
pe
ility
⇒ “1.3 Assembly overview - impact bar”, page 281
ot
wit
⇒ “1.4 Removing and installing bumper cover”, page 282 , is n
h re
hole
spec
⇒ “1.5 Removing and installing add-on parts”, page 285
es, in part or in w
t to the co
⇒ “1.6 Repairing bumper cover”, page 286
⇒ “1.7 Installing brackets for parking aid system”, page 287
rrectness of i
⇒ “1.8 Installing brackets for park assist steering”, page 291
l purpos
1.1 Assembly overview - bumper cover
nform
ercia
Optional equipment Volkswagen R GmbH

m
a
com
tion in
Note
r
te o
thi
s
iva
do
Minor differences may be encountered in respect of bumper cover, depending on vehicle model.
r
rp
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en
ng
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Cop py
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pyri by
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by
cted agen
Prote AG.
274 Rep. gr.63 - Bumpers

Passat 2015 ➤
1 - Bumper cover
❑ Material PP/EPDM.
❑ Different versions; for agen
AG. Volkswagen AG d
oes
allocation refer to ⇒ Volksw not
gu
y
Electronic parts cata‐ d b ara
ise nte
logue “ETKA” thor eo
au ra
❑ Removing and installing ss c
⇒ page 282
ce
e
nl
pt
du
an
itte
2 - Bolts
y li
erm
ab
❑ Left and right
ility
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wit
❑ Points upwards.
, is n
h re
❑ 2 Nm
hole
spec
es, in part or in w
3 - Bolts
t to the co
❑ Up to 4 on each side de‐
pending on version
rrectness of i
❑ Bolted to wheel housing
liner.
l purpos
❑ 2 Nm
4 - Bolts
nform
ercia
❑ Qty. 3
m
at
om
i
on
c
in t
liner.
or
his
ate
❑ 2 Nm
do
priv
cum
or
5 - Bolts
f
en
ng
t.
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❑ Qty. 2 t. Cop py
rig
❑ Bolted to lock carrier.
gh ht
pyri by
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co
❑ 2 Nm
by lksw
cted agen
Prote AG.
❑ Bolts ► 04/2019
❑ Clips 05/2019 ►
7 - Guide profile
❑ Left and right
1. Bumper, front 275

Passat 2015 ➤
1.2 Assembly overview - add-on parts

⇒ “1.2.1 Assembly overview - add-on parts”, page 276
⇒ “1.2.2 Assembly overview – add-on parts, GTE ”, page 278
⇒ “1.2.3 Assembly overview – add-on parts, R-Line ”, page 280
1.2.1 Assembly overview - add-on parts
Note
The attachments may be slightly different, depending on vehicle model, and these differences must be taken
into account.
1 - Bumper cover
⇒ page 282
Note
♦ On a new bumper cover, there

are transportation struts in area
of ventilation grille.
♦ The transportation struts must
be cut out before attachments
parts are installed.
2 - Headlight washer system

cover n AG. Volkswagen AG do
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❑ Left and right byV
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ua
d ran
ir se
3 - Reinforcing member tho tee
or
au ac
❑ Left and right ss
ce
e
❑ Engaged in front bump‐

nl
pt
du
an
er cover
itte
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erm
ab
❑ Can only be removed

ility
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with front bumper cover

wit
, is n
removed
h re
hole
4 - Bolts
spec
es, in part or in w
❑ 2 Nm
t to the co
❑ For securing bumper

cover
rrectness of i
5 - Number plate carrier

l purpos
❑ Installed only in selec‐

ted models available in
selected markets.
nform
ercia
❑ Different versions; for

m
at
allocation refer to ⇒
om
ion
Electronic parts catalogue “ETKA”

c
in t
or
his
e

at
do
priv
cum
or
Note
f
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ng
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op py
♦ The wires can run behind the
t. C rig
gh ht
holes for the clips in the bumper pyri by
Vo
co
cover.
by lksw
cted agen
Prote AG.

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tee 2015 ➤
ho
aut
or
ac 03.2019
ss
ce
e
nl
♦ Holes for clips must be drilled be‐
pt
du
an
fore installing the lines.
itte
y li
erm
ab
ility
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6 - Clips
wit
, is n
❑ Different number for securing.
h re
hole
spec
es, in part or in w
Note
t to the co
holes for the clips in the bumper
rrectness of i
cover.
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nf
ercia
o
7 - Centre air intake grille
rm
m
atio
m
❑ Different versions, allocation ⇒ Electronic parts catalogue “ETKA”

o
n in
or c
8 - Trim strip
thi
te
sd
iva
❑ Left and right
o
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cu
o
m
❑ Can only be removed with front bumper cover removed
f
en
ng
t.
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op
9 - Fog light trim C py
t. rig
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yri
❑ Left and right p by
co Vo
by lksw
❑ Pull forwards out of detent.
cted agen
Prote AG.

10 - Bolt
❑ 2 Nm
❑ Bolt ► 04/2019
❑ Clip 05/2019 ►
11 - Spoiler
12 - Clips
❑ For securing spoiler
13 - Trim strip
14 - Cover for towing eye

Passat 2015 ➤
1.2.2 Assembly overview – add-on parts, »GTE «
Note
The attachments may be slightly different, depending on vehicle model, and these differences must be taken
into account.
lkswage es n
o ot g
byV ua
1 - Bumper cover ir se
d ran
tee
o
❑ Material
au PP/EPDM.
th or
ac
ss
ce
e
nl
⇒ page 282
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

cover
❑ Left and right
nf
ercia
orm
3 - Bolts
m
atio
m
❑ 2 Nm
o
n in
or c
thi
❑ For securing support el‐

te
sd
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ement
iv
o
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4 - Reinforcing member
f
en
ng
t.
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❑ Left and right Cop py
t. rig
gh
❑ Engaged in bumper
ht
pyri by
Vo
o
cover from inside and
c by lksw
cted agen
screwed from outside Prote AG.
❑ Can only be removed

with front bumper cover
removed
5 - Daytime running lights
⇒ Electrical system;
Rep. gr. 94 ; Headlights;
Removing and installing
headlights .
6 - Bolts
❑ 2 Nm
❑ For securing daytime running lights
7 - Bolts
❑ 2 Nm
❑ For securing bumper cover
8 - Trim
❑ Left and right
❑ Engaged in bumper cover from inside

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
9 - Cover d by V gu
ara
ise nte
❑ Qty. 2 on thor each side eo
au ra
❑ Engaged
ss in bumper cover from inside c
ce
le

un
pt
an
d
itte
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10 - Bolts
erm
ab
ility
❑ 2 Nm
ot p
wit
is n
❑ Qty. 4
h re
ole,
❑ For securing number plate holder
spec
t to the co
Note
rrectne
cover.
ss
o
cial p
f
inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
Note en
ng
t.
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Cop py
t. rig
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yri by
cop Vo
by lksw
cover. cted agen
Prote AG.


13 - Trim strip
❑ Left and right
❑ Engaged in bumper cover from inside
14 - Rivets
❑ Qty. 10
❑ For securing reinforcement
15 - Spoiler
16 - Bolts
❑ 2 Nm
❑ Qty. 4
17 - Bolts
❑ 2 Nm
❑ Qty. 3
18 - Reinforcement

Passat 2015 ➤
1.2.3 Assembly overview – add-on parts, »R-Line«
1 - Bumper cover
⇒ page 282
Note


cover
❑ Left and right
❑ Installed only in selec‐
ted models available in
selected markets
❑ Different versions, allo‐
cation ⇒ Electronic
parts catalogue “ETKA”
⇒ page 285 n AG. Volkswagen AG do
lkswage es n
o ot g
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Note ir se
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ran
o tee
th or
u
♦ Thesswires can run behind the
a ac
ce
le
un
pt
cover.
an
d
itte
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erm
ab
ility

ot p
wit
is n
h re
4 - Clips
ole,
spec
❑ Different number for securing.

t to the co
Note
rrectne

cover.
ss o
cial p

inform

mer
atio
om
5 - End plate
n
c
i
or
n thi
❑ Left and right

te
sd
iva
o
pr
6 - Reinforcing member
cum
r
fo
en
ng
❑ Left and right

t.
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op py
❑ Engaged in front bumper cover t. C rig
gh ht
yri by
❑ Can only be removed with front bumper cover removed cop Vo
by lksw
cted agen
Prote
7 - Fog light cover
AG.
❑ Left and right

❑ Pull forwards out of detent.

Passat 2015 ➤
8 - Centre trim strip

9 - Trim strip
❑ Left and right
❑ Can only be removed when fog light cover is removed
❑ Cannot be removed without being damaged
10 - Trim for fog light cover
❑ Left and right
11 - Lower centre trim strip
12 - Lower trim strip
❑ Left and right
13 - End plate
❑ Left and right
14 - Spoiler
olkswagen AG
en AG. V
1.3 Assembly overview
yV
olks
wag - impact bardoes n
ot g
b ua
ed ran
Optional equipment Volkswagen
ho
ris R GmbH tee
t or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
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cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by
cted agen
Prote AG.

Passat 2015 ➤
1 - Impact bar
2 - Centre hex studs
3 - Guide profile
❑ Left and right
4 - Nuts
❑ 2 Nm
5 - Bolts
❑ 8 Nm agen
AG. Volkswagen AG d
oes
olksw not
6 - Bolts d by V gu
ara
ise nte
❑ Qty. 4 on each side uthor eo
a ra
❑ 55 Nm ss c
ce
e
nl
pt
du
an
itte
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8 - Bolt
erm
ab
ility
ot p
❑ Qty. 4
wit
, is n
❑ 8 Nm
h re
hole
spec
9 - Foam element
es, in part or in w
t to the co
❑ Is fitted onto impact bar
❑ Not installed in all model
versions
rrectness of i
10 - Pedestrian protection
l purpos
❑ Not installed in all mar‐

kets nf
ercia
11 - Pop rivet
rm
m
atio
m
❑ Left and right

o
n in
or c
❑ Insert with special pop

thi
e
rivet pliers - V.A.G 1753A-

t
sd
iva
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op
1.4 Removing and installing bumper cover C py
t. rig
gh ht
pyri by
co Vo
by lksw
cted agen
Prote AG.

Passat 2015 ➤
Note
♦ The removal and installation procedures for front bumper cov‐

er may have to be revised slightly depending on model varia‐
tions.
♦ The radiator grille may remain installed when removing and
installing the bumper cover.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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o
m
f
en
ng
t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
Removing
– Unscrew bolts of radiator grille ⇒ page 345 .
– Undo bolts -5- in wheel housing (pointing upwards) on left and
right.
– Unscrew bolts -5- on left and right.
– Unscrew bolts -6- from underneath.
ic.

Passat 2015 ➤
– Pull bumper cover -1- out of catches on guide brackets -4- on

wings on left and right -arrows a-. AG. Volkswagen AG d
agen oes
lksw not
– Pull rear bumper cover -1- out of catches in centre guide -2- d by Vo gu
ara
-arrows b-. orise nte
th eo
u ra
– Pull bumper cover -1- off vehicle in parallel movement ss a c
-arrow c-.
ce
e
nl
pt
du
an
– Detach washer fluid line hose couplings (if there are any) ⇒
itte
y li
Electrical system; Rep. gr. 92 ; Headlight washer system; As‐
erm
ab
ility
sembly overview - headlight washer system .
ot p
wit
, is n
– Disconnect connectors of electrical components (if present).
h re
hole
spec
General information and work instructions for the parking aid can
es, in part or in w
be found in ⇒ Electrical system; Rep. gr. 94 ; Parking aid .
t to the co
General information and work instructions for the Park Assist sys‐
tem can be found in ⇒ Electrical system; Rep. gr. 94 ; Park Assist
rrectness of i
system .
l purpos
For notes and work instructions on overhead view camera, see

⇒ Rep. gr. 91 ; Overhead view camera; Overview of fitting loca‐
tions - overhead view camera
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat 2015 ➤
Installing
Further installation requires thegeassistance
n AG. Volkswaof
gean Asecond
Gd mechanic.
wa oes
olks no
– Connect connectors
d b of all installed electrical components.
yV t gu
ar
e an
ris tee
utho or
a ac
Note ss
ce
le
un
pt
an
d
When positioning the bumper cover, make sure that the front wheel housing liner is correctly seated.
itte
y li
rm
ab
pe
ility
– Guide bumper cover -1- onto lock carrier -arrows a- in a par‐
ot
wit
, is n
allel movement until retaining hooks -6- engage.
h re
hole
spec
– Press bumper cover -1- onto guide brackets -2- on wing on left
es, in part or in w
and right until they engage with each other -arrows b-.
t to the co
– Observe gaps/shut lines ⇒ Body Repairs; Rep. gr. 00 ; Panel
gaps; Body – front .
rrectness of i
Specified torques
l purpos
♦ ⇒ “1.1 Assembly overview - bumper cover”, page 274
1.5 Removing and installing add-on parts
nform
mercia
a
⇒ “1.5.1 Installing front number plate carrier”, page 285
com
tion in
r
1.5.1 Installing front number plate carrier

te o
thi
s
iva
do
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cum
fo
en
g
Note
n
t.
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Cop py
t. rig
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♦ Number plate carrier is not installed in all models or in all markets.
ht
pyri by
Vo
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by
♦ Number plate carriers of different sizes are fitted in various markets.
cted agen
Prote AG.
♦ The height of the number plate carrier is specified by the contour to the bumper.
♦ The wires can run behind the holes for the clips in the bumper cover.
♦ Holes for clips must be drilled before installing the lines.
♦ Adherence to a depth of 12 mm is required when drilling holes.

Passat 2015 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
Holes exist
rm
m
atio
m
– Fit number plate carrier -3- to front bumper cover -2- and press
o
n in
c
in clips -4-.
or
thi
te
sd
iva
Holes do not exist

o
r
rp
cu
o
m
f
– Centre number plate carrier -3- on front bumper cover -2- rel‐
en
ng
t.
yi
ative to emblem -1-.
Co
Cop py
t. rig
gh ht
– Set bit stop of drill to 12 mm and drill holes. yri
p by
co Vo
by lksw
cted
– Fit number plate carrier -3- to front bumper cover -2- and press
agen
Prote AG.
in clips -4-.
1.6 Repairing bumper cover
Note
If bumper cover is damaged, determine whether plastic can be

repaired before renewing bumper.
Description under: ⇒ General Information; Body Repairs, General

Body Repairs ; Plastic repair procedures

Passat 2015 ➤
1.7 Installing brackets for parking aid sys‐

tem
♦ Installation tool for PDC bracket - VAS 6614-
♦ Drill bit - VAS 6614/4-
♦ Retrofit kit - VAS 6614C-
♦ Screw hole punch - VAS 6614/9-
Materials
♦ Cleaning solution - D 009 9) 1
401 04-
AG. Volkswagen AG d
agen oes
olksw not
V gu
9) Observe manufacturer's instructions
d by enclosed in the packaging. ara
rise nte
Installing brackets ut ho eo
ra
s a c
s
ce
e
nl
pt
du
Note
an
itte
y li
erm
ab
The brackets are installed after the bumper cover has been painted.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
The 4 markings for brackets -1- can be found on the inside of the
l purpos
bumper cover.
– If there are no markings, the centre point -2- must be deter‐
nf
ercia
mined.
orm
m
atio
m
– The holes must be drilled from the inside to the outside with
o
n in
c
the drill bit - VAS 6614/4- -3- from the supplied tool kit.
or
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Fit screw-hole punch - VAS 6614/9- with bolt head -1-, washer
-2- and counter-support -3- from inside of bumper cover -5-.
– Screw on punch -4-, not quite as far as bumper cover.
– Press punch -4- against bumper cover.
– Tighten hole puncher -1-.
Note
Do not permit the punch -4- to turn on the paint of the bumper cover.
– Pull punch -4- through material of bumper cover -5- -arrows-

by turning bolt head -1-.
– Remove hole punch and make next holes.
– Thoroughly clean bumper cover and bracket with cleaning sol‐
ution.

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Thoroughly clean bonding surfaces on bumper cover -4-.
rrectne
– Push bracket -2- onto centring pin -1-.
– Pull off backing from double-sided adhesive tape -3- on re‐
tainer. ss o
cial p
f in
– Insert centring pin -1- into hole until the bracket is touching the
form
mer
bumper cover -4-.

atio
m
– Press bracket forcefully against bonding surface -3-.

o
n
c
i
or
n thi
e
– Removing centring pin and repeat the procedure for all brack‐
t
sd
va
ets.
i
o
pr
cum
r
fo
en
– Further work can carried out on bumper cover only after min‐
ng
t.
yi Co
imum curing period 10)
. t. Cop py
rig
gh ht
10) Minimum curing period yri
p by
o Vo
by c lksw
Do not carry out any further work on the bumper cover or brackets
cted agen
Prote AG.
until the minimum curing period of 2 hours has expired.
The minimum curing period must be observed so that the adhe‐
sive tape can develop its full adhesive strength.
In this time, the bumper cover must remain where it is. Do not
move it.

Passat 2015 ➤
1.8 Installing brackets for park assist steer‐

ing
♦ Assembly tool for park assist steering sensors - VAS 895 003-
Materials
401 04-
Installing brackets
Note
The brackets are installed after the bumper cover has been pain‐
ted.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat 2015 ➤
bumper cover.
mined.
the drill bit - VAS 6614/4- -3- from the supplied tool kit.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Fit assembly tool for park assist steering sensors - VAS 895
rrectness of i
003- , hole punch with bolt head -1-, washer -2- and counter-
support -3- from inside of bumper cover -5-.
l purpos

nform
ercia

m

a
com
tion in
r
te o
thi
s
Note
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh
ht
pyri by
co Vo
by lksw
cted agen
Prote AG.

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
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ce
le
un
pt
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d
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erm
ab
ility
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wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
r
fo
en
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t.
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op
– Thoroughly clean bonding surfaces on bumper cover -4-. C py
t. rig
gh ht
yri by
– Pull off backing from double-sided adhesive tape -3- on re‐ cop Vo
by lksw
tainer. cted agen
Prote AG.
– Place retainer -2- on bumper cover -4-.

– Repeat work steps for all retainers.
imum curing period ⇒ page 293 .
Minimum curing period
The minimum curing period must be observed so that the adhe‐
move it.

Passat 2015 ➤
2 Bumper, rear
⇒ “2.1 Assembly overview - bumper cover”, page 294
⇒ “2.2 Assembly overview - bumper guides”, page 295
⇒ “2.3 Assembly overview - add-on parts”, page 296
⇒ “2.4 Assembly overview - impact bar”, page 298
⇒ “2.5 Removing and installing bumper cover”, page 298
⇒ “2.6 Removing and installing impact bar”, page 301
⇒ “2.7 Repairing bumper cover”, page 303
⇒ “2.8 Installing brackets for parking aid system”, page 304
⇒ “2.9 Installing brackets for park assist steering”, page 308
2.1 Assembly overview - bumper cover

Note
Minor differences may be encountered in respect of bumper cover, depending on vehicle model.
1 - Bumper cover agen

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❑ Material PP/EPDM. d by
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❑ Different versions, allo‐ hor eo
ut
cation ⇒ Electronic ss a ra
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ce
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nl
pt
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⇒ page 298
erm
ab
ility
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2 - Bolts
wit
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❑ Left and right

h re
hole
❑ Points upwards.
spec
es, in part or in w
❑ Bolted to side panel. t to the co
❑ 2 Nm
3 - Bolts
rrectness of i

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liner.
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❑ 2 Nm
orm
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atio
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4 - Bolts
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❑ Bolted to spoiler
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❑ 2 Nm
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5 - Bolts t. Cop py
rig
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❑ Bolted to underbody
lksw
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covers
AG.
❑ 2 Nm
6 - Spreader rivet
❑ Qty. 3 or 5, depending
on type

Passat 2015 ➤

8 - Guide profile
❑ Left and right
9 - Guide profile
❑ For tail light on left and right
2.2 Assembly overview - bumper guides

Note
Different versions; for allocation refer to ⇒ Electronic parts catalogue “ETKA” .
AG. Volkswagen AG d
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1 - Impact bar by Vo gu
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2 - Bolts uthor eo
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❑ Qty. 3 left ss c
ce
e
nl
❑ Qty. 4 right
pt
du
an
itte
❑ 55 Nm
y li
erm
ab
ility
3 - Nuts
ot p
wit
, is n
❑ Qty. 2 on each side for
h re
guide bracket with tail
hole
spec
light
es, in part or in w
t to the co
❑ Qty. 4 for centre guide
bracket
❑ 3.5 Nm
rrectness of i
4 - Guide profile
l purpos
❑ Left and right

❑ Is installed together with
nf
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tail light
rm
m
atio
m
5 - Bracket
o
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or c
❑ Not fitted on all versions

thi
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❑ Left and right

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6 - Bolts
f
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t.
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❑ Only when bracket -5- is t. Cop py
installed
rig
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❑ Qty. 2
co lksw
by
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❑ 6 Nm
AG.
7 - Bolts
❑ For lateral guide.
❑ 6 Nm
8 - Guide profile
❑ Left and right
9 - Expanding nuts
2. Bumper, rear 295

Passat 2015 ➤
2.3 Assembly overview - add-on parts

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⇒ “2.3.1 Assembly overview V- oadd-on
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⇒ “2.3.2 Assembly overview
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ise – add-on parts, R-Line ”, page 297 antee
th or
au
2.3.1 Assembly overview - add-on parts
ac
ss
ce
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nl
pt
du
an
itte
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1 - Bumper cover
erm
ab
ility
ot p
wit
, is n
h re
hole
⇒ page 298
spec
es, in part or in w
2 - Bolt
t to the co
cover
rrectness of i
3 - Bolt
l purpos

cover
nf
ercia
4 - Expansion nut
orm
m
atio
5 - Towing eye cap
om
n in
c
or
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cover
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❑ In various markets
t.
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Cop py
t.
7 - Spreader rivet
rig
gh ht
pyri by
Vo
❑ Qty. 4 minimum
o
by c lksw
cted agen
Prote AG.
8 - Spoiler
❑ Material PC/ABS
cover
❑ Only remove when
bumper cover is re‐
moved
9 - Bolt
10 - Spreader rivet
11 - Cover
❑ Left and right
❑ Engaged in bumper cover
❑ Only remove when bumper cover is removed
12 - Trim strip
❑ 3 parts, left, right and centre

Passat 2015 ➤
13 - Cover
❑ Left and right
14 - Frame
❑ Left and right
15 - Dampers
❑ Cut to size according to template
2.3.2 Assembly overview – add-on parts, »R-Line«
1 - Bumper cover
⇒ page 298
2 - Dampers
❑ Cut to size according to
template
3 - Towing eye cap
cover
4 - Bumper brackets
❑ Left and right agen
AG. Volkswagen AG d
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5 - Number plate carrier ed by
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ara
is nte
❑ In various markets ut
hor eo
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❑ Different versions, allo‐ ss c
cation ⇒ Electronic ce
le
un
pt
parts catalogue “ETKA” an
d
itte
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erm
ab
6 - Spreader rivet ility
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❑ Qty. 4 minimum
wit
is n
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ole,
7 - Trim strip
spec
❑ Left and right

t to the co
cover
rrectne

moved
ss o
8 - Centre trim strip

cial p
f inform
mer
cover
atio
om

n
c
i
or

thi
te
sd
moved
iva
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pr
cum
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9 - Bumper brackets
fo
en
ng
t.
yi
❑ Left and right
Co
Cop py
t. rig
gh
10 - Rear trim panel
ht
pyri by
Vo
o
by c lksw
❑ Left and right Prote
cted AG.
agen
❑ Engaged in bumper bracket

11 - Spoiler
❑ Material: PP+EPDM-TD10
2. Bumper, rear 297

Passat 2015 ➤
12 - Rear spoiler trim
❑ Material: PP+EPDM-TD10
❑ Engaged in spoiler
2.4 Assembly overview - impact bar

1 - Impact bar
⇒ page 301
❑ Vehicles with towing
bracket ⇒ page 418
2 - Cross panel
3 - Bolts
❑ Qty. 4 right
❑ Qty. 3 left
❑ 20 Nm +90°
lkswage es n
o ot g
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ir se tee
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a ac
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nl
pt
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ab
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
2.5 Removing and installing bumper cover

nf
ercia
or

m
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Note
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The removal and installation procedures for the bumper cover

o
m
f
en
ng
may vary slightly, depending on vehicle model.

t.
yi Co
Cop py
t. rig
gh ht
Special tools and workshop equipment required pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
Removing
m
atio
om
n in
c
– Remove tail lights in side panel ⇒ Electrical system; Rep. gr.

or
thi
94 ; Tail lights; Removing and installing tail light .

te
sd
iva
o
r
– Undo bolts -3- in wheel housing (pointing upwards) on left and

rp
cu
o
right.
f
en
ng
t.
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op
– Remove bolts -4- on left and right sides in area of wheel hous‐
C py
t. rig
gh
ing liner.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Bumper, rear 299

Passat 2015 ➤

– Remove spreader rivets -7- from underneath.
ic.
– Pull bumper cover -1- out of guide fasteners on left and right
-2- of side panel -arrows a-.
– Detach rear bumper cover -1- from catches below tail lights
and in centre -arrows b-.
– Pull bumper cover -1- off vehicle in parallel movement
-arrows c-.
– Disconnect connectors from installed electrical components.
General information and work instructions for the parking aid can
be found in ⇒ Electrical system; Rep. gr. 94 ; Parking aid .
General information and work instructions for the Park Assist sys‐
tem can be found in ⇒ Electrical system; Rep. gr. 94 ; Park Assist
system .
AG. Volkswagen AG d
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byV gu
ara
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ris nte
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aut ra
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ce
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un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
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fo
en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Passat 2015 ➤
Installing
Further installation requires the assistance of a second mechanic.
– If present, connect connectors to electrical components.
– Guide bumper cover -1- onto vehicle in a parallel movement
-arrows a-.
– Press bumper cover -1- onto guide brackets in centre as well
as on left and on right below tail light -2- until it engages in
guide brackets -arrow b-.
– Press bumper cover -1- onto guide brackets on left and right
-5- of side panel until it engages in guide brackets -arrow c-.
– Observe gaps/shut lines ⇒ Body Repairs; Rep. gr. 00 ; Panel
gaps; Body – rear .
– Push on spreader rivets -8- from below.
– On vehicles with lane change assist, the rear radar system
must be calibrated following every removal and every instal‐
lation ⇒ Electrical system; Rep. gr. 96 ; Lights, bulbs, switches
– interior, anti-theft protection; Lane change assist .
Specified torques
♦ ⇒ “2.1 Assembly overview - bumper cover”, page 294
2.6 Removing and installing impact bar

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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nl
pt
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ab
ility
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hole
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es, in part or in w
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Bumper, rear 301

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
– Lift impact bar -1- upwards -arrow- out of tabs in cross panel
-2-.

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
Installing
atio
m

o
n
c
i
or
n thi
e
– Guide guides of impact bar -1- from top to bottom -arrow- into
t
sd
va
tabs in cross panel -2-.

i
o
pr
cum
r
fo
en

ng
t.
yi Co
op py
Specified torques
. C rig
ht ht
rig by
py
♦ ⇒ “2.4 Assembly overview - impact bar”, page 298
co Vo
by lksw
cted agen
Prote AG.
2.7 Repairing bumper cover
Note
♦ If bumper cover is damaged, determine whether plastic can

be repaired before renewing bumper.
♦ On vehicles with lane change assist, lane change assist con‐
trol units - J769 / J770- are located behind bumper cover.
♦ With this equipment, the bumper cover may not be repaired in
this area. The bumper cover must be renewed in this instance.
2. Bumper, rear 303

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
Passat 2015 ➤ rised
nte
o eo
aut
h
exterior - Edition 03.2019 ra
ss c
ce
le
Description under: ⇒ General Information; Body Repairs, General
un
pt
an
d
Body Repairs ; Plastic repair procedures
itte
y li
erm
ab
2.8 Installing brackets for parking aid sys‐
ility
ot p
wit
tem
is n
h re
ole,
spec
t to the co
♦ Installation tool for PDC bracket - VAS 6614-
rrectne
♦ Retrofit kit - VAS 6614C-
♦ Screw hole punch - VAS 6614/9-
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Materials
401 04-
Installing brackets
Note
The brackets are installed after the bumper cover has been painted.

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
bumper cover.
rrectness of i
mined.
l purpos
– Holes must be drilled from inside out with drill bit - VAS 6614/4-
-3- from tool kit supplied.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
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t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Bumper, rear 305

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
– Fit screw-hole punch - VAS 6614/9- with bolt head -1-, washer
ility
ot p
-2- and counter-support -3- from inside of bumper cover -5-.

wit
, is n
h re

hole
spec

es, in part or in w
t to the co

rrectness of i
Note
l purpos
nform
ercia

m
at

om
ion
c
in t
r

o
his
ate
do
riv
– Thoroughly clean bumper cover and bracket with cleaning sol‐

p
cum
or
ution.
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re

hole
spec
– Push bracket -2- onto centring pin -1-.

es, in part or in w
t to the co

tainer.
rrectness of i
– Insert centring pin -1- into hole until the bracket is touching the
bumper cover -4-.
l purpos

nform
ercia
– Removing centring pin and repeat the procedure for all brack‐
ets.
m
a
com
tion in
r
te o
imum curing period 13)

.
thi
s
iva
do
r
13) Minimum curing period

rp
cum
fo
en
g
n
t.
yi Co
until the minimum curing period of 2 hours has expired. Cop py
ht. rig
rig ht
The minimum curing period must be observed so that the adhe‐ py by
co Vo
by lksw
cted agen
Prote AG.
move it.
2. Bumper, rear 307

Passat 2015 ➤
2.9 Installing brackets for park assist steer‐

ing
♦ Assembly tool for park assist steering sensors - VAS 895 003-
Materials
401 04-
Installing brackets
Note
The brackets are installed after the bumper cover has been pain‐
AG. Volkswagen AG d
ted. lkswagen oes
n o ot g
yV ua
edb ran
ris tee
tho or
au ac
ss ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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cu
o
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f
en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
bumper cover.

AG. Volkswagen AG d
agen oes
olksw not
d by
V
Passatgu 2015 ➤
ar
risGeneral body repairs, exterior - Edition a03.2019
e nte
ho eo
aut ra
ss c
ce
le
un
mined.
pt
an
d
itte
y li
rm
ab
pe
the drill in the tool kit -3-.
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Set hole puncher in position with bolt head -1-, washer -2- and
thrust bearing -3- from inside bumper cover -5-.
Note

2. Bumper, rear 309

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
tainer.
rrectness of i
– Place retainer -2- on bumper cover -4-.
l purpos

nf
ercia
– Repeat work steps for all retainers.

orm
m
atio
m
o
n in
c
imum curing period ⇒ page 310 .

or
thi
te
sd
a
Minimum curing period

iv
o
r
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cu
o
f
en
ng
t.
yi Co
Cop py
t. rig
The minimum curing period must be observed so that the adhe‐ gh ht
yri by
op Vo
by c lksw
cted agen
Prote AG.
move it.

Passat 2015 ➤
64 – Glazing
1 Repair instructions
⇒ “1.1 Minimum curing periods for bonded windows”, page 311
⇒ “1.2 Window repair”, page 311
⇒ “1.3 Installation instructions for bonded windows”, page 312
⇒ “1.4 Preparing old undamaged windows for fitting”, page 313
⇒ “1.5 Preparing new windows for installing”, page 313
⇒ “1.6 Preparing body flange for fitting”, page 315
⇒ “1.7 Cleaning off excess adhesive”, page 315
1.1 Minimum curing periods for bonded win‐

dows
Note
♦ There are special requirements for renewing bonded windows.

♦ The vehicle is safe to use only after the minimum curing period
has elapsed. agen
AG. Volkswagen AG d
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V gu
by ara
2-pack window adhesive rised
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ut
The minimum curing period for 2-pack windowssadhesive is 2 hours
a ra
c
for all windows.
ce
le
un
pt
an
The specified minimum curing period remains the same even if
d
itte
y li
1-pack window adhesive needs to be used for additional residual
erm
ab
work or for sealing purposes.
ility
ot p
wit
is n
Minimum curing period is the time from bonding the window until
h re
ole,
vehicle may be used. During this time, the vehicle must be stand‐
spec
ing on a level surface at room temperature (at least 15°C).
t to the co
The minimum curing period for 1-pack window adhesive is 6 hours
for all windows. rrectne
Minimum curing period is the time from bonding the window until
ss
vehicle may be used. During this time, the vehicle must be stand‐
o
cial p
ing on a level surface at room temperature (at least 15°C).

inform
mer
1.2 Window repair

atio
om
n
c
i
or
n thi
e
Note
t
sd
iva
o
pr
cum
r
fo
♦ Before renewing windscreen, explore possibilities of repairing

en
ng
t.
yi
damage to glass.
Co
Cop py
t. rig
gh
♦ Damaged windscreens can be repaired with the window repair
ht
pyri by
Vo
o
kit - VAS 6092- . by c lksw
cted agen
Prote AG.
♦ This damage must remain within a certain size or position.
♦ Each window repair kit comes with a set of instructions.
1. Repair instructions 311

Passat 2015 ➤ agen
AG. Volkswagen AG d
oes
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General body repairs, exterior
b y V - Edition 03.2019
ol
gu
a
ed ran
oris tee
♦ Window repair kit - VAS 6092-
au
th or
ac
ss
ce
le
un
pt
an
d
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1.3 Installation instructions for bonded win‐

dows
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– Apply adhesive sealing material -1- in continuous bead, hold‐

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ing applicator at right angle to window -2-. Cop py
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Note
agen
Prote AG.
Window must be installed within 10 minutes, or adhesive proper‐

ties of glass adhesive will be impaired.
♦ Adhere to the specified dimensions for the adhesive beads.

♦ Using 2 suction lifters - V.A.G 1344- , install glass pane in win‐
dow aperture, align to centre and press in onto spacing lip.
♦ Replace stickers (e.g. for airbag) if there were any.
1.3.2 Materials
Note

♦ 2-pack window adhesive 1) 2) 3)
♦ 1-pack window adhesive 1) 2)
♦ Activator 1)
♦ Primer 1)
♦ Cleaning solution 1)
♦ Primer applicator
312 Rep. gr.64 - Glazing

Passat 2015 ➤
♦ Adhesive remover 1)
♦ Cutting cord 357 853 999 4
♦ Wire reel VAS 4

6452/1
♦ Cutting cord 4
6888/1
1)Observe manufacturer'skinstructions enclosed in

dothe
. Volkswag
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en AG
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2) ris tee
Observe minimum
tho curing period ⇒ page 311 . or
au ac
3) ss
Double cartridge gun - VAS 5237- must be used to apply these
ce
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nl
materials.
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The cutting cords stated above can be used alternatively to the
ab
ility
cutting wires, and vice versa. They are designated for single use.
ot p
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1.4 Preparing old undamaged windows for
h re
hole
spec
fitting
es, in part or in w
t to the co
Cutting back adhesive bead
♦ If an undamaged window is being re-used, cut back the resid‐
rrectness of i
ual adhesive sealant to 1 to 2 mm shortly before bonding it
back in.
l purpos
♦ Do not damage primer and ceramic coating when doing this.

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♦ Do not treat bonding surface with activator, glass/paint primer

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– Apply activator evenly in one stroke using applicator . Prote
cted AG.
agen
NOTICE
Allow to air dry for approx. 10 minutes.
1.5 Preparing new windows for installing
Note
♦ The application area for the adhesive bead is not precoated

or primed.
♦ The relevant area is a ceramic coating.
♦ No windows are precoated.
♦ The sealing lip is included with a new windscreen.

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Passat 2015 ➤ tho tee
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General body repairs, exterior - Edition 03.2019 ss
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– Using cleaning solution , clean edge of window all round to a
an
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width of 20 mm.
rm
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– Then rub edge of window dry using a lint-free cloth.
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– Using applicator -2-, apply primer -3- evenly in one pass onto
hole
ceramic coating -1-.
spec
es, in part or in w
t to the co
rrectness of i
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NOTICE
nform
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a
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ti
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♦ Allow to air dry for approx. 10 minutes.
do
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Cop py
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by
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Prote AG.

AG. Volkswagen AG d
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autho
General body repairs, exteriore o - Edition 03.2019
r ac
ss
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le
1.6 Preparing body flange for fitting
un
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♦ Do not damage primer and paintwork structure when doing
h re
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this.
spec
t to the co
♦ Do not treat bonding surface with activator, glass/paint primer
rrectne
ss o
– Cut back remaining material on body flange with U-shaped
cial p
f in
blade - V.A.G 1561/3- , but do not remove completely.
form
mer
atio
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NOTICE
Co
Cop py
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co
by lksw
cted agen
Prote
AG.
♦ If the window flange has been repaired or partially renewed,

the area concerned must be cleaned and primed again after
painting.
– Clean metal flange all around using cleaning solution .
– Then rub edge of window dry using a lint-free cloth.
– Apply glass/paint primer evenly in one pass onto paintwork
structure using applicator .
Note
It is possible that a laser weld seam lies outside the area of the
adhesive bead. In this case, the exposed weld seam must be
sealed with glass adhesive before bonding the window.
– If laser weld seam -3- on metal flange -4- is not covered by

existing adhesive bead -1-, coat laser weld seam -3- with pri‐
mer -3-. Then fill laser weld seam with glass adhesive -1-.
Touching up paint damage
Paint structure must be restored after damage to the paintwork
according to specifications in the “Paint” workshop manual.
1.7 Cleaning off excess adhesive

– Use adhesive remover as cleaning agent. Safety precautions
must be observe for all work procedures.

Passat 2015 ➤
Note
♦ When cleaning the vehicle interior, do not press freshly instal‐

led window outwards.
♦ Otherwise, the window will be detached.
AG. Volkswagen AG d
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– First, clean the painted surfacedroughlyby V with a dry cloth. Re‐ gu
ara
move residue using adhesive o riseremover . nte
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– Cleaning plastic trim: Allow
ss a
adhesive sealant to cure (approx. c
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tion in
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat 2015 ➤
2 Windscreen
⇒ “2.1 Assembly overview - windscreen”, page 317
⇒ “2.2 Removing and installing windscreen”, page 318
2.1 Assembly overview - windscreen
1 - Windscreen
⇒ page 318
2 - Water deflector
3 - PUR adhesive sealant
❑ Cross section of bead:
width = 7 mm
-dimension a-, height =
10 mm -dimension b-
(including precoating,
residual material on win‐
dow glass and window
flange).
❑ Minimum curing period
⇒ page 311 .
❑ Adhesive bead starts
and ends at -arrow-
4 - Body flange
. Volkswagen AG
❑ Touch up paintwork kswagen AG does
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5 - Gaps/shut lines ut
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❑ Must be uniform.
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6 - Seal
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7 - Windscreen adjuster
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❑ 443 845 631 A

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spec
❑ Remove 2 hours after

installation of wind‐
t to the co
screen.
8 - Windscreen seal
rrectne
❑ Is part of windscreen
ss
plenum chamber cover ⇒ page 18

o
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form
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Prote AG.
2. Windscreen 317
Passat 2015 ➤
2.2 Removing and installing windscreen

⇒ “2.2.1 Removing and installing windscreen”, page 318
⇒ “2.2.2 Removing broken windscreen”, page 324
2.2.1 Removing and installing windscreen
Note
G. Volkswagen AG d
♦ The removal of a bonded window is described using the lRe‐
ksw
agen
A
oes
moval kit for flush bonded windows - V.A.G 1474 A- .by Vo
not
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♦ Alternatively, you can also use the cutting tool for
ut
hobonded win‐
r eo
dows - VAS 6452- . ss
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c
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♦ Another alternative is to use the window removal set - VAS
nl
pt
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6888- .
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♦ Removal kit for flush bonded windows - V.A.G 1474 A- or Re‐
hole
moval kit for flush bonded windows - VAS 6452-
spec
es, in part or in w
t to the co
♦ Suction lifter - V.A.G 1344-
♦ Cutting tool - V.A.G 1351-
rrectness of i
♦ Windscreen removal kit - V.A.G 1755-
l purpos
♦ Hand-cartridge gun - V.A.G 1628-

♦ Cartridge heater - V.A.G 1939-
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Cop py
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Prote AG.
♦ Electric cutter - V.A.G 1561 A-

♦ Blade - V.A.G 1561/2-
♦ Blade - V.A.G 1561/8-
♦ Blade - V.A.G 1561/19-

Passat 2015 ➤
♦ Double cartridge gun - VAS 5237-
AG. Volkswagen AG d
agen oes
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Removing
– Remove A-pillar upper trims on left and right ⇒ General body
repairs, interior; Rep. gr. 70 ; Trims, interior; Removing and
rrectne
installing A-pillar trim .
– Remove left and right sun visors ⇒ General body repairs, in‐
ss o
terior; Rep. gr. 68 ; Equipment; Removing and installing sun
cial p
f in
visor .
form
mer
– Remove interior mirror ⇒ General body repairs, interior; Rep.
atio
m
gr. 68 ; Interior mirror; Removing and installing interior mirror .

o
n
c
i
or
n thi
– On vehicles with front camera for driver assist systems -
te
sd
va
R242- , remove front camera ⇒ Electrical system; Rep. gr.

i
o
pr
cum
96 ; Front camera for driver assist systems; Removing and
r
fo
en
ng
installing front camera for driver assist systems .

t.
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Cop py
– Lower moulded headliner in area of windscreen ⇒ General
t. rig
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body repairs, interior; Rep. gr. 70 ; Roof trims; Removing and p by
o Vo
by c lksw
installing moulded headliner . Prote
cted AG.
agen
– Moulded headliner can now be lowered sufficiently to allow

windscreen to be cut out without damage occurring to moulded
headliner.
– Removing plenum chamber cover ⇒ page 18 .
2. Windscreen 319
Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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aut ra
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nl
pt
du
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itte
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erm
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ility
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es, in part or in w
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nform
mercia
at
om
ion
c
in t
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ate
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for
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Cop py
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pyri by
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cted agen
Prote AG.
Only for vehicles with windscreen heater

– Unscrew securing nut -6-.
– Bond cable -5- to windscreen.
– Separate electrical connectors -1 and 3-.
– Bond cables -2 and 4- to windscreen.
Note
♦ On vehicles with sliding sunroof, the windscreen seal may be very close to the sliding sunroof frame.
♦ If the seal is damaged, a new windscreen must be installed. The seal cannot be renewed individually.

Passat 2015 ➤
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o ot g
byV ua
d ran
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– Slide suitable covering film - V.A.G 1474/8- between wind‐

un
pt
screen and dash panel.

an
d
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erm
ab
– Pull end of cutting cord -1- through adhesive sealing material

ility
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into inside of vehicle using awl - V.A.G 1474/2- .

wit
is n
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
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c
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or
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Windscreen 321
Passat 2015 ➤
– Secure inside end of cutting cord against falling out using Pull
toggle - V.A.G 1351/1- -3-.
– Insert cutting cord -2- into window flange using tube -1-.
– Place cutting cord around the front windscreen.
– Ensure that cutting cord lies under front windscreen in corners.
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
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nl
pt
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es, in part or in w
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nf
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Cop py
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rig ht
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co Vo
by lksw
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Prote AG.
– Attach the ends of cords -4- on removal kit for flush bonded
windows - VAS 6452- -1-.

Passat 2015 ➤
– Put cutting cord around suction

gen AG cups of nreel
. Volkswage AG device -arrow-.
d wa oes
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– Use plastic wedge d b -2- to press cutting cord against windscreen
yV t gu
ara
while cuttingorin
ise order to have clearance at window flange nte and
eo
dash panel.
au
th
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nl
pt
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ab
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spec
es, in part or in w
t to the co
rrectness of i
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nf
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orm
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n in
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
– Position removal kit for flush bonded windows - VAS 6452- at

lower corners of windscreen.
– Change position of left removal kit for flush bonded windows
- VAS 6452- from “position I”to “position III” and cut windscreen
free.
– Change position of right removal kit for flush bonded windows
- VAS 6452- from “position IV”to “position VI” and cut wind‐
screen free.
– Use 2 suction lifters - V.A.G 1344- to lift off windscreen from
vehicle.
Installing
– On vehicles with front camera for driver assist systems -
R242- , install front camera ⇒ Electrical system; Rep. gr. 96 ;
Front camera for driver assist systems; Removing and instal‐
ling front camera for driver assist systems , and calibrate front
camera ⇒ Running gear, axles, steering; Rep. gr. 44 ; Front
2. Windscreen 323
Passat 2015 ➤
camera for driver assist systems; Calibrating front camera for

driver assist systems .
– Preparing old undamaged window for glazing ⇒ page 313 .
. Volkswagen AG
gen AG does
– Preparing new window for glazing ⇒ pageV313
olks .
wa not
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– Preparing body flange for glazing ⇒orpage
ise 315 . nte
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ut ra
– Installation instructions ⇒ page s312
sa c
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– Minimum curing period ⇒ page 311 le
un
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– After inserting, secure windscreen on roof using adhesive
erm
ab
tape.
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2.2.2 Removing broken windscreen
h re
ole,
spec
Removal of a broken windscreen is performed in the same man‐

ner as the removal a broken rear window ⇒ page 331 .
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
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te
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat 2015 ➤
3 Rear windscreen
⇒ “3.1 Assembly overview - rear window”, page 325
⇒ “3.2 Removing and installing rear window”, page 326
3.1 Assembly overview - rear

swa
genwindow
AG. Volkswagen AG d
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1 - Rear windscreen tho eo
au ra
ss c
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⇒ page 326
nl
pt
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2 - PUR adhesive sealant
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❑ Cross section of bead:
ility
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width = 7 mm
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-dimension a-, height =
h re
hole
10 mm -dimension b-
spec
(including precoating,
es, in part or in w
t to the co
residual material on win‐
dow glass and window
flange).
rrectness of i
❑ Minimum curing period
⇒ page 311 .
l purpos
❑ Adhesive bead starts

and ends at -arrow-
nform
ercia
3 - Body flange
m
at
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4 - Spacer
n
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ate
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Prote AG.
3. Rear windscreen 325

Passat 2015 ➤
3.2 Removing and installing rear window

⇒ “3.2.1 Removing and installing rear window”, page 326
⇒ “3.2.2 Removing broken rear window”, page 331
3.2.1 Removing and installing rear window
Note
♦ The removal of a bonded window is described using the Re‐

moval kit for flush bonded windows - V.A.G 1474 A- .
♦ Alternatively, you can also use the cutting tool for bonded win‐
dows - VAS 6452- .
♦ Another alternative is to use the window removal set - VAS
6888- .

♦ Removal kit for flush bonded windows - V.A.G 1474 A- or Re‐
moval kit for flush bonded windows - VAS 6452-
♦ Suction lifter - V.A.G 1344-
♦ Cutting tool - V.A.G 1351-
wage
♦ Windscreen removal kit - V.A.G 1755- yV
olks es n
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d b ua
ran
♦ Hand-cartridge gun - V.A.G 1628- ir se tee
tho
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♦ Cartridge heater - V.A.G 1939- ss
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nl
pt
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es, in part or in w
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Removing
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If the rear window is reused, make sure that the electrical connections for the rear window heating are not
c by lksw
cted agen
damaged.
Prote AG.

Passat 2015 ➤
n AG. General body
Volkswagen AG dorepairs, exterior - Edition 03.2019
lkswage es n
Vo ot g
by ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove C-pillar trim ⇒ General body repairs, interior; Rep.

gr. 70 ; Trims, interior; Removing and installing C-pillar trim .
– Pull off connectors for heated rear window -4- and for window
aerial -3 and 5-.
– Attach cables of disconnected connectors to rear window.
– Remove high-level brake light -1- ⇒ Electrical system; Rep.
gr. 94 ; High-level brake light; Removing and installing high-
level brake light .

Passat 2015 ➤
General body repairs, exterior - EditionA03.2019
G. Volkswagen A n G do
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Volks ot g
by ua
ed ran
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th or
au ac
ss
ce
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nl
pt
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itte
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erm
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ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
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orm
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n in
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te
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Using the awl - V.A.G 1474/2- pull cutting cord -1- through the
adhesive sealant inwards at the location -arrow a- shown in
the illustration.
– Use the pull toggle - V.A.G 1351/1- to secure end of cutting
cord before pulling it out.
– Lay cutting cord around rear window, and guide second end
of cord inwards -arrow b-.
– Attach end of cutting cord to removal kit for flush bonded win‐
dows - VAS 6452- or reel device - V.A.G 1654 A- .

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
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te
sd
iva
o
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cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Carefully guide protective film -3- or plastic strip - V.A.G

1474/15- between rear window and metal flange.
– Place reel device - V.A.G 1654 A- in indicated position.
– Convert reel device - V.A.G 1654 A- accordingly and cut rear
window free towards sides starting in upper area.
– Use wedge - V.A.G 1474/5- to press cutting cord -1- against
rear window glass while cutting in order to have clearance at
body flange.
– Then cut rear window -2- free in lower area.
– Hold rear window on 2 suction lifters while cutting free.

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
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an
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Passat 2015 ➤
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– Preparing old undamaged window for glazing ⇒ page 313 .

es, in part or in w
t to the co
– Preparing new window for glazing ⇒ page 313 .

– Preparing body flange for glazing ⇒ page 315 .
rrectness of i

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– Guide rear window -1- under rear lid -2- -arrow a- taking care
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nform
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– Centre rear window, and press it onto flange -arrow b-.

m
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– Minimum curing period ⇒ page 311

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Passat 2015 ➤
– Cover flange -2- all round with textile-reinforced adhesive

tape.
CAUTION
Risk of injury to hands and eyes caused by glass splinters.
Risk of cuts.
– Wear protective gloves!
– Cut through adhesive material (with glass remains) in window

aperture using electric cutter - V.A.G 1561 A- and U-shaped
blade - V.A.G 1561- .
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Passat 2015 ➤
4 Door windows
⇒ “4.1 Assembly overview - front door window”, page 333
⇒ “4.2 Assembly overview - rear door window”, page 334
⇒ “4.3 Removing and installing front door window”, page 334
⇒ “4.4 Removing and installing rear door window”, page 337
⇒ “4.5 Removing and installing
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⇒ page 334
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2 - Locking lug
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❑ Component part of fixed
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s
⇒ page 339
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4 - Bolt
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openings completely
6 - Locking lug
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❑ Qty. 2
❑ For securing the door
window on window reg‐
ulator
4. Door windows 333

Passat 2015 ➤
4.2 Assembly overview - rear door window
1 - Door window
⇒ page 337
2 - Spreader pin
❑ Together with spreader
plug for securing door n AG. Volkswagen AG do
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⇒ page 182
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❑ Qty. 3
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7 - Bolt
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openings completely
9 - Locking lug
❑ Qty. 2
❑ Component part of fixed door window
10 - Fixed door window
4.3 Removing and installing front door win‐

dow

Passat 2015 ➤
Note
Removal and installation are described only for the right door
window. The left side is similar.
Removing
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4. Door windows
Passat 2015 ➤

trim .
– Lower door window -1- until retaining hooks -2- for door win‐
dow are accessible.
Note
♦ If this part of the work cannot be done due to a fault in the window regulator motor, the window regulator
motor can be removed -4-.
♦ The window can then be pushed to required working position.
– Carefully push retaining hooks -2- through opening in window

-arrow a-. Lift door window slightly to prevent it from falling
back again in retaining hook.
– Raise door window -1- at rear and swing out forwards from
window channels -3- -arrows b-.
Installing
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Passat 2015 ➤
– Swing door window -1- into window channels -3- -arrows a-.
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– Before the inner door cover, the cable feed and the door trim
are installed, carry out a functional check.
rrectne
4.4 Removing and installing rear door win‐
dow
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Removing
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4. Door windows 337

Passat 2015 ➤
AG. Volkswagen AG d
General body repairs, exterior - Edition 03.2019 agen oes
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– Remove rear door trim ⇒ General body repairs, interior;
rise Rep. nte
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gr. 70 ; Rear door trims; Removing and installing
s a rear door
ut ra
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trim . s
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-3- in cut-out of window regulator -5- are accessible.
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Note
If work is not possible due to a malfunction caused by the electric window regulator, the window regulator motor
rrectness of i
-4- must be unbolted. Window can then be pushed to required working position.
l purpos
– Screw a 5 mm bolt (approx. 70 mm long) into spreader pin

-2-, and pull bolt with spreader pin out of spreader plug -3-
nform
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-arrow a-.
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– Screw an 8 mm bolt (approx. 80 mm long) into spreader plug
ion in
-3-.
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– Pull spreader plug -3- out of door window -1-.
– Pull door window -1- upwards at an angle -arrow c- to vehicle
exterior out of window slot.
Installing
Note
♦ When installing door window, always renew spreader plug and

spreader pin.
♦ Before inserting spreader plug -2- and spreader pin -3-, check
window glass -1- for damage.

Passat 2015 ➤
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window glass -1- removed -arrows a-. p by
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– Push spreader pin -2- flush -arrows b- into spreader plug -3-. Prote AG.
– Insert door window -1- into door -arrow d-, and push it into
window regulator guide -4- -arrows c-.
– Engage door window -1- in window regulator by pressing
slightly from above.
– Then perform remaining installation in reverse order of remov‐
al.
– Carry out functional check before fitting door trim.
4.5 Removing and installing fixed front door

window
Removing
4. Door windows 339

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Passat 2015 ➤ swagen AG. V does
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General body
d by repairs, exterior - Edition 03.2019
V gu
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trim .
– Pull off sticker -5-, and unscrew bolt -4-.
– Pull inner seal off metal flange.
– Guide release tool - T10236- one after the other under both
clips -2-.
– When doing this, push door window -1- outwards slightly
-arrows a- until clips -2- are pushed out of door.
– Then, pull door window -1- with web upwards -arrow b- out of
door -3-.
Installing

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
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Prote AG.
– Slide door window -1- into door -arrow a-.

– Push door window -1- against door until clips -2- engage au‐
dibly -arrow b-.
– Door window seal must be seated firmly in door frame -3-.
– Tighten bolts -5-, and attach sticker -4-.
Specified torques
♦ Fixed front door window ⇒ page 333
4.6 Removing and installing fixed rear door

window
Removing
4. Door windows 341

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
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Prote AG.
– Remove door trim panel ⇒ General body repairs, interior; Rep.

gr. 70 ; Rear door trim panels; Removing and installing rear
door trim panel .
– Remove window slot seal ⇒ page 210 .
– Pull off sticker -2-, and unscrew bolts -3-.
– Pull inner seal off metal flange.
– Guide release tool - T10236- one after the other under both
clips -4-.
– When doing this, push door window -1- outwards slightly
-arrows a- until clips -4- are pushed out of door.
– Then, pull door window -1- with web upwards -arrow b- out of
door.
Installing

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
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rise nte
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– Slide door window -1- into door -arrow a-. s
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-arrows b-.
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Specified torques
t to the co
♦ Fixed rear door window

⇒ “4.2 Assembly overview - rear door window”, page 334 .
rrectness o
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343
AG.
4. Door windows
AG. Volkswagen AG d
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Passat 2015 ➤ d by
V gu
ara
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horis
exterior - Edition 03.2019 eo
aut ra
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66 – Exterior equipment
nl
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1 Radiator grille and front trim
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⇒ “1.1 Assembly overview - radiator grille”, page 344
spec
es, in part or in w
⇒ “1.2 Removing and installing radiator grille”, page 345
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1.1 Assembly overview - radiator grille
rrectness of i
⇒ “1.1.1 Assembly overview - radiator grille”, page 344
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⇒ “1.1.2 Assembly overview - radiator grille GTE (hybrid)”,

page 345
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1.1.1 Assembly overview - radiator grille

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1 - Radiator grille
AG.

⇒ page 345
2 - Bolts
❑ Qty. 4
❑ 2 Nm
3 - Bumper cover
⇒ page 282
4 - Badge
⇒ page 409
344 Rep. gr.66 - Exterior equipment

Passat 2015 ➤
1.1.2 Assembly overview - radiator grille »GTE« (hybrid)
1 - Radiator grille
⇒ page 345
❑ Allocation ⇒ Electronic
2 - Seal
❑ Clipped into radiator
grille
3 - Control element
⇒ page 348
4 - Bolts
❑ Qty. 3 AG. Volkswagen AG d
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5 - Immediate charge button
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⇒ page 348
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7 - Bolts
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❑ Qty. 4
❑ 2 Nm
rrectness of i
8 - Charging socket flap unit
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⇒ page 348
nf
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9 - Cover
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10 - Charging socket flap

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11 - Badge
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❑ Model designation ⇒ page 409 C py
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1.2 Removing and installing radiator grille
⇒ “1.2.1 Removing and installing radiator grille”, page 345
⇒ “1.2.2 Removing and installing charging socket flap unit”, page
348
1.2.1 Removing and installing radiator grille

1. Radiator grille and front trim 345

Passat 2015 ➤
AG. Volkswagen AG d
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– Slightly pull off radiator grille -1- on top -arrows a- to detach

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tors for actuator and immediate charge button - E766- Prote AG.
⇒ page 348

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
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– On vehicles with charging socket, join electrical connectors for Prote AG.
actuator and immediate charge button - E766- ⇒ page 348
– Insert radiator grille -1- in front bumper cover, and centre it.
– With slight pressure, push radiator grille -1- into lower catches
of bumper cover -arrows a-.
– With slight pressure, push radiator grille -1- into upper catches
of bumper cover -arrows b-.
Specified torques
♦ ⇒ “1.1 Assembly overview - radiator grille”, page 344

Passat 2015 ➤
1.2.2 Removing and installing charging socket flap unit
AG. Volkswagen AG d
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Removing charging socket flap unit

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-6- and actuator -5-.

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– Rotate charging socket flap unit -1- approx. 90° and remove by c lksw
cted agen
from radiator grille inwards.
Prote AG.
Installing charging socket flap unit

Guide charging socket flap unit -1- with charging socket flap
through radiator grille from inside.
– Rotate charging socket flap unit -1- and bring into installation
position.
– Tighten bolts -2-, specified torque ⇒ page 345
Removing actuator
– Separate electrical connector -5- on actuator.

Passat 2015 ➤
AG. Volkswagen AG d
– Unscrew bolts -4- and remove actuator -3-. ksw
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Installing actuator ise
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-6-.
spec
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Installing immediate charge button E766
rrectness of i
– Bring button -7- into installation position.
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Passat 2015 ➤ ut
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General body repairs, exterior - Editions 03.2019
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nl
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2 Mouldings, trims, extensions
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⇒ “2.1 Assembly overview - trim strip and covers”, page 350
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⇒ “2.2 Assembly overview - side member trim”, page 351
hole
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⇒ “2.3 Assembly overview - water deflector”, page 352
t to the co
⇒ “2.4 Assembly overview - heat shield”, page 353
⇒ “2.5 Removing and installing cover”, page 353
rrectness of i
⇒ “2.6 Removing and installing side member trim”, page 356 l purpos
⇒ “2.7 Removing and installing water deflector”, page 359
nform
ercia
⇒ “2.8 Removing and installing B-pillar trim on door”, page 360

m
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⇒ “2.9 Removing and installing trim strip”, page 362
om
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⇒ “2.10 Removing and installing entry moulding”, page 366

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⇒ “2.11 Removing and installing underbody heat shield”,

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page 369
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1 - Rear door moulding Prote AG.

⇒ page 353
2 - Front door moulding
⇒ page 353
3 - Adhesive tape
❑ Part of moulding.
4 - Clip
❑ Qty. 6 for trim strip on
front door
❑ Qty. 4 for trim strip on
rear door
5 - Protective sheet
❑ Covers adhesive tape.
6 - Clip
❑ Qty. 2 for each cover
7 - Bolt
❑ Qty. 2 for each cover
❑ Tightening torque:
1.5 Nm
8 - Grommet
❑ Qty. 6 for front door
❑ Qty. 4 for rear door
9 - Bonding surface

Passat 2015 ➤
2.2 Assembly overview - side member trim

1 - Side member trim

❑ Removing and installing AG. Volkswagen AG d
⇒ page 356 agen oes
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2 - Clip rised
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3 - Adhesive tape
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❑ Part of moulding.
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❑ Covers adhesive tape.
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5 - Clip
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6 - Clip
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7 - Bolt
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❑ Qty. 2
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❑ Tightening torque:
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1.5 Nm
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8 - Spreader rivet
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❑ Qty. 6 for spreader rivet
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12 - Bonding surface
13 - Bonding surface
2. Mouldings, trims, extensions 351

Passat 2015 ➤
2.3 Assembly overview - water deflector
Note
The right side is shown. The left side is similar.
1 - Water deflector
⇒ page 359
2 - Retaining strip
– During removal, drill out
rivet heads and chop
through rivet shanks.
3 - A-pillar
4 - Pop rivet
❑ Qty. 5
❑ Insert with pop rivet pli‐
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❑ Position clip in wingaut hole
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6 - Wings
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⇒ page 11
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Prote AG.

Passat 2015 ➤
2.4 Assembly overview - heat shield

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1 - Underbody heat shield ised b ara
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❑ Removing and installing auth eo
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⇒ page 369 ss c
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2 - Dampers
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3 - Clamping washer
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❑ Qty. 6
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4 - Left heat shield for centre
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exhaust system
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⇒ page 369
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5 - Heat shield for left rear si‐

lencer
nform
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⇒ page 369
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6 - Heat shield for centre ex‐
on in
haust system
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⇒ page 369
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7 - Heat shield for spare wheel

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❑ Removing and installing p by
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⇒ page 369 Prote
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8 - Heat shield for right rear si‐

lencer
⇒ page 369
9 - Additional underbody heat
shield
⇒ page 369
❑ Not fitted on all models
2.5 Removing and installing cover

Installation instructions for bonded mouldings
Note
♦ Before removing the trim strip, heat it up using hot air blower
- V.A.G 1416- .
♦ Adhesive remover - D 002 000 10- must be used exclusively.
♦ Ensure that the adhesive surfaces are free of dust and grease.
♦ Letterings, films or emblems must be bonded in place imme‐
diately after cleaning.
♦ Remove protective foil immediately before installation.
♦ The working temperature is approx. 21°C.

Passat 2015 ➤
Removing
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♦ Hot-air blower - V.A.G 1416- horis tee
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Note
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♦ The removal and installation sequence is for the front and rear door mouldings on the left only. Removal
mer
and installation of the front and rear door mouldings on the right is analogous.
atio
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♦ Mouldings cannot be removed without damage.
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Prote AG.

Passat 2015 ➤
Front door moulding

– Unscrew bolts -7- on inner side of door.
– Heat up trim strip in area of adhesive tape -3- using hot air
blower - V.A.G 1416- .
– Pull off cover -2- forcibly from door.
Rear door moulding
– Unscrew bolts -7- on inner side of door.
– Heat up trim strip in area of adhesive tape -3- using hot air
– Pull off cover -1- forcibly from door.
Installing
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Front door moulding

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– Check all grommets -8- and clips -4- for damage, and renew
in t
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them if necessary.
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– Fit cover -2- with clips -4- into grommets -8-, and push it on.
um
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– Pull off backing -5- from adhesive tape -3-.
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355
Prote AG.
2. Mouldings, trims, extensions
Passat 2015 ➤
– Press trim strip in area of adhesive tape -3- firmly onto door.
Rear door moulding
– Check all grommets -8- and clips -4- for damage, and renew
them if necessary.
– Fit cover -1- with clips -4- into grommets -8-, and push it on.
– Press trim strip in area of adhesive tape -3- firmly onto door.
AG. Volkswagen AG d
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Specified torques Volksw not
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♦ Bolts ⇒ page 350 rise nte
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2.6 Removing and installing side member ss c
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Installation instructions for bonded side member trim
wit
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spec
Note
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♦ Before removing the side member trim, heat it up using hot air
rrectne
♦ Adhesive remover - D 002 000 10- must be used exclusively.
♦ Ensure that the adhesive surfaces are free of dust and grease. ss o
cial p
f in
♦ Letterings, films or emblems must be bonded in place imme‐

form
mer
diately after cleaning.

atio
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♦ Remove protective foil immediately before installation.

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♦ The working temperature is approx. 21°C.

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♦ Hot-air blower - V.A.G 1416-
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Prote AG.

Passat 2015 ➤
Note
♦ Removal and installation are described only for the left side member trim. The removal and installation of
the right side member trim are similar.
♦ The removal and installation procedures may have to be modified slightly depending on model variants.
♦ The side member trim cannot be removed without being damaged.
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– Unscrew bolts -7- on wing.

– Unscrew spreader rivets -8-, and pull them out of grommets.
– Heat up side member trim -1- in area of adhesive tape -3- using
hot air blower - V.A.G 1416- .
– Pull side member trim -1- firmly off side member.
Installing

AG. Volkswagen AG d
Passat 2015 ➤ ksw
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Prote AG.
– Check all grommets -8-, clips -4- and spreader rives -8- for
damage, and renew them if necessary.
– Fit side member trim -1- with clips -2 and 6- into grommets
-10-, and push it on.
– Press side member trim in area of adhesive tape -3- firmly onto
side member.
Specified torques
♦ Bolts ⇒ page 351

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General body ac
repairs, exterior - Edition 03.2019
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2.7 Removing and installing water deflector
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Note
, is n
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spec
Removal and installation are described only for the left side. Removal and installation of the right side are
es, in part or in w
similar.
t to the co
rrectness of i
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nform
mercia
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r
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Removing
– Starting at bottom end, pull water deflector -1- out of clip -3-
and retaining strip -2-.
Installing
– Position upper inner edge of water deflector -1- on upper edge
of windscreen.
– Press water deflector -1- from above into retaining strip -2- and
clip -3-.
– Fit contact lip between water deflector and windscreen behind
window.

Passat 2015 ➤
AG. Volkswagen AG d
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2.8 Removing and installing B-pillar trim on d by
Vol not
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ara
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⇒ “2.8.1 Removing and installing B-pillar trim on front door”, page s
ce
e
360
nl
pt
du
an
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⇒ “2.8.2 Removing and installing B-pillar trim on rear door”, page
erm
ab
361
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2.8.1 Removing and installing B-pillar trim on front door
h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
similar.
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at
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Prote AG.
Removing
– Run door window down to bottom position.
– Pull window channel -3- in area of B-pillar trim-1- out of door
frame.
– Unclip spreader rivets -2-.

Passat 2015 ➤
– Push B-pillar trim -1- downwards and pull off door frame.
– Pull out B-pillar trim -1- upwards.
Installing
– Position B-pillar trim -1- on door frame.
– Guide in B-pillar trim -1- at bottom and fit it in place.
– Push B-pillar trim -1- upwards until it is in contact with window
channel -3-.
– Hook in spreader rivet -2- from top to bottom and insert window
channel -3- into B-pillar trim.
2.8.2 Removing and installing B-pillar trim on rear door
Note
similar.
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Removing
– Run door window down to bottom position.

Passat 2015 ➤
– Pull window channel -3- in area of B-pillar trim-1- out of door

frame. agen
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– Unclip spreader rivets -2-. ed
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– Push B-pillar trim -1- downwards and pull off
au
thodoor frame. or
ac
ss
– Pull out B-pillar trim -1- upwards.
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Installing
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– Insert B-pillar trim -1- on door frame.
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– Fit B-pillar trim -1- in longitudinal holes -4- in frame section.
h re
hole
– Position B-pillar trim -1- and push until stop.
spec
es, in part or in w
t to the co
– Push B-pillar trim -1- upwards until it is in contact with window
channel -3-.
– Hook in spreader rivet -2- from top to bottom and insert window
rrectness of i
channel -3- into B-pillar trim.
l purpos
2.9 Removing and installing trim strip
nform
ercia
⇒ “2.9.1 Removing and installing window channel trim strip of front

door”, page 362
m
a
com
tio
⇒ “2.9.2 Removing and installing window channel trim strip of rear
n in
r
door”, page 364

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2.9.1 Removing and installing window chan‐
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nel trim strip of front door
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Removing
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Prote AG.

Passat 2015 ➤
AG. Volkswagen AG d
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Prote
– Starting at front, detach trim strip -1- evenly from window
AG.
channel -2- -arrows b-.

– Push trim strip -1- towards rear out of window channel -2-
-arrow a-.
Installing

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
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– Push trim strip -1- towards front into window channel -2-
for
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-arrow a-.
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– Press trim strip -1- evenly into window channel -2-
t. rig
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-arrows b-.
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2.9.2 Removing and installing window chan‐
Prote AG.
nel trim strip of rear door

Removing

Passat 2015 ➤
AG. Volkswagen AG d
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– Detach trim strip -1- evenly from window channel -2-
wit
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-arrows-.
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Installing spec
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Passat 2015 ➤
AG. Volkswagen AG d
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– Align trim strip -1- with B-pillar trim -arrow a-.

– Press trim strip -1- into window channel -2- -arrows b-.
2.10 Removing and installing entry moulding

Fitting instructions
♦ If a sill panel trim is installed for the first time on a new vehicle
or on newly painted surfaces, the procedure in ⇒ Workshop
manual “Paint”; ⇒ Paintwork repairs; ⇒ Paint finish; ⇒ Mould‐
ings & film should be observed.
♦ If the sill panel trim is removed and reinstalled, use only ad‐
hesive remover - D 002 000 10- to remove the adhesive
remains in installation area.
♦ The sill panel trim must be bonded in place immediately after
cleaning.
♦ Remove protective film immediately before installation.
♦ Working temperature is approx. 21 °C.
Removing

Passat 2015 ➤
Note
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gen AG d
Sill panel trimVcannot
olks
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oes
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– Heat sill panel trim -1- using hot air blower - V.A.G 1416- , and
pull it off sill.
Installing

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Passat 2015 ➤ wage
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– Assembly notes ⇒ page 366

– Pull off backing.
– Align front end of outer sill panel trim -1- with front end of inner
sill panel trim -arrows-.
– Make sure that dimension -a- of 12 mm between metal flange
and sill panel trim is adhered to over the entire length of the
sill panel trim.
– Smooth down using plastic scraper with paper towel wrapped
around it.
quence of removal.

Passat 2015 ➤
2.11 Removing and installing underbody

heat shield
⇒ “2.11.1 Removing and installing heat shield for centre tunnel”,
page 369
⇒ “2.11.2 Removing and installing heat shield for centre exhaust
system”, page 370
⇒ “2.11.3 Removing and installing heat shield for rear silencer”,
page 371
2.11.1 Removing and installing heat shield for centre tunnel
Note
Slight discrepancies may need to be allowed for depending on the type of engine.
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Removing
– Removing centre underbody panel ⇒ page 382 .
– Removing front tunnel cross-piece -3- ⇒ page 382 .

Passat 2015 ➤
– Removing rear tunnel cross-piece -2- ⇒ page 387 .

– Remove rear exhaust system ⇒ Rep. gr. 26 ; Exhaust system/
silencer; Assembly overview - silencers .
Only for vehicles with all-wheel drive
– On vehicles with all-wheel drive, remove propshaft ⇒ Rep. gr.
39 ; Propshaft; Assembly overview - propshaft .
All vehicles
– Detach lock washers -4- (qty. 6) and remove tunnel heat shield
-1- to the back.
Installing
Install in reverse order.
2.11.2 Removing and installing heat shield for centre exhaust system
Note
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Prote AG.

Passat 2015 ➤
Removing
– Remove rear exhaust system ⇒ Rep. gr. 26 ; Exhaust system/
silencer; Assembly overview - silencers .
– Loosen lock washers -2-.
– Remove heat shield -1-.
Installing
2.11.3 Removing and installing heat shield for

rear silencer
♦ Engine and gearbox jack - V.A.G 1383 A-
AG. Volkswagen AG d
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Passat 2015 ➤
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spec
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– Loosen bracket for rear silencer and slightly lower using the
t to the co
engine and gearbox jack - V.A.G 1383 A- ⇒ Rep. gr. 26 ;

Exhaust pipes/silencers; Assembly overview - silencer .
rrectness of i
– Loosen lock washers -2-.

l purpos
– Remove heat shield -1-.

Installing
nf
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Passat 2015 ➤
3 Noise insulation
⇒ “3.1 Assembly overview - noise insulation”, page 373
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gen AG
3.1 Assembly overview - noise
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horis insulation”, page 373 nte
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⇒ “3.1.2 Assembly overview - long
s noise insulation”, page 374
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⇒ “3.1.3 Assembly overview - skid plate”, page 375
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3.1.1 Assembly overview - short noise insulation
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Note
spec
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1 - Short noise insulation
l purpos
❑ Removing:
– Unscrew bolts -2- and
nform
ercia
-3-.
m
a
com
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– Pull out noise insulation
ion in
off lock carrier to the
r
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3 - Bolt
❑ 1 on lock carrier
❑ 1 Nm
3. Noise insulation 373

Passat 2015 ➤
3.1.2 Assembly overview - long noise insulation
Note
1 - Short noise insulation agen

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❑ Qty. 3 left
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❑ Qty. 4 right
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❑ 2.0 Nm
3 - Bolt
rrectne
❑ Micro-encapsulated; re‐
new after each removal
ss
❑ Qty. 3
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❑ 6.0 Nm
form
mer
4 - Bolt atio
om
n
❑ 1 on lock carrier
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❑ 1 Nm
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Prote AG.

Passat 2015 ➤
3.1.3 Assembly overview - skid plate
Note
1 - Skid plate
❑ Removing:
– Remove bolts -2-, -3-
and -4-.

back.
2 - Bolt
❑ Qty. 2 each on left and
right
❑ 20 Nm
3 - Bolt
❑ Qty. 3 left
❑ Qty. 4 right
❑ 2.0 Nm
4 - Bolt
❑ Qty. 3
❑ 20 Nm agen
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3. Noise insulation 375

Passat 2015 ➤
4 Underbody cladding
⇒ “4.1 Overview of fitting locations - underbody cladding”,
page 376
⇒ “4.2 Assembly overview - bracing on underbody”, page 382
⇒ “4.3 Removing and installing underbody cladding”, page 382
⇒ “4.4 Removing and installing tunnel cross-piece”, page 387
4.1 Overview of fitting locations - underbody

cladding
⇒ “4.1.1 Assembly overview - underbody cladding”, page 376
⇒ “4.1.2 Assembly overview - underbody cladding hybrid (GTE)”,
page 378
⇒ “4.1.3 Assembly overview - low-noise underbody cladding 1/3”,
page 379
page 380
page 381 gen AG
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Prote AG.

Passat 2015 ➤
1 - Front underbody cover

❑ Left and right
⇒ page 382
2 - Nut
❑ Captive
❑ 2.0 Nm
3 - Panel nut
4 - Left underbody cladding ex‐
tension
⇒ page 382
5 - Bolt
❑ (2 Nm)
6 - Clamping washer
7 - Insert nut
8 - Rear left underbody cover
❑ Unscrew bolts -5- and
nuts -2-
9 - Rear right underbody clad‐
ding
❑ Unscrew bolts -5- and
nuts -2-
10 - Right underbody cladding
extension
AG. Volkswagen AG d
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⇒ page 382
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11 - Cover utho or
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12 - Spreader rivet
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❑ Qty. 4
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13 - Centre underbody cover

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14 - Plugs
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❑ Left and right

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4. Underbody cladding 377

Passat 2015 ➤
4.1.2 Assembly overview - underbody cladding hybrid (GTE)
1 - Underbody cladding, front agen

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❑ Removing and installing orise nte
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⇒ page 382 auth
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2 - Nut
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❑ Captive
itte
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3 - Bolt
hole
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❑ (2 Nm)
4 - Underbody cladding, front
rrectness of i
left
l purpos
⇒ page 382
5 - Nut
nf
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❑ Captive
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7 - Cover
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❑ Left and right
agen
Prote AG.
❑ Engaged with under‐

body cladding
8 - Left underbody cladding ex‐
tension
❑ Pushed into underbody
cladding and screwed in
place
9 - Right underbody cladding extension
❑ Pushed into underbody cladding and screwed in place
10 - Bolt
❑ (2 Nm)

Passat 2015 ➤
4.1.3 Assembly overview - low-noise underbody cladding 1/3
1 - Low-noise underbody clad‐

ding
2 - Insert nut
❑ Qty. 5
3 - Bolt
❑ (2 Nm)
❑ Qty. 5
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Prote AG.

Passat 2015 ➤

ding
2 - Clamping washer
❑ Qty. 1
3 - Insert nut
❑ Qty. 6
4 - Bolt
❑ (2 Nm)
❑ Qty. 9
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Prote AG.

Passat 2015 ➤

ding
2 - Insert nut
❑ Qty. 8
3 - Bolt
❑ (2 Nm)
❑ Qty. 15
4 - Clamping washer
❑ Qty. 1
AG. Volkswagen AG d
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Prote AG.

Passat 2015 ➤
4.2 Assembly overview - bracing on underbody
1 - Front bracing
2 - Rear bracing
3 - Hexagon nut
❑ Qty. 2
❑ 20 Nm
4 - Bolt
❑ Qty. 2
❑ 20 Nm
AG. Volkswagen AG d
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c
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4.3 Removing and installing underbody

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⇒ “4.3.1 Removing and installing underbody cladding”,

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page 382 C py
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⇒ “4.3.2 Removing and installing centre underbody cladding”, op Vo
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page 384 cted agen
Prote AG.
⇒ “4.3.3 Removing and installing short centre underbody clad‐

ding”, page 385
⇒ “4.3.4 Removing and installing underbody cover extension”,
page 386
4.3.1 Removing and installing underbody

cladding

Passat 2015 ➤
Note
AG. Volkswagen AG d
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mercia
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Prote AG.
Removing
– If fitted, remove centre underbody cladding ⇒ page 384 .

Passat 2015 ➤
– Release retaining tab and pull out front cover -2- or -5- in di‐
rection of travel backwards off catches.
– Unscrew nuts -3-.
– Remove underbody panel -1- or -4-.
Installing
Specified torque
• Nuts ⇒ page 376
4.3.2 Removing and installing centre underbody cladding
Note
AG. Volkswagen A
Slight discrepancies may need to be allowed for
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agen on the type
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es, in part or in w
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mercia
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ion
c
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for
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Removing
Unclip spreader river -2- and remove centre underbody panels.

Passat 2015 ➤
Installing
AG. Volkswagen AG d
Install in reverse order. agen oes
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4.3.3 Removing and installing short centre underbody cladding ise nte
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Note
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ab
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es, in part or in w
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nf
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cted agen
Prote AG.
Removing
Unclip spreader river -2- and remove centre underbody panels.
Installing
Specified torques
• Bolt ⇒ page 376

Passat 2015 ➤
4.3.4 Removing and installing underbody cov‐

er extension
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Note
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rrectness of i
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nf
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Passat 2015 ➤
wage es n
– Loosen lock washer -3-.y Volks ot g
ua
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– Unclip spreader rivet
horis
-2- and remove bolt -4-. tee
aut or
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– Remove rear underbody
ss panel -1-.
ce
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un
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Installing
an
d
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ab
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ot p
Specified torques
wit
is n
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ole,
• Bolt ⇒ page 376
spec
4.4 Removing and installing tunnel cross-
t to the co
piece
rrectne
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
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t.
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Cop py
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Prote AG.
Removing

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
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ce
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spec
t to the co
rrectness o
cial p
f inform
Front tunnel cross-piece

mer
atio
– Detach underbody covers, and push them slightly downwards

om
⇒ page 382 .
c
i
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– Remove tunnel cross-piece -1-.

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⇒ page 382 .
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– Remove nuts -3-.
– Remove tunnel cross-piece -2-.
Installing

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
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d by ara
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or eo
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ce
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nl
pt
du
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es, in part or in w
t to the co
rrectness of i
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at
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c
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cted agen
Prote AG.
Front tunnel cross-piece

– Fit tunnel cross-piece -1-.
– Install underbody cover ⇒ page 382 .
Rear tunnel cross-piece
– Fit tunnel cross-piece -2-.
– Tighten nuts -3-.
– Install underbody cover ⇒ page 382 .
Specified torques
♦ Nuts ⇒ page 382

Passat 2015 ➤
5 Exterior mirror
⇒ “5.1 Assembly overview - exterior mirror”, page 390
⇒ “5.2 Removing and installing exterior mirror”, page 391
⇒ “5.3 Removing and installing mirror glass”, page 393
⇒ “5.4 Removing and installing mirror adjustment unit”,
page 395
⇒ “5.5 Removing and installing mirror cover”, page 397
⇒ “5.6 Removing and installing mirror trim”, page 398
5.1 Assembly overview - exterior mirror
Note
The illustrations show the left-hand side. The right side is similar.
1 - Mirror mounting
❑ Removing and installing agen
AG. Volkswagen AG d
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2 - Turn signal hor eo
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⇒ Electrical system;
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Rep. gr. 94 ; Lights in

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ing and installing turn

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3 - Bolt
hole
spec
❑ Qty. 2
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t to the co
❑ 1.0 Nm
4 - Camera
rrectness of i
5 - Camera bracket
l purpos
6 - Bolt
❑ Qty. 2
nf
ercia
❑ 1.0 Nm
rm
m
atio
m
7 - Mirror cover
o
n in
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❑ Material: ABS
thi
te
sd
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⇒ page 397
o
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8 - Ambient light
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⇒ Electrical system; op Vo
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Rep. gr. 94 ; Lights in cted agen
Prote AG.
exterior mirror; Assem‐
bly overview - lights in
exterior mirror
9 - Bolt
❑ Qty. 1
❑ 12 Nm

Passat 2015 ➤
10 - Connector
11 - Seal
❑ Between cover and outer door panel
12 - Adjuster unit AG. Volkswagen AG d
agen oes
❑ Removing and installing ⇒ page 395 olksw not
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13 - Bolt horis
eo
ut ra
❑ Qty. 1 ss a c
ce
le
❑ 1.0 Nm
un
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14 - Mirror frame
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ility
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15 - Bolt
h re
hole
❑ Qty. 2
spec
es, in part or in w
❑ 1.0 Nm
t to the co
16 - Mirror glass
rrectness of i
l purpos
5.2 Removing and installing exterior mirror
nform
ercia

m
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Prote AG.
Note
♦ The removal and installation sequence is for the left exterior mirror only. The right side is similar.
♦ The cables and connectors in a new exterior mirror are always ready for the highest equipment level.
♦ Any superfluous connectors are secured to prevent noise.
5. Exterior mirror 391

Passat 2015 ➤
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es, in part or in w
t to the co
rrectness of i
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at
om
ion
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or
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ate
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for
en
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t.
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Cop py
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Prote AG.
Removing
trim .
– Disconnect connectors for exterior mirror -4-.
– Detach wire from retainers -5- and guide it through opening
-6- in door.
– Remove sticker -3-, and unscrew bolt -2-.
– Remove exterior mirror -1-, and guide out wire through open‐
ing in door.
Installing
– Grommet -6- must be inserted properly.
– Attach sticker -3- free of creases. The opening must be cov‐
ered completely.
– Then check function.
Specified torques

Passat 2015 ➤
5.3 Removing and installing mirror glass

♦ Assembly lever - 80-200-
Note
Removal and installation are described only for the left mirror G. Volkswage
glass. The right side is similar. lksw
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A n AG d
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Removing ho
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tion in
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Cop py
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co lksw
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Prote AG.

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
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CAUTION
t to the co
Risk of injury to hands and eyes caused by glass splinters.

Risk of cuts.
rrectness of i

l purpos
– Wear protective gloves!

nform
ercia
– Protect housing edges e.g. with textile-reinforced tape to pre‐

vent damage to paintwork.
m
at
om
ion
c
– Press bottom of mirror glass -1- into mirror housing.

in t
or
his
ate
– Press mirror glass -1- off adjuster unit -2- using the removal
do
riv
lever - 80-200- .
p
cum
for
en
ng
t.
– Swivel mirror glass -1- to side and detach connectors -3- for
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electric mirror heating on back of mirror glass -1-.
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Installing co Vo
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Prote AG.
– Fit connector contacts -3- on mirror glass -1-.
– Push mirror glass -1- centrally onto adjustment unit -2- in
housing.
Mirror glass engages audibly.

Passat 2015 ➤
Note
When fitting the mirror glass, only press on the centre of the mir‐
ror.
5.4 Removing and installing mirror adjust‐

ment unit
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Note
wit
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The removal and installation sequence is only for the left adjustment unit with motor. The right side is similar.
spec
t to the co
rrectness o
cial p
f inform
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or
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Cop py
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Prote AG.

Passat 2015 ➤
AG. Volkswagen AG d
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olksw not
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Removing
du
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– Remove mirror glass ⇒ page 393 .

ab
ility
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– Unscrew bolt -2- (qty. 1), and remove adjustment unit -1- from
wit
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mirror mounting.
h re
hole
spec
– Swivel adjustment unit together with motor -1- to the side and
es, in part or in w
pull off connector -3-.

t to the co
Installing
rrectness of i
– Attach connector -3- to adjusting unit -1-.

l purpos
– Fit adjustment unit -1- to mirror mounting, and secure it by

tightening bolt -2- (qty. 1).
nf
ercia
– Install mirror glass

or
⇒ “5.3 Removing and installing mirror glass”, page 393 .

m
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atio
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Specified torques
o
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Prote AG.

Passat 2015 ➤
5.5 Removing and installing mirror cover
Note
Removal and installation are described only for the left mirror cover. The right side is similar.
AG. Volkswagen AG d
agen oes
olksw not
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es, in part or in w
t to the co
rrectness of i
Removing
l purpos

– Release locking hooks -arrows A-.
nform
ercia
– Pull mirror cover -1- in -direction of arrow B- off mirror mount‐

m
at
om
ing.
ion
c
in t
or
Installing
his
ate
do
riv
– Position mirror cover -1- and press on until locking hooks en‐
p
cum
or
gage audibly.
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– Install mirror glass C py
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⇒ “5.3 Removing and installing mirror glass”, page 393 .
gh ht
pyri by
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cted agen
Prote AG.

Passat 2015 ➤
5.6 Removing and installing mirror trim

AG. Volkswagen AG d
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olksw not
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nl
pt
du
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erm
ab
ility
ot p
wit
, is n
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hole
spec
Note
es, in part or in w
t to the co
Removal and installation are described only for the left mirror trim. The right side is similar.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Passat 2015 ➤
Removing
– Remove mirror cover ⇒ page 397 .
Installing
Specified torques
AG. Volkswagen AG d
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olksw not
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nl
pt
du
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erm
ab
ility
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es, in part or in w
t to the co
rrectness of i
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Cop py
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co Vo
by lksw
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Prote AG.

Passat 2015 ➤
6 Wheel housing liner AG. Volkswagen AG d

agen oes
lksw not
⇒ “6.1 Assembly overview - front wheel housing liner”, by Vo gu
ara
page 400 rise
d
nte
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u
⇒ “6.2 Assembly overview - rear wheel housing
ss a liner”, ra
c
page 401
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le
un
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an
d
⇒ “6.3 Removing and installing front wheel housing liner”,
itte
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page 401
rm
ab
pe
ility
⇒ “6.4 Removing and installing rear wheel housing liner”, ot
wit
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page 403
h re
hole
spec
6.1 Assembly overview - front wheel housing liner
es, in part or in w
t to the co
Note
rrectness of i
♦ Minor differences may be encountered in respect of front wheel housing liner, depending on vehicle model.
l purpos
♦ The illustrations show the left-hand side. Adapt accordingly for the right-hand side.
nform
mercia
a
com
t
1 - Front wheel housing liner
ion in
r
te o
thi
s
iva
do
r
rp
c
⇒ page 401
um
fo
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ng
t.
yi
2 - Bolt
Co
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rig
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❑ 2.0 Nm
co lksw
by
cted agen
Prote AG.
3 - Snap-on nut
4 - Wheel housing liner front
part
5 - Expansion nut
6 - Locking element
❑ 2.0 Nm

lkswage es n
o ot g
byV ua Passat 2015 ➤
d ran
ir se
tho General body repairs,teeexterior
or - Edition 03.2019
au ac
ss
6.2 Assembly overview - rear wheel housing liner
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
Note
ot p
wit
, is n
h re
♦ Minor differences may be encountered in respect of front wheel housing liner, depending on vehicle model.
hole
spec
♦ The illustrations show the left-hand side. The procedure for the right-hand side is basically the same.
es, in part or in w
t to the co
1 - Rear wheel housing liner
rrectness of i
l purpos

⇒ page 403
nf
ercia
o
2 - Bolt
rm
m
atio
m
❑ Qty. 9 on each side, for

o
n in
c
wheel housing liner

or
thi
e
❑ Qty. 4 on each side, for

t
sd
iva
o
side member cover
r
rp
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o
m
f
❑ 2.0 Nm
en
ng
t.
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3 - Side member cover t. C rig
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❑ Removing and installing cop Vo
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⇒ page 403 cted agen
Prote AG.
4 - Expanding nuts
5 - Speed nuts
6 - Expansion nut
❑ Gas-tight.
❑ The expanding nut
seals the interior against
exhaust gases and must
always be renewed in
the event of damage.
7 - Adapter
❑ On right side only, not
for petrol engines
❑ Mounting prior to instal‐
ling the rear wheel hous‐
ing liner -1-
6.3 Removing and installing front wheel

housing liner
6. Wheel housing liner 401

Passat 2015 ➤
Note
♦ Removal and installation is described for the front left wheel housing liner only. The procedure for the right-
hand side is basically the same.
♦ For reasons of clarity of bolt illustration, the wheel is not shown.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
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au ra
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un
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an
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rm
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pe
ility
ot
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
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t.
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Cop py
t. rig
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pyri by
Vo
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402
c by lksw
cted agen
Rep. gr.66 - Exterior equipment Prote AG.
Passat 2015 ➤
Removing
– Pull front wheel housing liner -1- and front section of wheel
housing liner -4- out of wing.
Installing
Note
Check expanding nuts for damage and renew if necessary.

AG. Volkswagen AG d
agen oes
ksw
– Push front section of wheel by V housing liner -4- and front wheel
ol not
gu
ara
housing liner -1- into ris wing.
e d
nte
ho eo
ut
– Align wheel housing
ss a liners -1 and 4-. ra
c
ce
le
Specified torques
un
pt
an
d
itte
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♦ Bolts
rm
ab
⇒ “6.1 Assembly overview - front wheel housing liner”,
pe
ility
page 400 .
ot
wit
, is n
h re
6.4 Removing and installing rear wheel
hole
spec
housing liner
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
Removing
by lksw
cted agen
Prote AG.
Note
♦ Removal and installation are described for the rear left wheel housing liner only. The procedure for the right-

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Remove wheel ⇒ Running gear, axles, steering; Rep. gr. 44 ;

l purpos
Wheels, tyres; Specified torque for wheel bolts .

Wheel housing liner
nform
ercia

m
a
com
ti
– Pull rear wheel housing liner -1- out of wheel housing.

on in
r
te o
thi
Side member cover

s
iva
do
r
Detach rear wheel housing liner -1-.

rp
cum
fo
en
ng
t.
Unscrew bolts -2- and remove sill panel cover downwards.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
Note
c by lksw
cted agen
Prote AG.
Check spreader nuts for damage, and renew them if necessary ⇒ Item 6 (page 401) .

Passat 2015 ➤
Installing
Note
♦ Removal and installation are described for the rear left wheel housing liner only. The procedure for the right-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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rise nte
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au ra
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nl
pt
du
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itte
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erm
ab
ility
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, is n
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hole
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es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
Check spreader nuts for damage, and renew them if necessary ⇒ Item 6 (page 401) .
Wheel housing liner

– Insert rear wheel housing liner -1- in wheel housing without
kinking the liner.
– Mount wheel ⇒ Running gear, axles, steering; Rep. gr. 44 ;

Passat 2015 ➤
Side member cover

Position and bolt sill panel cover.
– Mount wheel ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Specified torques olkswage es n
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♦ Bolts ir se
d ran
tee
⇒ “6.2 Assembly overview
utho - rear wheel housing liner”, or
page 401 . ss
a ac
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nl
pt
du
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itte
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erm
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ility
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t to the co
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Cop py
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Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
rise
d b ara
nte Passat 2015 ➤
autho
General
e o body
ra repairs, exterior - Edition 03.2019
ss c
ce
e
nl
pt
du
7 Lettering and emblems
an
itte
y li
erm
ab
⇒ “7.1 Dimensions - lettering and emblems on rear”, page 407
ility
ot p
wit
, is n
⇒ “7.2 Dimensions - lettering and emblems on sides”, page 409
h re
hole
spec
⇒ “7.3 Removing and installing badges at front”, page 409
es, in part or in w
t to the co
⇒ “7.4 Renewing lettering and badges at rear”, page 413
7.1 Dimensions - lettering and emblems on
rrectness of i
rear
l purpos
⇒ “7.1.1 Removing and installing bonded lettering”, page 407

⇒ “7.1.2 Dimensions - lettering on rear lid”, page 408
nform
ercia
7.1.1 Removing and installing bonded letter‐

m
at
om
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ing
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or
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or

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Prote AG.
♦ Adhesive strip remover - VAS 6349-
Note
♦ The vertical and horizontal dimensions of lettering for the dif‐

ferent engines are identical.
♦ When fitting the lettering, observe the assembly instructions
as follows.
♦ Heat lettering or emblem with hot air blower - V.A.G 1416- be‐
fore removing.
7. Lettering and emblems 407

Passat 2015 ➤
♦ If the lettering or emblem is removed and reinstalled, only use

adhesive remover - D 002 000 10- to remove the adhesive
remains.
♦ Remove existing adhesive residue of adhesive tape using ad‐
♦ The lettering or emblem must be bonded in place immediately
after cleaning.
♦ Remove backing only immediately before installation.
♦ Lettering or emblem cannot be removed without being dam‐
aged.
7.1.2 Dimensions - lettering on rear lid
Note
When fitting the lettering, observe the fitting notes ⇒ page 407 .
1 - Lettering
❑ Model designation.
❑ Height dimension -a-:
12 ± 1 mm from lower
edge of lettering to edge
in rear lid
❑ Side dimension -b-: 20 ±
1 mm from outer edge of n AG. Volkswagen AG do
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rear lid to lettering byV
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2 - Lettering tho tee
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❑ Engine designation ss
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e
❑ Height dimension -d-:

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erm
ab
ility
in rear lid
ot p
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❑ Side dimension -e-: 8 ±

h re
1 mm from lettering to
hole
spec
lettering, if a technical
es, in part or in w
designation is fitted
t to the co
❑ Side dimension -c-: 20 ±

1 mm from outer edge of
rear lid to lettering with‐
rrectness of i
out technical designa‐

l purpos
tion
3 - Lettering
nform
ercia
❑ Technical designation
m
at
❑ Height dimension -d-:

om
io
n
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in t
or

his
ate
in rear lid
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❑ Side dimension -c-: 20 ±

f
en
g
1 mm from outer edge of

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t.
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rear lid to lettering C py
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Prote AG.

Passat 2015 ➤
7.2 Dimensions - lettering and emblems on

sides
⇒ “7.2.1 Dimensions - lettering on wing”, page 409
7.2.1 Dimensions - lettering on wing
Note
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♦ Follow the fitting notes when removing or applying the lettering
ed
by ua
ran
⇒ page 407 . thoris tee
u or
a ac
♦ The dimensions are indicated only for the left wing.
ss The di‐
mensions for the right wing are analogous.
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♦ The dimensions are applicable for any lettering.
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ility
♦ The lettering cannot be removed without damage.
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Dimension -a-: 4 mm, from character line in wing to upper edge
hole
spec
of lettering.
es, in part or in w
t to the co
Dimension -b-: 5 mm, from character line in wing to upper edge
at rear of lettering.
rrectness of i
Dimension -b-: 1 mm, from edge of wing to lower edge of lettering.
l purpos
7.3 Removing and installing badges at front
nform
ercia
⇒ “7.3.1 Removing and installing brand emblem, vehicles without

adaptive cruise control unit ”, page 409
m
a
com
tio
⇒ “7.3.2 Removing and installing brand emblem, vehicles with
n in
r
te o
adaptive cruise control unit J428 ”, page 411
thi
s
iva
do
⇒ “7.3.3 Removing and installing emblem with model designation,
r
rp
cum
R-Line ”, page 412
fo
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ng
t.
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7.3.1 Removing and installing brand emblem, vehicles without adaptive cruise C py
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control unit
pyri by
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by
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Prote AG.

Passat 2015 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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co lksw
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Removing Prote AG.
– Remove radiator grille -2- ⇒ page 345 .

– Release the two retaining hooks -3- on the rear -arrow a-.
– Push badge -1- out of radiator grille -2- slightly.
– Pull emblem -1- upwards out of radiator grille -2- -arrow b-.
Installing
– Push badge -1- into radiator grille -2- until retaining hooks
-3- can be heard to engage.

Passat 2015 ➤
7.3.2 Removing and installing brand emblem, vehicles with adaptive cruise con‐
trol unit - J428-
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Removing
– Push seal -3- slightly to one side.
rrectness of i
– Guide screwdriver -4- through opening -arrow a-.

l purpos
– While doing this, push screwdriver -4- towards rear -arrow b-.
Screwdriver -4- is thereby guided onto locking device -5-.
nform
ercia
– Release locking device -5- -arrow a-.

m
at
om
– Pull emblem -1- slightly towards front out of radiator grille

ion
c
-arrow c-. Locking devices -6- will disengage autonomously

in t
or
his
e
while doing this.

at
do
priv
– Pull emblem -1- upwards out of radiator grille -2- -arrow d-.
um
for
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Installing
Co
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– Push emblem -1- into radiator grille -2- until retaining hooks
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-5 and 6- can be heard to engage.
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Prote AG.

Passat 2015 ➤
7.3.3 Removing and installing emblem with model designation, »R-Line«
Note
Do not remove unless radiator grille -1- is removed.
AG. Volkswagen AG d
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Removing
nf
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orm
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atio
– Working from the inside, carefully unclip emblem -2- from ra‐
om
diator grille -1-.

n in
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Installing
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Passat 2015 ➤
7.4 Renewing lettering and badges at rear
Note
The badge cannot be removed without damage.
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Removing
– Use a screwdriver -3- to carefully lever manufacturer emblem
-1- off swivel badge -2- in -direction of arrow A-.
Installing
– Press manufacturer emblem -1- onto swivel badge -2- until it
engages audibly.

Passat 2015 ➤
8 Decorative film / protective film
8.1 Removing and installing protective film

♦ Adhesive strip remover - VAS 6349-
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Note
spec
es, in part or in w
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♦ The description applies to all models. Only optical differences

exist depending on the model.
rrectness of i
♦ When fitting the lettering, observe the assembly instructions

as follows.
l purpos
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♦ Heat up film before removing using a hot air blower - V.A.G

m
1416- .
a
com
tion in
♦ If film is removed, only use adhesive remover - D 002 000 10-

r
te o
thi
to remove adhesive residue.

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♦ Remove existing adhesive residue of adhesive tape using ad‐

um
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♦ The film must be applied immediately after cleaning.
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♦ Remove backing only immediately before installation.
♦ The bonded film cannot be removed without being damaged.

Passat 2015 ➤
Note
Renewing scuff protection film is described for the left-hand side only. The right side is analogous.
AG. Volkswagen AG d
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t to the co
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cial p
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Removing
– Heat up front scuff protection film -1- or rear scuff protection
film -2- using a hot air blower - V.A.G 1416- and pull off scuff
protection film from side members.
Installing
– Observe fitting instructions ⇒ page 414
– Pull off backing.
Note
Film is aligned between pillar curves.
– Position front scuff protection film -1- or rear scuff protection

film -2- and press it smooth using a plastic blade wrapped in
a soft paper towel -arrow- in centre first.
8. Decorative film / protective film 415

Passat 2015 ➤
– Check position.
– Then smooth down at front and rear -arrows-, forcing out any
bubbles.
AG. Volkswagen AG d
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Passat 2015 ➤
9 Special add-on parts
9.1 Assembly overview – special add-on

parts
1 - Model designation »R-

Line«
⇒ page 412
2 - Rear bumper cover
⇒ page 298
3 - Side member extension
❑ Left and right
⇒ page 356
swage es n
4 - Lettering on wing yV
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❑ Left and right o
ir se tee
th or
❑ Removing and installing ss
au ac
⇒ page 409
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nl
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5 - Front bumper cover
itte
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⇒ page 282
wit
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9. Special add-on parts 417

Passat 2015 ➤
10 Towing bracket
⇒ “10.1 Assembly overview - towing bracket”, page 418
⇒ “10.2 Removing and installing towing bracket”, page 419
⇒ “10.3 Removing and installing trigger unit”, page 421
10.1 Assembly overview - towing bracket
Note n AG. Volkswagen AG do

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♦ Minor differences willisbeed encountered on removal and installation,
b ua
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tee
depending on version.
or
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♦ The specified torques
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refer only to factory-installed towing brackets. ora
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♦ Request torque specifications for other towing brackets from the manufacturers.
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❑ Swivel-mounted towing
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bracket
spec
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2 - Bolt
t to the co
❑ The bolts function as
plugs and seal the pas‐
senger compartment
rrectness of i
against exhaust fumes,
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and must be installed

without fail
❑ Qty. 3
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❑ 20 Nm + 90°
m
at
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❑ From towing bracket to

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control unit
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4 - Bolt
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5 - Control unit for towing Prote AG.
bracket
– Removing: unscrew
bolt, and pull control unit
out of bracket
– Installing: push control

unit into bracket
-arrow a-, and tighten
bolt -4-
6 - Expansion nut
❑ Qty. 1
❑ From control unit to ve‐
hicle

Passat 2015 ➤
8 - Bolt

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Note different bolts and specified ise
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torques. thor eo
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❑ Bolt - N 911 784 01- (M10x38) 50 Nm + 90°
an
itte
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❑ Bolt - N 911 730 01- (M10x45) 50 Nm + 180°
erm
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❑ Always renew bolts after loosening
wit
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hole
spec
10.2 Removing and installing towing bracket
es, in part or in w
t to the co
Removing
rrectness of i
Note
l purpos
Minor differences will be encountered on removal and installation,
nf
ercia
depending on version.
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atio
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10. Towing bracket 419

Passat 2015 ➤
– Remove bumper cover ⇒ page 298 .

Remove lock carrier trim ⇒ General body repairs, interior; Rep.
lock carrier trim .
– Separate electrical connector -3- on control unit.
– If present, remove reducing agent tank ⇒ Rep. gr. 26 ; SCR
system (selective catalytic reduction), Assembly overview -
reducing agent tank
– Pull towing bracket -1- in a parallel movement out of longitu‐
dinal members.
Installing
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t to the co
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– Install in reverse order.
Note
The bolts -2- function as plugs and seal the passenger compartment against exhaust fumes. They must be
installed without fail.

Passat 2015 ➤
Ensure that the grommet on wire -3- is properly secured in the

cross panel.
– Perform functional check after installation of towing bracket.
Specified torques
♦ Bolts
⇒ “10.1 Assembly overview - towing bracket”, page 418
. Volkswagen AG
gen AG
10.3 Removing andy Vinstalling trigger unitoes not gu
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rrectness of i
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tion in
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Removing
– Remove bumper cover ⇒ page 298 .
– Remove towing bracket -4- ⇒ page 419 .
– Remove cover -2-.
– Remove drive -1-.
10. Towing bracket 421

Passat 2015 ➤
Installing
Note
♦ Before fitting cover, the area where the seal touches it must be cleaned.
♦ Under no circumstances must water be allowed to enter the trigger unit -1-.
Specified torques
AG. Volkswagen AG d
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Cover 1 Nm
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D4B804A2FD1-General Body Repairs Exterior

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D4B804A2FD1-General Body Repairs Exterior

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Service

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Service Department. Technical Information

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Copyright © 2019 Volkswagen AG, Wolfsburg D4B804A2FD1

2.1 Assembly overview - wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.1 Assembly overview - plenum chamber bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.2 Assembly overview - plenum chamber cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.3 Removing and installing plenum chamber bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

57 - Front doors, door components, central locking . . . . . . . . . . . . . . . . . . . . . . . . . . 96

1.4 Removing and installing door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

3.1 Overview of fitting locations - central locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

58 - Rear doors, door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

1.1 Assembly overview - door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

1.3 Adjusting door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

1.4 Adjusting striker pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

1.5 Removing and installing door arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

1.6 Removing and installing inner door seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

2.3 Assembly overview - door handle and door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

2.2 Assembly overview - bumper guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

2.3 Assembly overview - add-on parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296

2.4 Assembly overview - impact bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298

2.5 Removing and installing bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298

2.6 Removing and installing impact bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301

2.7 Repairing bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303

2.8 Installing brackets for parking aid system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304

1 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

1.2 Window repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

1.3 Installation instructions for bonded windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312

1.4 Preparing old undamaged windows for fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313

1.5 Preparing new windows for installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313

1.6 Preparing body flange for fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315

1.7 Cleaning off excess adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315

66 - Exterior equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344

2 Mouldings, trims, extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350

2.2 Assembly overview - side member trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351

Different versions; for allocation refer to ⇒ Electronic parts catalogue “ETKA” .

1 - Lock carrier with add-on

❑ Left and right

❑ Qty. 1 on each side

2 Rep. gr.50 - Body - front

11 - Centre guide profile

Special tools and workshop equipment required

♦ Torque wrench - V.A.G 1331-

4 Rep. gr.50 - Body - front

♦ Do not hang condenser and hydraulic oil cooler from lines.

1.3 Moving to and back from service posi‐

6 Rep. gr.50 - Body - front

♦ Torque wrench - V.A.G 1331-

♦ Torque wrench - V.A.G 1332-

Moving to service position

– Remove front bumper cover ⇒ page 282 .

– Remove headlights ⇒ Electrical system; Rep. gr. 94 ; Head‐

lights; Removing and installing headlights .

– Unhook filler neck for washer fluid reservoir on carrier -2- ⇒

Electrical system; Rep. gr. 92 ; Window washer system; Re‐

moving and installing washer fluid reservoir .

8 Rep. gr.50 - Body - front

Moving from service position

♦ Do not permit hoses and lines to be pinched.

– Adjust headlights ⇒ Electrical system; Rep. gr. 94 ; Head‐

⇒ “1.1 Assembly overview – lock carrier”, page 2 .

10 Rep. gr.50 - Body - front

2.1 Assembly overview - wing