Passat Body Repair Service Manual

Service
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Service Department. Technical Information

Service
Repair Group overview for Body Repairs
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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 © 2011 Volkswagen AG, Wolfsburg D3E80312527

Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Vehicle identification data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Moulded foam elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 Galvanized body parts, high/higher-strength and hot-formed body panels . . . . . . . . . . . . 6
4.1 Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5 Laser welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6 Body panel gaps/shut lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.1 Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.2 Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.3 Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.4 Body - rear (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7 Body dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7.1 Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7.2 Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.3 Body - centre (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.4 Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7.5 Body - rear (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.6 Floor group - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7.7 Floor group - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.8 Floor group - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
8 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9 Alignment bracket set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
9.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
10 Portal gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . .e.n .AG . .. V. o.lk.s.w.ag. e.n.A.G. . . . . . . . . . . . . . . . . . 29
ag do
10.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . .Vo. lk. s.w. . . . . . . . . . . . . . . . . .es. n.o.t g. . . . . . . . . . . . 29
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50 - Body - front . . . . . . . . . . . . . . . . . .ut.ho. . . . . . .
r
. . . . . . . . . . . . . . . . . . . . . . .or. . . . . 31
tee
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1 Renewing left console . . . . . . . .ss. . . . . . . . . . .
................................. 31
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1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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1.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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1.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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2 Renewing right console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
hole
spec
2.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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2.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3 Renewing retaining bracket for subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
rrectness of i
3.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
l purpos
3.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4 Renewing bumper bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
nform
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4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
m
4.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
com
tion in
4.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
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5 Renewing upper wheel housing longitudinal member . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

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5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
rp
cum
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5.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
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5.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
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6 Renewing front wheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
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Contents i
AG. Volkswagen AG d
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Passat 2011 ➤ , PassatrisVariant
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2011 ➤ ara
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Body Repairs - Edition
aut 04.2011
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6.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
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6.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
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6.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
ility
7 ot p
Repairing threads for securing subframe (suspension subframe) . . . . . . . . . . . . . . . . . . . . 66
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7.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
hole
spec
7.2 Contents of thread repair kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
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t to the co
7.3 Repairing threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
8 Renewing front longitudinal member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
rrectness of i
8.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
l purpos
8.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
9 Renewing front longitudinal member - part section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
nf
ercia
9.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
orm
m
9.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
atio
om
9.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
n in
or c
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sd
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51 - Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
iv
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1 Renewing roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
f
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1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Co
Cop py
t.
1.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
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1.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
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2 Renewing roof - vehicles with sliding/tilting sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
AG.
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

2.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
2.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3 Renewing roof (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
3.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4 Renewing roof - Variant with panorama sliding sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
4.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
5 Renewing roof side member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
5.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
5.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
5.4 Foam treating roof side member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
6 Renewing front roof cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
6.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
6.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
6.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
7 Renewing rear roof cross member (saloon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
7.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
7.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
7.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
8 Renewing rear roof cross member (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
8.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
8.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
8.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
9 Renewing A-pillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
9.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
9.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
9.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
ii Contents
10 Renewing A-pillar reinforcement - part section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

10.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
10.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
10.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
11 Renewing B-pillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
11.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
11.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
11.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
12 Renewing B-pillar reinforcement - part section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
12.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
12.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
12.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
13 Renewing inner B-pillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
13.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
13.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
13.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
14 Renewing side member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
14.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
14.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
14.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
15 Renewing front side member reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
15.1 Tools . . . . . . . . ..V.o.lk.sw. a. g.e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
n AG n AG
15.2 Removing olks
wag.e. . . . . . . . . . . . . .d.oe. s. n.o. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
V tg
15.3 Installing
d by . . . . . . . . . . . . . . . . . . . . . . u.a.ra.n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
rise te
16 authoRenewing rear side member reinforcement e o.r a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
16.1
ss Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
ce
le
16.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

un
pt
an
d
itte
16.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

y li
erm
ab
17 Renewing seat middle cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

ility
ot p
wit
17.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

is n
h re
17.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

ole,
spec
17.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252

urposes, in part or in wh
t to the co
18 Renewing inner mounting for seat cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255

18.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
18.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
rrectne
18.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

s
19 Renewing outer mounting for seat cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

s o
cial p
19.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

f inform
19.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

mer
19.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

atio
om
n
c
i
or
53 - Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

thi
te
sd
va
1 Renewing rear cross panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

i
o
pr
cum
r
fo
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

en
ng
t.
yi
1.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Co
Cop py
. rig
1.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
ht ht
rig by
opy Vo
2 Renewing rear cross panel (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
by c lksw
cted agen
Prote
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
AG.
2.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

2.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
3 Renewing lock carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
3.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
3.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Contents iii
4 Renewing tail light mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284

4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
4.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
4.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
5 Renewing tail light mounting (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
5.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
5.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
6 Renewing C-pillar reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
6.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
6.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
6.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
7 Renewing C-pillar reinforcement (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
7.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
7.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
7.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
8 Renewing D-pillar reinforcement - part section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
8.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
8.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
8.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
9 Renewing inner D-pillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
9.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. V. o.lk.s.w.ag. e. . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
n AG n AG
9.2 Removing . . . . . . . . . . . . . . . . . . . o. lk.s.w.ag. e. . . . . . . . . . . . . . d.o.es. n.o. . . . . . . . . . . . . . . . . . . . 318
V tg
9.3 Installing . . . . . . . . . . . . . . . . .ed. b.y. . . . . . . . . . . . . . . . . . . . . . . . . . .ua. r.an. . . . . . . . . . . . . . . . 319
ris te
10 Renewing rear longitudinalaumember tho - part section . . . . . . . . . . . . . . . . . .e .or.a . . . . . . . . . . . . 322
10.1 Tools . . . . . . . . . . . . . . s.s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c. . . . . . . . . . . . 323
ce
e
nl
10.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324

pt
du
an
itte
10.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326

y li
erm
11 Renewing side panel - part section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ab 332

ility
ot p
wit
11.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
, is n
h re
11.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
hole
spec
11.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335

es, in part or in w
t to the co
12 Renewing side panel (Variant) - part section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342

12.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
12.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
rrectness of i
12.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345

l purpos
13 Renewing outer wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352

13.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
nform
ercia
13.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353

m
13.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355

at
om
ion
c
14 Renewing outer wheel housing liner (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360

in t
or
his
e
14.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361

at
do
riv
14.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361

p
cum
for
14.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364

en
ng
t.
yi Co
op
15 Renewing spare wheel well . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
C py
ht. rig
rig ht
15.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
py by
co Vo
by lksw
15.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prote
cted AG.
agen
372
15.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
iv Contents
00 – Technical data olksw

agen
AG. Volkswagen AG d
oes
not
y V gu
d b ara
ise nte
1 Vehicle identification data or eo
th
au ra
ss c
ce
le
un
pt
an
d
1.1 Vehicle identification number
itte
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erm
ab
ility
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is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
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c
i
or
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fo
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gh ht
pyri by
Vo
co lksw
by
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Prote AG.
The vehicle identification number -1- is located in the area of the

lower left-hand side of the windscreen (driver's perspective).
Note
♦ The vehicle identification number is also stamped at three oth‐

er locations.
♦ If the component has to be renewed in the event of damage,
the repair must be documented according to the market-spe‐
cific legislation.
1. Vehicle identification data 1

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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ho eo
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es, in part or in w
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rrectness of i
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mercia
at
om
io
♦ The vehicle identification number -arrow A- is located on the

n
c
in t
wing mounting on the right in the luggage compartment (driv‐

or
his
e
er's perspective).
at
do
priv
cum
♦ The vehicle identification number -arrow B- is located on the

for
en
g
sill panel seat mounting in the vicinity of the front door on the
n
t.
yi Co
op
right side of the vehicle. C py
ht. rig
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♦ The vehicle identification number -arrow C- is located on the
py by
co Vo
by lksw
floor panel of the rear seats. Prote
cted AG.
agen
Note
The numbers are located at the same points on the Variant.
2 Rep. gr.00 - Technical data

2 Safety instructions
WARNING
Before beginning any cutting, alignment or dent removal, refer

to safety notes in the binder General information, body repairs
and general body repairs.
Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes
AG. Volkswagen AG d
agen oes
olksw not
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tho eo
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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
in t
or
his
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.
2. Safety instructions 3
AG. Volkswagen AG d
agen oes
lksw not
3 Moulded foam elements Vo gu
d by ara
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or eo
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On this vehicle, various bodywork
aut cavities are fitted with moulded ra
c
foam elements. ss
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un
pt
The moulded foam elements reduce the amount of driving noise
an
d
itte
y li
that is transmitted into the interior.
rm
ab
pe
ility
The moulded elements are fitted during body shell construction
ot
wit
and increase their volume in the paint shop drying oven at approx.
, is n
h re
180°C, after priming.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
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tion in
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te o
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cted agen
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The exact location of these moulded foam elements are shown

at the beginning of the respective repair description.
Caution
The replacement moulded foam elements expand first at ap‐

prox. 180° This is why a foam filler is used in some repair
cases.
The foam filler D 506 KD1 A2 is required for these repair cases.

As these temperatures cannot be achieved under normal work‐

shop conditions, proceed as follows:
Remove foam material remains on vehicle.
– Apply corrosion protection measures according to guidelines
in ⇒ Paint workshop manual: Corrosion and corrosion pro‐
tection, attached and welded parts, materials .
Prerequisites
AG. Volkswagen AG d
agen oes
Before continuing with this procedure, ensure Vthatolks the part for re‐
w not
gu
placement is correctly prepared e.g. cut and d by
adapt to fit, corrosion ara
e nte
protection measures. oris eo
th
a u ra
c
Renewing moulded foam element ss
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un
pt
Fix moulded foam element to vehicle.
an
d
itte
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erm
ab
Apply foam filler D 506 KD1 A2 to replacement part.
ility
ot p
Secure new part in position. Gently press new part, in vicinity of
wit
is n
h re
moulded foam element, until it makes contact and then weld in.
ole,
spec
The foam filler hardens within 25 minutes.
t to the co
Do not do perform shielded arc welding within 15 mm of foam
filler.
rrectne
Carry out cavity protection to repair area after painting vehicle.
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
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Moulded foam elements 5

4 Galvanized body parts, high/higher- agen

AG. Volkswagen AG d
oes
ksw
strength and hot-formed body panelsed by Vol not
gu
ara
ris nte
Working on galvanized body panels ⇒ General Information; aBody
ut
ho eo
ra
Repairs, General Body Repairs ; Steel panel repairs; galvanized
ss c
body parts .
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an
d
itte
4.1 Body
y li
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, is n
Note
h re
hole
spec
es, in part or in w
Repairs may only be made according to the manufacture instruc‐
t to the co
tions in the respective repair manual. Higher-strength and hot-
formed body panels may only be repaired using modern inverter
technology, otherwise the optimum passenger protection after
rrectness of i
repairs is not possible. Form tempered steel panels are used in
areas under extreme stress. These panels offer a clearly higher
l purpos
strength than conventional high-strength panels for less weight.
nform
ercia
Work on strengthened body panels must comply with guide lines

in Workshop Manual ⇒ General Information; Body Repairs, Gen‐
m
a
com
t
eral Body Repairs ; Steel panel repairs, strengthened body panels
ion in
r
te o
The body of the vehicle is predominantly manufactured from
thi
s
iva
galvanized steel panels.
do
r
rp
cum
fo
This illustration shows those parts of the body manufactured from
en
ng
t.
hot-formed body panels.
yi Co
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by
cted agen
Prote AG.

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du
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ility
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
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om
n in
or c
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te
sd
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Prote AG.
4. Galvanized body parts, high/higher-strength and hot-formed body panels 7

Body Repairs - Edition 04.2011 lkswage es n
o ot g
byV ua
d ran
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u or
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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a
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tion in
r
te o
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do
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en
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t.
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Cop py
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Vo
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by
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Prote AG.

5 Laser welding
On this vehicle, the roof and parts of the body are laser welded.
With laser welding, a high-energy beam of light is directed over
the seam to be welded by optical lenses or optical fibre.
During the welding process, the upper panel is melted onto the
partially molten lower panel, creating a welded joint without the
need of additional material.
For repairs (except for roof repairs), the laser weld seam is re‐
placed by a RP spot weld seam.
AG. Volkswagen AG d
agen oes
olksw not
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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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o
pr
cum
r
fo
en
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t.
yi Co
Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
5. Laser welding 9
6 Body panel gaps/shut lines
Note
Use setting gauge -3371- to set or check shut lines.
6.1 Body - front
a - 2.5 mm ± 0.5 mm
b - – 2.6 mm ± 0.8 mm
c - 2.8 mm ± 0.5 mm
d - – 0.1 mm ± 0.5 mm
e - 0.8 mm ± 0.5 mm
f - 2.0 mm ± 0.5 mm
AG. Volkswagen AG d
agen oes
g - 5.0 mm ± 0.5 mm Volksw not
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d by ara
h - 4.7 mm ± 0.5 mm orise nte
eo
h
aut ra
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nl
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du
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itte
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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
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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t. rig
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Vo
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cted agen
Prote AG.

AG. Volkswagen AG d
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agen oes
not
Vol
by gu
ara
ed
6.2 Body - centre
thoris nte
eo
au ra
c
ss
ce
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nl
a - 2.0 mm ± 1.0mm
pt
du
an
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b - 0.6 mm ± 0.5 mm
erm
ab
ility
ot p
c - 0.0 mm + 1.0 mm
wit
, is n
h re
d - 4.2 mm ± 1.5 mm
hole
spec
e - 0.0 mm + 1.0 mm
es, in part or in w
t to the co
f - 3.2 mm – 0.5 mm + 1.0 mm
g - 12.7 mm ± 0.5 mm
rrectness of i
h - 4.2 mm – 0.5 mm + 1.0 mm
l purpos
i - 0.0 mm + 1.0 mm
nf
ercia
j - 12.7 mm ± 0.5 mm
orm
m
atio
k - 3.5 mm – 0.5 mm + 1.0 mm
om
n in
c
l - 0.0 mm – 1.0 mm
or
thi
te
sd
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t.
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rig ht
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co Vo
by lksw
cted agen
Prote AG.
6. Body panel gaps/shut lines 11

6.3 Body - rear
a - 2.5 mm ± 0.5 mm
b - – 3.2 mm ± 0.5 mm
c - 5.5 mm ± 0.5 mm
d - 3.5 mm ± 0.5 mm
e - – 0.7 mm ± 0.5 mm
f - 2.5 mm ± 1.0 mm
AG. Volkswagen AG d
agen oes
g - – 6.6 mm ± 0.5 mm olksw not
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d by ara
e
h - 3.5 mm ± 0.5 mm horis nte
eo
aut ra
i - – 0.5 mm ± 0.5 mm ss c
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nl
pt
du
an
itte
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ab
ility
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, is n
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
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m
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n in
or c
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te
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Prote AG.

6.4 Body - rear (Variant)
a - 5.0 mm ± 0.5 mm
b - – 0.8 mm – 1.0 mm + 0.5
mm
c - 5.0 mm ± 0.5 mm
d - 3.5 mm ± 0.5 mm
e - – 1.1 mm ± 0.5 mm
f - – 0.6 mm ± 0.5 mm
g - 3.5 mm ± 0.5 mm
h - 5.0 mm ± 0.5 mm
i - – 4.3 mm ± 0.5 mm
AG. Volkswagen AG d
agen oes
olksw not
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es, in part or in w
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nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
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cum
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t.
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Cop py
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Prote AG.
6. Body panel gaps/shut lines 13

7 Body dimensions
Note
AG. Volkswagen AG d
agen oes
♦ Dimensions only given for checking purposes. The yalignment
Vol
ksw not
gu
bracket set is the final authority. ed
b ara
nte
oris eo
Bolts, screws, plugs, trim and attached components must be
h
♦ au
t ra
removed before starting the measuring process.
ss c
ce
le
un
pt
♦ Use Telescopic gauge -VAS 5159- or Telescopic gauge -VAS
an
d
5160- to determine body dimensions. itte
y li
rm
ab
pe
ility
♦ Ensure measuring probes are always of even length to prevent
ot
wit
inaccuracies when measuring.
, is n
h re
hole
spec
es, in part or in w
7.1 Body - front
t to the co
a - 938 mm ± 2.0 mm
rrectness of i
b - 1,438 mm ± 2.0 mm
l purpos
c - 1,550 mm ± 2.0 mm
nform
ercia
d - 1,513 mm ± 2.0 mm
m
a
com
tion in
r
te o
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t.
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Cop py
t. rig
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Vo
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by c lksw
cted agen
Prote AG.

a - 920 mm ± 2.0 mm
b - 1,479 mm ± 2.0 mm
AG. Volkswagen AG d
agen oes
olksw not
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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
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
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m
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t.
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t. rig
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Vo
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by c lksw
cted agen
Prote AG.
7. Body dimensions 15
7.2 Body - centre
a - 1,445 mm ± 2.0 mm
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
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
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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.

a - 1,480 mm ± 2.0 mm
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
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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t.
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t. rig
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by c lksw
cted agen
Prote AG.
Passat 2011 ➤ , Passat Variant 2011 ➤ AG. Volkswagen
en AG do
Body Repairs - Edition 04.2011 olkswag es n
o
yV t gu
db ara
a - 1,472 mm ± 2.0 mm ir se nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
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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
en
ng
t.
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Cop py
t. rig
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by
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Prote AG.

lkswage es n
d
Passat
byV
o
2011 ➤ , Passat Variant 2011
ot g
ua ➤
ran
ho
ir se Body Repairs - Edition 04.2011 tee
ut or
a ac
ss
a - 882 mm ± 2.0 mm
ce
e
nl
pt
du
b - 896 mm ± 2.0 mm
an
itte
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ility
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es, in part or in w
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ion
c
in t
or
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ate
do
priv
cum
for
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ng
t.
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AG. Volkswagen AG d
agen oes
lksw not
a - 970 mm ± 2.0 mm d by
Vo gu
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r
b - 741 mm ± 2.0 mm ut
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an
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es, in part or in w
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tion in
r
te o
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Cop py
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cted agen
Prote AG.

7.3 Body - centre (Variant)
a - 972 mm ± 2.0 mm
b - 740 mm ± 2.0 mm
AG. Volkswagen AG d
agen oes
olksw not
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tho eo
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nl
pt
du
an
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ab
ility
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es, in part or in w
t to the co
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nf
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atio
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7.4 Body - rear
a - 528 mm ± 2.0 mm
b - 1,125 mm ± 2.0 mm
AG. Volkswagen AG d
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olksw not
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es, in part or in w
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l purpos
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mercia
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tion in
r
te o
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do
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t.
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by
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Prote AG.

7.5 Body - rear (Variant)
a - 857 mm ± 2.0 mm
b - 938 mm ± 2.0 mm
c - 1,198 mm ± 2.0 mm
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
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au ra
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un
pt
an
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ole,
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t to the co
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f inform
mer
atio
om
n
c
i
or
n thi
te
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t.
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Prote AG.
7.6 Floor group - front
a - 430 mm ± 2.0 mm
b - 874 mm ± 2.0 mm
c - 678 mm ± 2.0 mm
d - 1,152 mm ± 2.0 mm
AG. Volkswagen AG d
agen oes
olksw not
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or eo
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aut ra
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un
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an
d
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is n
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ole,
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t to the co
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mer
atio
om
n
c
i
or
n thi
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t.
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AG. Volkswagen AG d
agen oes
7.7 Floor group - centre d byV
olksw not
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Note ss c
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pt
an
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Dimension -a- is measured on floor at the left and right B-pillar.
itte
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a - 1,486 mm ± 2.0 mm
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
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cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
7.8 Floor group - rear
a - 1,000 mm ± 2.0 mm
b - 1,085 mm ± 2.0 mm
c - 987 mm ± 2.0 mm
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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itte
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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
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.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
horis Passat
nte
eo 2011 ➤ , Passat Variant 2011 ➤
aut ra Body Repairs - Edition 04.2011
ss c
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un
pt
an
d
8 Tools
itte
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Note
h re
hole
spec
♦ The use of different types and different thicknesses of steel
es, in part or in w
t to the co
requires that only the welding units (inverters) authorised by
Volkswagen AG may be used to carry out repairs properly.
♦ The welding units (inverters) and body tools authorised by
rrectness of i
Volkswagen AG are listed in ⇒ ServiceNet, Workshop Equip‐
l purpos
ment, EH catalogue, Workshop equipment, Body and paint‐

work .
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
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cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
8. Tools 27
9 Alignment bracket set
Note
Alignment tasks may only be performed using Volkswagen AG

approved alignment bracket sets or measurement and alignment
systems .
9.1 Overview
Special tools and workshop equipment required
♦ Alignment bracket set Passat 2011 -VAS6325/3-
♦ Basic alignment bracket set -V.A.G 1610/-
Set up of complete alignment bracket set for Passat 2011 -
VAS6325/3- .
lkswage es n
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d ran
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es, in part or in w
t to the co
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l purpos
nform
mercia
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com
tion in
r
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do
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10. Portal gauge 29

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1. Renewing left console 31

1.2 Removing
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32 Rep. gr.50 - Body - front

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RO: 50 40 55 53
2 Renewing right console
WARNING

2.1 Tools
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2. Renewing right console 37

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2.3.1 Welding in
New part
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set and fix in place.

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2. Renewing right console 39

RO: 50 43 55 00
3 Renewing retaining bracket for sub‐

frame
WARNING

Note
The description of the procedure for renewing the front left sub‐
frame retaining bracket uses this vehicle as an example. The
procedure, as appropriate, should be used for the other 3 retain‐
ing brackets.
3.1 Tools
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3. Renewing retaining bracket for subframe 41

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3.3.2 Welding in
AG. Volkswagen AG d
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3. Renewing retaining bracket for subframe 43

RO: 50 65 55 50
4 Renewing bumper bracket
WARNING

1 - Bumper bracket
2 - Longitudinal member with
cover plate
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4. Renewing bumper bracket 45

4.3 Installing
Note

⇒ page 45 . agen
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4. Renewing bumper bracket 47

RO: 50 72 55 00
5 Renewing upper wheel housing lon‐

gitudinal member
Comprises: upper outer longitudinal member and upper inner
longitudinal member
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1 - Front outer longitudinal

member
2 - Front inner longitudinal
member
3 - Bonded area
4 - Aperture to plenum cham‐
ber
Cut out together with
⇒ Item 1 (page 49) .
5 - Parting cut for partial re‐

placement
A partial replacement can also
be made with the specified
parting cut.
Dimension -a- = 270 mm
AG. Volkswagen AG d
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5. Renewing upper wheel housing longitudinal member
5.2 Removing
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5. Renewing upper wheel housing longitudinal member 51

olkswagen AG
ag en AG. V
Passat 2011Vo➤lks,wPassat Variant 2011 ➤
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5.3 Installing
Note

⇒ page 49 .

New part
♦ Upper inner longitudinal member
♦ Upper outer longitudinal member
♦ 2K body adhesive -D 180 KD3 A2-

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t to the co
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ment bracket set and fix in position.
rrectne
– Check fit with bolt-on parts.

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AG.
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– Weld in upper inner longitudinal member -1-, RP spot weld

seam and SG staggered continuous weld seam.
– Apply 2K body adhesive -D 180 KD3 A2- to areas bonded in
the factory.

– Adapt upper outer longitudinal member to fit with upper inner

longitudinal member and check fit with adjacent parts.
AG. Volkswagen AG d
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5. Renewing upper wheel housing longitudinal member 55

RO: 50 74 55 50
6 Renewing front wheel housing

Includes: suspension strut mounting
WARNING

Repairs ; Safety notes wage
e ks s no
Vol t gu
• Longitudinal member for upper wheel housing already
db
y re‐ ara
moved ⇒ page 48 . rise nte
tho eo
au ra
c
ss
ce
le
1 - Wheel housing
un
pt
an
d
itte
y li
2 - Plenum chamber
rm
ab
pe
ility
3 - Suspension strut mounting
ot
wit
, is n
h re
With suspension strut mount‐
hole
ing reinforcement
spec
es, in part or in w
t to the co
4 - Longitudinal member with
cover plate
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.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e nte
horis Passat
eo 2011 ➤ , Passat Variant 2011 ➤
ut
ss a ra
c Body Repairs - Edition 04.2011
ce
e
nl
pt
du
6.1 Tools
an
itte
y li
erm
ab
ility
ot p
wit
Note
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
work .
nf
ercia
6.2 Removing
orm
m
atio
m
Partial renewal
o
n in
or c
Depending on damage, a partial renewal is possible using parting
thi
te
sd
a
cut -1-.
iv
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.
– Separate original joint to front longitudinal member cover plate

and to plenum chamber from wheel housing side.
6. Renewing front wheel housing 57

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
– Separate remainder of joint to plenum chamber -1-.

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.

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
m

o
n in
or c
thi
6.3 Installing
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi
Note
Co
Cop py
t. rig
gh ht
yri
p by
co Vo
by lksw
⇒ page 57 . cted agen
Prote AG.
6.3.1 Preparing new parts

♦ Wheel housing
♦ Suspension strut mounting
♦ Suspension strut mounting reinforcement

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
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.
Note
♦ Drill a double row of holes in area -1-.

♦ Distance between holes: approx. 30 mm.

6.3.2 Welding in
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
– Adapt new part with assistance of alignment bracket fixtures

-item 13-, -item 15-, -item 16- and -item 17- from alignment
bracket set and to adjacent parts and fix in place.
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.

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
ercia
– Weld suspension strut mounting to suspension strut mounting

reinforcement, SG plug weld seam.
m
at
om
ion
– Drill holes -1- (10 mm ∅) for mounting suspension strut. Ad‐

c
in t
or
ditionally secure suspension strut mounting and suspension

his
ate
strut mounting reinforcement to alignment bracket fixture -2-

do
priv
using bolts.
um
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

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
– Weld wheel housing and suspension strut mounting reinforce‐

wit
is n
ment, SG plug weld seam.

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.

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.
– Recreate joint between suspension strut mounting and ple‐

num chamber; SG plug weld seam.
– Recreate original joint between suspension strut mounting and
suspension strut mounting reinforcement, RP spot weld seam.
– Recreate remaining joints for wheel housing, RP spot weld
seam.

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
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.
– Enlarge hole in suspension strut mounting reinforcement to
dimension -a-.
Note
Item 17 of alignment bracket set can be used to check dimension -a- ⇒ page 27 .
– Install upper longitudinal member for wheel housing

⇒ page 52 .

RO: 50 79 49 90
7 Repairing threads for securing sub‐

frame (suspension subframe)
WARNING

Note
The thread repair is described for the front left retaining bracket
for the subframe on this vehicle and the procedure, as appropri‐
ate, should be used for the other 3 retaining brackets.
1 - Longitudinal member n AG. Volkswagen AG do

lkswage es n
o ot g
yV
2 - Threaded plate (welded to ised b ua
ran
subframe retaining bracket) th or tee
or
au ac
ss
Note ce
le
un
pt
an
d
itte
y li
erm
3 - Retaining bracket for sub‐ ab

ility
ot p
frame wit
is n
h re
4 - Helicoil thread insert
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.

7.1 Tools
♦ M12x1.5 thread repair set -VAS 6058-
♦ Drill -VAS 6267-
7.2 Contents of thread repair kit
1 - Twist drill 12.5 mm ∅

2 - Thread-cutting tap M12 x
1.5
3 - Fitting spindle
4 - Thread insert M12 x 1.5 x
24 -VAS 6058/1-
5 - Pin breaker with magnetic
end 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
cted agen
Prote AG.
7. Repairing threads for securing subframe (suspension subframe) 67

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
o eo
Passat 2011 ➤ , Passat Variant 2011 ➤ aut
h
ra
s c
Body Repairs - Edition 04.2011 s
ce
e
nl
pt
du
an
7.3 Repairing threads
itte
y li
erm
ab
ility
ot p
wit
, is n
7.3.1 Drilling thread
h re
hole
spec
es, in part or in w
– Drill out thread using twist drill.
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.
Note
♦ The drill must be held by an assistant using an additional hand

support when drilling.
♦ Use drill -VAS 6267- when drilling and shaping.
♦ Do not cant drill.

7.3.2 Cutting thread

– Cut thread with thread-cutting tap
– Clean threaded sleeve (with compressed air).
AG. Volkswagen AG d
agen oes
olksw not
7.3.3 Inserting thread insert
y V gu
d b ara
rise nte
tho eo
– Screw
s a thread insert -3- onto fitting spindle until the fitting
u ra
c pin
-2- contacts the fitting lug -1- on the fitting spindle.
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
co lksw
by
cted agen
Prote AG.
7. Repairing threads for securing subframe (suspension subframe) 69

AG. Volkswagen AG d
agen oes
lksw not
– Screw thread insert into the threaded d by plate until the top of the
V o gu
ara
thread insert is flush with the outer
oris edge of the threaded plate
e nte
(visual check). aut
h eo
ra
ss c
– Then screw thread insert inwards a / turn. 1
ce
e
4
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
h re
Thread insert must screw in easily.
hole
spec
es, in part or in w
– Remove fitting spindle.
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
– Break off drive pin of thread insert using pin breaker.
or c
thi
te
– Install subframe (suspension subframe) ⇒ Suspension, axles,
sd
iva
o
r
steering; Rep. gr. 40 ; Subframe, anti-roll bar, suspension link .

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.

RO: 50 79 55 00
8 Renewing front longitudinal member

Includes: bumper mounting
WARNING

1 - Parting cut (cover plate)

2 - Parting cut (longitudinal
member)
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.
8. Renewing front longitudinal member 71

AG. Volkswagen AG d
Body Repairs - Edition l04.2011
kswagen oes
n o ot g
yV ua
edb ran
8.1 Tools tho
ris tee
or
au ac
ss
ce
e
nl
pt
du
Note
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
work .
rrectness of i
8.2 Removing
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
o
by c lksw
cted agen
Prote AG.

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
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Make parting cut on longitudinal member as shown.


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
ng
t.
yi
– Make parting cut on longitudinal member cover plate as
Co
op py
shown.
t. C rig
gh ht
pyri by
Vo
o
Dimension -a- = 55 mm by c lksw
cted agen
Prote AG.

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
8.3 Installing
nform
mercia
Note
com
tion in
r
te o
thi

s
iva
do
⇒ page 72 .
r
rp
cum
fo
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
yri
New part p by
o Vo
by c lksw
cted agen
♦ Longitudinal member assembly Prote AG.

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.
– Transfer parting cuts to new part and cut out.

8.3.2 Welding in

AG. Volkswagen AG d Body Repairs
- Edition 04.2011
agen oes
olksw not
V gu
– Check fit with adjacent parts. ed by ara
nte
ris
ho eo
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
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Butt weld parting cut of longitudinal member all around (SG

continuous weld seam).
– Butt weld cover plate parting cut, SG continuous weld seam.
– Restore remaining joint, SG plug weld seam and RP spot weld
seam.

8.3.3 Shortening new longitudinal member with cover plate
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.
Note
The longitudinal member -2- with cover plate -1- (parts designation: longitudinal member) is too long at the front
-shaded area- and must be shortened when adapting and welding in the bumper bracket.

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
ercia
– Assemble alignment bracket mounting for front longitudinal

m
member -RW 1- with spacer -RW 3- as shown and hold against

at
om
io
longitudinal member from below. n
c
in t
or
his
– Transfer dimensions (plus an additional 2mm) -a- to longitu‐

ate
do
riv
dinal member and cover plate and remove excessive material.

p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

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
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
– Fix front bumper bracket -1- in position in front of longitudinal

s
iva
do
member -2- with aid of -RW 1- and -RW 3-.

r
rp
cum
fo
en
ng
t.
yi Co
op py
Note
. C rig
ht ht
rig by
copy Vo
lksw
There must be a gap of 1-2 mm between longitudinal member -2- with cover plate -3- and bumper bracket
by
cted agen
Prote
-1-.
AG.

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.
– Weld in bumper bracket, SG continuous weld seam.

AG. Volkswagen AG d
agen oes
olksw not
Passat 2011 ➤ , Passat Variantd by
V
2011 ➤ gu
ara
e nte
Body Repairs - Editionth04.2011
oris
eo
au ra
ss c
ce
le
un
pt
RO: 50 79 55 02
an
d
itte
y li
9 Renewing front longitudinal member
rm
ab
pe
ility
- part section ot
wit
, is n
h re
Includes: bumper bracket and longitudinal member reinforcement
hole
spec
es, in part or in w
t to the co
WARNING
rrectness of i
l purpos

nform
mercia
a
com
t
1 - Cover plate
ion in
r
te o
2 - Longitudinal member
thi
s
iva
do
3 - Laser weld seam
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.

9.1 Tools
Note

work .
9.2 Removing
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
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.
Note
♦ The parting cut for cover plate -1- and the parting cut for longitudinal member -2- must be offset.
♦ Do not cut or weld 50 mm before or after the laser weld seam -3- (shaded area).
9. Renewing front longitudinal member - part section 83

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e nte
Passat 2011 ➤ , Passat Variant 2011 ➤ tho ris
eo
u
Body Repairs - Edition 04.2011 ss a ra
c
ce
le
un
pt
– Position parting cuts -1 and 3- on longitudinal member ac‐
an
d
itte
cording to degree of damage and cut out.
y li
rm
ab
pe
ility
ot
wit
Caution
, is n
h re
hole
spec
The parting cut for the longitudinal member is permitted only
es, in part or in w
in the area shown. If the longitudinal member is damaged be‐
t to the co
yond this area, it must be renewed entirely.
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.
– Position parting cut -1- for cover plate as shown and cut out.
– Remove cover plate.

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
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.
– Position parting cut -3- on longitudinal member -1- and longi‐

tudinal member -2- congruently and cut out.
– Take note of laser weld seam -4-.

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
– Remove residual material and remainder of longitudinal mem‐
cial p
f in
ber reinforcement -1-.
form
mer
atio
9.3 Installing
om
n
c
i
or
n thi
te
sd
va
Note
i
o
pr
cum
r
fo
en
ng
t.
yi Co
op
⇒ page 83 .
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
New part
♦ Longitudinal member
♦ Cover plate for longitudinal member
♦ Longitudinal member reinforcement (parts designation: bulk‐
head plate)

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by Passat 2011 ➤ , Passat Variant
ara 2011 ➤
ise nte
r
tho Body Repairs - Editione o 04.2011
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
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
o
by c lksw
cted agen
Prote AG.
– Transfer parting cut to longitudinal member and longitudinal

member cover plate and cut out.
9.3.2 Welding in

– Check fit with adjacent parts.
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
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Weld in longitudinal member parting cut (all round), SG con‐
tinuous weld seam.

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
– Weld in longitudinal member reinforcement, RP spot weld
seam.
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.

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
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
– Weld in cover plate, RP spot weld seam.
atio
om
n
c
i
or
n thi
e
Note
t
sd
iva
o
pr
cum
r
fo
Distance between weld points -a- approx. 35-40 mm

en
ng
t.
yi Co
Cop py
– Weld in cover plate parting cut, SG continuous weld seam.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

51 – Body - centre
RO: 51 03 55 00
1 Renewing roof
WARNING n AG. Volkswagen AG do

lkswage es n
o ot g
yV ua
Observe safety notes! ir se
d b ran
tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
1 - Roof
ot
wit
, is n
h re
2 - Laser solder seam
hole
spec
3 - Bonded areas
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.
1. Renewing roof 91
1.1 Tools lksw

agen
AG. Volkswagen AG d
oes
not
Vo gu
d by ara
ise nte
or eo
Note aut
h
ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
work .
t to the co
♦ Pneumatic cartridge gun -V.A.G 1761/1-
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
o
by c
♦ Cartridge heater -V.A.G 1939 A-
lksw
cted agen
Prote AG.
♦ Double-cartridge gun -VAS 5237-
92 Rep. gr.51 - Body - centre

♦ Setting gauge -3371-
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
♦ Tensioning strap -T10038-
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
♦ Suction lifter -V.A.G 1344-
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.
1. Renewing roof 93
1.2 Removing
Note
♦ Apply textile adhesive tape on left and right roof members parallel to laser solder seams. This reduces
danger of damage and contamination during repairs.
n AG. Volkswagen AG ge does
swa
♦ When separating, ensure sufficient distance
by
Vol of to roof member -2- is kept,
k not
gto
uaassure it is not damaged during
repairs. ris
ed ran
tee
tho
or
♦ When making parting cuts -1-,ssensure that the panels lying behind are not au damaged. ac
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
o
by c lksw
cted agen
Prote AG.
– Separate original joint to front and rear roof cross members.

– From interior, separate bonded joints to front and rear roof
cross members.
– Roughly cut roof out parallel to laser solder seams.

Note
♦ Roof side member -1- must not be damaged when removing residual remains of roof -2-.
♦ Use flap or felt discs only, do not use cutting disks or rough grinding disks.
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
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Remove all adhesive and sealant residues from front and rear
roof cross members.
– Remove all adhesive residues from left and right roof side
members.
– Touch up paint damage in accordance with Paint Workshop
Manual.
1. Renewing roof 95
1.3 Installing
Note

⇒ page 92 .

New part
♦ Roof
♦ 1K assembly adhesive -D 190 MKD A3- (3 cartridges)
♦ 2K body adhesive -D 180 KD3 A2- (2 cartridge sets)
♦ Adhesive sealant -AKD 476 KD5 05-
♦ Cavity sealant -AKR 321 M15 4-
♦ Felt -533 867 910 B-
Note
♦ Following working sequence must be adhered to in order to

ensure correct and long-lasting roof repairs.
♦ For this repair, it is absolutely necessary to work with great
care to prevent faults during processing.
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
96
AG.
Rep. gr.51 - Body - centre
AG. Volkswagen AG d
agen oes
olksw not
yV gu
ed b Passat 2011 ➤ , Passat Variant ara2011 ➤
nte
ris
ut
ho Body Repairs - Edition 04.2011 eo
ra
s a c
s
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.
– Lightly sand down bonding areas on left and right of roof.

This ensures that the 2K body adhesive -D 180 KD3 A2- bonds
well with bonding areas.
– 4 suction lifters -V.A.G 1344- are positioned on outer sides of
roof.
– Position roof on roof frame.
– Check roof fit with windscreen and rear window.
1. Renewing roof 97
1.3.2 Adjusting roof depth
Note
♦ The securing belts -1- prevent the roof lifting off the roof frame or shifting during the adhesion process.
♦ Securing belts must not be tightened too tightly in order to avoid damage.
♦ Dimension -a- can be set by tightening and loosening tensioning belts, adjusts position roof relative to side
parts/panels.
♦ Use setting gauge -3371- to check dimension -a-.
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
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
tio
– In areas shown, tension securing belts -T10038- transversely

n in
over roof to vary height of roof.

r
te o
thi
s
iva
do
– Secure roof in front and rear window apertures using vice-grip

r
rp
cum
pliers.
fo
en
ng
t.
yi
– Check line of roof versus roof side members.
Co
Cop py
ht. rig
ht
♦ Dimension -a- = 4.0 ± 0.5 mm
rig by
copy Vo
by lksw
cted
– If necessary for compensation purposes, place pieces of felt
agen
Prote AG.
-533 867 910 B- on roof frame.

1.3.3 Bonding roof

AG. Volkswagen AG d
– Remove roof. lksw
agen oes
not
Vo gu
by
– Apply corrosion protection measuresrised according to guidelines ara
nte
in ⇒ Paint workshop manual: uCorrosion
tho and corrosion pro‐ eo
ra
tection, attached and weldedss parts, materials .
a c
ce
le
– Lightly sand down bonding areas on left and right roof side
un
pt
an
d
members.
itte
y li
rm
ab
– Clean adhesive surfaces on roof and vehicle with silicone re‐
pe
ility
ot
mover -LSE 020 100 A3- .
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
♦ The adhesive must be applied very quickly.
rrectness of i
♦ Always observe the application time (pot life).
♦ Use pneumatic or electric cartridge guns to apply adhesive.
l purpos
– Cut approx. 2 mm off nozzle -B- to provide appropriate bead
nform
ercia
geometry.
m
a
com
tion in
r
Note
te o
thi
s
iva
do
r
rp
c
For this repair, it is absolutely necessary to work with great care
um
fo
to prevent faults during processing.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Renewing roof 99
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
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
– Apply 1K assembly adhesive -D 190 MKD A3- to roof cross

i
or
n thi
member in area of the factory-fitted bonds using compressed

te
sd
va
air gun -V.A.G 1761/1- .

i
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.

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
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– In area of roof side member, apply 1K assembly adhesive -D

190 MKD A3- -1- using pneumatic cartridge gun -
V.A.G 1761/1- .
♦ Dimension -a- = approx. 12 mm
♦ Dimension -b- = approx. 9 mm
1. Renewing roof 101

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.
– Apply 1K assembly adhesive -D 190 MKD A3- on inner side

of roof parallel to left and right roof flange with pneumatic car‐
tridge gun -V.A.G 1761/1- .
Note
♦ The application time (pot life) of the 2K body adhesive -D 180

KD3 A2- is approx. 90 min.
♦ Remove excessive 2K body adhesive -D 180 KD3 A2- from
bonding areas immediately. Once cured 2K body adhesive -D
180 KD3 A2- can only be removed using mechanical means.
♦ An assistant is required for the following work.

– Cut first step of static mixer -D- off to achieve corresponding

bead cross-section.
– Carefully operate double cartridge gun -VAS 5237- without
static mixer until adhesive is discharged uniformly from both
chambers of cartridge connector.
– Screw static mixer onto cartridge connector.
– Apply the first 100 mm of adhesive to a piece of cardboard and
only then begin to apply the adhesive to the vehicle.
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
a
– Fill area -1- with 2K body adhesive -D 180 KD3 A2- using
iv
o
pr
double cartridge gun -VAS 5237- .

um
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

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
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness
– Coat roof flanges with 2K body adhesive -D 180 KD3 A2- .

o
cial p
f in
– Immediately position and align roof.

form
mer
atio
– Secure roof at front and rear window apertures using vice-grip

om
pliers and also secure centre of roof using securing belts

n
c
i
or
⇒ page 98 .
thi
te
sd
iva
– Check roof depth dimension and adjust if necessary.

pr
cum
r
fo
en
ng
– Remove excessive 2K body adhesive -D 180 KD3 A2- along

t.
yi Co
op
edge of roof immediately using a cloth soaked in silicone re‐ C py
t. rig
mover -LSE 020 100 A3- . gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
♦ After bonding, vehicle must remain stationary on a level sur‐

face for 8-10 hours at room temperature (min. 15 °C) so that
adhesive can harden.
♦ No further work should be performed on the vehicle until the
„minimum curing time“ has expired.

1.3.4 Welding in
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
– Weld roof in front and rear window apertures, RP spot weld

seam.
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.

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
– Apply adhesive sealant -AKD 476 KD5 05- to seam between

f in
roof and roof side member to fully seal bonded seam -1-.
form
mer
atio
– After painting, preserve roof cavities -arrow- with corrosion-

om
preventive wax -AKR 321 M15 4- .

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.

RO: 51 03 55 03
2 Renewing roof - vehicles with sliding/

tilting sunroof
WARNING
Observe safety notes! agen

AG. Volkswagen AG d
oes
olksw not
y V gu
d b ara
rise nte
o
Safety notes ⇒ General Information; Body Repairs,
auth General Body eo
ra
Repairs ; Safety notes ss c
ce
e
nl
pt
du
an
itte
y li
1 - Roof
erm
ab
ility
ot p
wit
, is n
h re
3 - Bonded areas
hole
spec
4 - Reinforcing frame
es, in part or in w
t to the co
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2. Renewing roof - vehicles with sliding/tilting sunroof 107

2.1 Tools
Note

work .

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2.2 Removing
Note
♦ When separating, ensure sufficient distance of to roof member -2- is kept, to assure it is not damaged during
repairs.
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2.3 Installing
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♦ Roof


♦ Felt -533 867 910 B-
Note

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roof.

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– Secure roof in front and rear window apertures using vice-grip
pliers.


2.3.3 Bonding roof

– Remove roof.
tection, attached and welded parts, materials .
– Lightly sand down bonding areas on left and right roof side
members.
mover -LSE 020 100 A3- .
Note


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AG. Volkswagen AG d
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Note


lkswage es n
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nte Repairs - Edition 04.2011
eo
th
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AG. Volkswagen AG d
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nf
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– Secure roof at front and rear window apertures using vice-grip
rm
m
atio
pliers and also secure centre of roof using securing belts
om
⇒ page 114 .
n in
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2.3.4 Welding in
AG. Volkswagen AG d
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2. Renewing roof - vehicles with sliding/tilting sunroof
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AG. Volkswagen AG d
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Vol Passatnot
g2011
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d
rise Body
ran
te Repairs - Edition 04.2011
ho eo
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RO: 51 03 55 10
3 Renewing roof (Variant) lksw

agen
AG. Volkswagen AG d
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WARNING hor eo
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Repairs ; Safety notes ot p
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1 - Roof
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3 - Bonded areas
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3.1 Tools
Note

work .

AG. Volkswagen AG d
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3. Renewing roof (Variant) 125

♦ Setting gauge -3371-
AG. Volkswagen AG d
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3.2 Removing
Note AG. Volkswagen AG d

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♦ Apply textile adhesive tape on left and right roof members ed bparallel
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♦ When separating, ensure sufficient distance of to roof
ss member -2- is kept, to assure it is not damaged during
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ce
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y li
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cross members.

Note
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roof cross members.
members.
Manual.

3.3 Installing
Note

⇒ page 125 .

New part
♦ Roof
♦ Felt -533 867 910 B-
AG. Volkswagen AG d
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Note ise
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AG. Volkswagen AG d
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– Drill 6 mm ∅ holes for SG plug weld seam at transition to tail‐

ion
c
gate aperture.
in t
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Note
parts/panels.
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– Secure roof in windscreen aperture and tailgate aperture using
vice-grip pliers.

3.3.3 Bonding roof

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tection, attached and welded
agen
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AG. Volmaterials
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nform
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air gun -V.A.G 1761/1- .
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lkswage es n
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te
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auth Body Repairs - Edition e04.2011
or
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Note



bead cross-section.
AG. Volkswagen AG d
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AG. Volkswagen AG d
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ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Immediately position and align roof. rrectness of i
– Secure roof in area of windscreen aperture and tailgate aper‐

l purpos
ture using vice-grip pliers and secure centre of roof using

securing belts ⇒ page 131 .
nf
ercia

orm
m
atio

om

n in
or c
mover -LSE 020 100 A3- .

thi
te
sd
iva
o
r
rp
cu
o
m
f
Note
en
ng
t.
yi Co
Cop py
t. rig
♦ After bonding, vehicle must remain stationary on a level sur‐ gh ht
yri by
op Vo
by c lksw
cted agen
Prote AG.


3.3.4 Welding in
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
– Weld roof in windscreen aperture, RP spot weld seam.

t to the co
– Weld roof in tailgate aperture, SG plug weld seam and MIG

solder seam.
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.

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
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.


RO: 51 03 55 13
4 Renewing roof - Variant with panora‐

ma sliding sunroof
WARNING
Safety notes ⇒ General Information; Body Repairs,

agen General
AG. V Body
olkswagen AG
does
Repairs ; Safety notes olksw not
yV gu b ara
ed nte
oris e
th or
1 - Roof ss
au ac
ce
e
2 - Bonded areas (roof cross

nl
pt
du
an
member)
itte
y li
erm
ab
ility
ot p
wit
, is n
4 - Reinforcing frame (panora‐
h re
ma sliding sunroof)
hole
spec
5 - Bonded areas (reinforcing
es, in part or in w
t to the co
frame)
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.

4.1 Tools
Note

work .

♦ Cartridge heater -V.A.G 1939 A- 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
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
4. Renewing roof - Variant with panorama sliding sunroof 141

Passat 2011 ➤ , Passat Variant 2011 ➤ agen
AG. Volkswagen AG d
oes
Body Repairs - Edition 04.2011 olksw not
byV gu
ara
ed
ris nte
♦ Setting gauge -3371- aut
ho eo
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
cted agen
Prote AG.

4.2 Removing
Note
♦ When separating, ensure sufficient distance of to roof member -2- is kept, to assure it is not damaged during
repairs.
♦ When making parting cuts -1-, ensure that the panels lying behind are not damaged.
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
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne

ss o
– Separate bonded joints to front and rear roof cross members.

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
143
by lksw
cted agen
Prote 4. Renewing roof - Variant with panorama sliding sunroof
AG.
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
– Release bonded joints -1- from reinforcing frame -2-.

nform
ercia
– Separate original joint to inner side panel on left and right.

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

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
roof cross members.

wit
, is n
– Remove all adhesive residues from left and right roof side h re
hole
spec
members.
es, in part or in w
t to the co

Manual.
rrectness of i
4.3 Installing
l purpos
Note
nform
ercia

m
at
om
⇒ page 141 .
on
c
in t
or
his
ate

do
priv
cum
for
en
New part
ng
t.
yi Co
op py
♦ Roof
. C rig
ht ht
rig by
py
co Vo
by lksw
cted agen
Prote AG.


♦ Felt -533 867 910 B-
Note

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
– Drill 8 mm ∅ holes for SG plug weld seam at transition to tail‐

do
priv
gate aperture.
um
for
en
ng
t.
yi
– Lightly sand down bonding areas on left and right of roof and
Co
op py
on reinforcing frame.
. C rig
ht ht
rig by
opy Vo
This ensures that the 2K body adhesive -D 180 KD3 A2- bonds by c lksw
cted agen
well with bonding areas. Prote AG.

. Volkswagen AG
do gen AG
– 4 suction lifters -V.A.G 1344-
Vol
ksware positioned on outeressides
a
not of
roof. ed by gu
ara
is nte
or
– Position roof onaroof
ut
h frame. eo
ra
ss c
– Check roof fit with windscreen and tailgate.
ce
le
un
pt
an
d

itte
y li
rm
ab
pe
ility
ot
wit
, is n
Note
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
parts/panels.
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.

– Secure roof in windscreen aperture and tailgate aperture using
vice-grip pliers.


4.3.3 Bonding roof

– Remove roof.
olkswagen AG
en AG. V
– Apply corrosion protection measures
ksw
ag according to guidelines
does
not
Vol
in ⇒ Paint workshop manual:
edb
y Corrosion and corrosion pro‐ gu
ara
tection, attached and
ho
rwelded
is parts, materials . nte
e t or
au ac
– Lightly sand down
ss bonding areas on left and right roof side
members.
ce
e
nl
pt
du
an
itte
y li
erm
ab
mover -LSE 020 100 A3- .
ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

geometry.
nform
mercia
at
om
Note
ion
c
in t
or
his
e

at
do
riv

p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

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
rm
ab
pe
ility
member and roof frame in area of the factory-fitted bonds us‐
ot
wit
, is n
ing pneumatic cartridge gun -V.A.G 1761/1- .

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.

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.

V.A.G 1761/1- .

AG. Volkswagen AG d
agen oes
Volksw Passat 2011 not ➤ , Passat Variant 2011 ➤
gu
y
rise
d b
Body aRepairs
ran
tee
- Edition 04.2011
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
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.

Note



bead cross-section.
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
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
152
op Vo
by c lksw
Rep. gr.51 - Body - centre Prote
cted AG.
agen
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
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Secure roof in area of windscreen aperture and tailgate aper‐
ture using vice-grip pliers and secure centre of roof using
securing belts ⇒ page 147 .
mover -LSE 020 100 A3- .
Note


4.3.4 Welding in
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
cted agen
Prote AG.
– Weld roof in windscreen aperture, RP spot weld seam.

– Weld roof in tailgate aperture, SG plug weld seam and MIG
solder seam.

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
– Weld reinforcing frame to inside of side panel, SG staggered

fo
en
g
continuous weld seam.

n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

wage es n
Passat 2011 ➤ , Passat yV
o Variant 2011 ➤
lks ot g
b ua
ir se
d 04.2011 ran
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
cted agen
Prote AG.


RO: 51 05 55 50
5 Renewing roof side member
WARNING

Welding, parting using spark generating machines/tools or tin‐
ning in foam treated areas creates gases which are hazardous
to health and environment. Therefore, refrain from using these
processes.

1 - Roof member
2 - Reinforcing (roof carrier)
3 - Roof cut line
4 - Cut line at pillars
5 - Moulded foam element
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
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
157
cted agen
Prote AG.
5. Renewing roof side member
5.1 Tools
Note

work .
5.2 Removing
Note
Do not damage underlying panels when cutting out.

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
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.
– Position parting cut on B-pillar as shown.


Partial renewal
A part section repair is possible using parting cut -1-.
Dimension -b- approx. 250 mm
Keep the cutting of the replacement part in mind.
– Separate original joint in door apertures.
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
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.
– Separate as shown.
Dimension -b- = 100 mm
Dimension -c- = 50 mm
-1- Reinforcing (roof carrier)
Note
Remove as much of the foam residue -1- as possible before starting grinding work.
5. Renewing roof side member 159

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
s c
– Remove remaining material. s
ce
e
nl
pt
du
– Remove remaining adhesive completely and grind bonded

an
itte
y li
surface back to bare metal.

erm
ab
ility
ot p
5.3 Installing
wit
, is n
h re
hole
spec
es, in part or in w
Note
t to the co

⇒ page 158 .
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.

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
Note
ility
ot p
wit
, is n
MIG solder seams or SG continuous weld seams are permitted at the parting cuts shown in the illustration.
h re
hole
spec
es, in part or in w

t to the co
New part
rrectness of i
♦ Side panel
l purpos
♦ Roof member cavity foam treatment kit -D 506 110 A2-

nf
ercia
or
♦ Blind rivet nut

m
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.

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
– Transfer parting cut to new part and cut out.

an
d
itte
y li
rm
– Generously mask interior area to be foam treated -1- using

ab
pe
ility
textile adhesive tape ⇒ Item 4 (page 167) from roof member

ot
wit
cavity foam treatment kit -D 506 110 A2- .

, is n
h re
hole
spec
es, in part or in w
Note
t to the co
♦ Structural foam must not contact outer panel of roof side member.
rrectness of i
♦ Expansion of structural foam can cause roof side member to buckle.

l purpos
5.3.2 Moulded foam elements

nform
ercia
Follow repair instructions.

m
a
com
Moulded foam elements ⇒ General Information; Body Repairs,

ion in
General Body Repairs ; General Notes; Moulded foam elements

r
te o
thi
s
iva
Position of the moulded foam elements ⇒ page 4

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.

5.3.3 Welding in
Note

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
– Apply 2K body adhesive -D 180 KD3 A2- in the areas indica‐

ted.
rrectness of i
– Secure roof carrier reinforcing -1- with adhesive.

l purpos

nform
ercia

m
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
o
163
by c lksw
cted
5. Renewing roof side member
agen
Prote AG.
Body Repairs - Edition 04.2011 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
cted agen
Prote AG.
– Weld in parting cuts, MIG solder seam or SG continuous weld

seam are permitted.
Note
Both weld symbols are shown in the figure.
Note
♦ In the area of the A, B and C-pillars, high tensile, highest tensile and hot formed steels are used. The weld
flanges in these areas are about 13mm wide.
♦ If spot welds are located at the edge of hot formed steel panels, the high temperature will cause the bond
between the panels to change, which will subsequently have an effect on crash safety.

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
Therefore, locate spot welds as close to the centre as possible.

nform
ercia
• Dimension -a- of 8mm can be achieved using angled welding

m
tips.
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.

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
gh ht
pyri by
Vo
o
by c lksw
cted agen
– Weld in B-pillar parting cut, MIG solder seam or SG continuous Prote AG.
weld seam are permitted.
Note
– Weld roof side member to door apertures, RP spot weld seam

(inverter).
5.4 Foam treating roof side member
5.4.1 Treating with foam

– Heat 2K structural foam cartridge in an approx. 60 °C water
bath for 20 minutes.

1 - 2K structural foam cartridge

– Open cap
2 - Static mixer
– Cut of the front section
of the cone only.
3 - Extension hose
AG. Volkswagen AG d
4 - Textile adhesive tape ksw
agen oes
not
Vol
by gu
d ara
Note horise nte
eo
aut ra
ss c
5 - Adapter
ce
le
un
pt
an
d
itte
y li
Note
rm
ab
pe
ility
ot
wit
, is n
6 - Union nut
h re
hole
spec
– Connect static mixer -2-
es, in part or in w
to 2K structural foam
t to the co
cartridge -1- using union
nut.
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.

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
– Inject structural foam through opening for blind rivet nuts
ility
ot p
-arrow- in roof -1- using pneumatic cartridge gun -V.A.G

wit
, is n
1761/1- and static mixer.

h re
hole
– Then seal opening with a blind rivet nut.

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
cted agen
Prote AG.

RO: 51 07 55 50
6 Renewing front roof cross member
WARNING

Roof already removed.
• Saloon ⇒ page 91
• Saloon with sliding/tilting sunroof ⇒ page 107
• Variant ⇒ page 124
• Variant with panorama sliding sunroof ⇒ page 140
1 - Front roof cross member

2 - Left and right roof frames
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
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
6. Renewing front roof cross member 169

6.1 Tools agen

AG. Volkswagen AG d
oes
olksw not
V gu
d by ara
ise nte
Note ut
hor eo
ra
s a c
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
work .
es, in part or in w
t to the co
6.2 Removing
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.
– Separate original joint from inside.

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
– Remove residues at transition to left and right roof frame.

es, in part or in w
t to the co
6.3 Installing
rrectness of i
Note
l purpos

⇒ page 170 .
nf
ercia
orm
m
atio
m
6.3.1 Welding in
o
n in
or c
thi
e
New part
t
sd
iva
o
r
rp
cu
♦ Front roof cross member

o
m
f
en
ng
t.
yi
Co
op py
t. C rig
gh ht
pyri by
Vo
o
– Check fit of roof and windscreen.
c by lksw
cted agen
Prote AG.
Note
Use the existing elongated holes to weld the new part to the left and right roof frames.
6. Renewing front roof cross member 171

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
– Weld in front roof cross member, RP spot weld seam and SG

pt
du
an
plug weld seam.

itte
y li
erm
ab
Install roof.
ility
ot p
wit
, is n
h re
hole
spec

es, in part or in w
t to the co
• Variant ⇒ page 129

• Variant with panorama sliding sunroof ⇒ page 129
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.

RO: 51 09 55 50
7 Renewing rear roof cross member

(saloon)
WARNING

olkswagen AG
1 - Rear roof crossswmember
agen
AG. V does
olk not
yV gu
2- Left andseright
db roof frames ara
nte
ri
tho eo
au ra
c
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
7. Renewing rear roof cross member (saloon) 173

7.1 Tools
Note

♦ The welding units (inverters) and body tools authorised by AG. Volkswagen AG d
Volkswagen AG are listed in ⇒ ServiceNet, Workshop Equip‐ ksw
agen oes
not
ment, EH catalogue, Workshop equipment, Body and paint‐y Vol gu
db ara
work . or
ise nte
eo
th
s au ra
c
s
7.2 Removing
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.

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
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.
– Remove residues at transition to left and right roof frame.
7.3 Installing
Note

⇒ page 174 .
7.3.1 Welding in
New part
♦ Rear roof cross member
– Check fit to roof and rear window.
Note
Use the existing elongated holes to weld the new part to the left and right roof frames.
7. Renewing rear roof cross member (saloon) 175

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
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Weld in roof cross member, SG plug weld seam and RP spot

weld seam.
– Install roof ⇒ page 96 .

RO: 51 09 55 60
8 Renewing rear roof cross member

(Variant)
WARNING

• Variant ⇒ page 124 agen
AG. Volkswagen AG d
oes
olksw not
• Variant with panorama sliding sunroof ⇒ page 140 ed byV gu
ara
ris nte
ho eo
aut ra
c
1 - Rear roof cross member ss
ce
e
nl
pt
du
2 - Bonded section
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
cted agen
Prote AG.
8. Renewing rear roof cross member (Variant) 177

Passat 2011 ➤ , PassatwaVariant
gen AG 2011 ➤ n AG doe
. Volkswage
ks s no
by
Vol 04.2011 t gu
ara
ed nte
oris e
8.1 Tools th or
au ac
ss
ce
e
nl
pt
du
an
itte
Note
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
work .
rrectness of i
l purpos
8.2 Removing
nform
ercia
Note
m
at
om
ion
c
Roof cross member and roof cross member reinforcement are cut
in t
or
out together.
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

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
yri by
cop Vo
by lksw
cted agen
Prote
AG.
8.3 Installing
Note

⇒ page 178 .

New part
♦ Rear roof cross member (Variant)

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
8.3.2 Welding in ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
New part must be welded in within 90 minutes or adhesion of adhesive will be impaired.
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.

the factory.


– Check fit to roof and tailgate.
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
cted agen
Prote AG.
– Weld rear roof cross member to left and right D-pillars -1- from
inside, SG continuous weld seam.
– Weld in remaining joint, SG plug weld seam, MIG solder seam
and RP spot weld seam.
– Install roof ⇒ page 129 .
– Install roof with panorama sliding sunroof ⇒ page 129 .

RO: 51 37 55 00
9 Renewing A-pillar
WARNING

processes.

• Upper outer longitudinal member AG.already removed
Volkswagen AG d
agen
⇒ page 50 . Volksw
oes
not
by gu
ara
ed nte
oris eo
th
1 - A-pillar au ra
c
ss
2 - Upper parting cut ce
e
nl
pt
du
an
itte
3 - Moulded foam elements y li

erm
ab
ility
4 - Parting cut for side member
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
t to the co
5 - Bonded areas
6 - Parting cut for partial re‐
placement
rrectness of i
Partial renewal
l purpos
Partial replacement of A-pillar

is possible using this parting
nform
ercia
cut.
m
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.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
o eo
aut
h
Passat 2011 ➤ , Passat r a Variant
2011 ➤
s c
s Body Repairs - Edition 04.2011
ce
le
un
pt
an
d
9.1 Tools
itte
y li
erm
ab
ility
ot p
wit
is n
Note
h re
ole,
spec
t to the co
rrectne
ss
work .
o
cial p
f inform
mer
9.2 Removing
atio
om
n
c
i
or
n thi
e
Note
t
sd
iva
o
pr
cum
r
fo
♦ Do not damage underlying panels when cutting out.
en
ng
t.
yi Co
op
♦ If the A-pillar reinforcement is damaged, it must always be re‐ C py
ht. rig
newed. rig ht
py by
co Vo
by lksw
♦ Rewelding A-pillar reinforcement is not permitted due to safety cted agen
Prote AG.
reasons »crash safety«.
9. Renewing A-pillar 183

olkswagen AG
ag en AG. V
Passat 2011 ➤ , Passat Variant 2011Vo➤lksw
does
not
gu
Body Repairs - Edition 04.2011 sed by ara
nte
ri
ho eo
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.
– Locate parting cuts -1- and -2- according to degree of damage

and cut out.
Retainer for wing -3- is cut out as well and replaced.
Note

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

um
fo
en
ng
t.
yi Co
op py
surface back to bare metal. t. C rig
gh ht
pyri by
9.3 Installing
co Vo
by lksw
cted agen
Prote AG.
Note

⇒ page 183 .

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
cted agen
Prote AG.
Note

New part
♦ Front side panel subpart (replacement part designation: sub‐
part with side member)
♦ Moulded foam element

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
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.


9.3.3 Welding in
Note
AG. Volkswagen AG d
agen oes
ksw
New part must be welded in within 90 minutes by or adhesion of adhesive will begimpaired.
l not
♦ Vo
ua
ed ran
ris
♦ Adhesive must be cleaned from holesutfor
ho fastening hinges after bonding in.
tee
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
o
by c lksw
cted agen
Prote AG.

the factory.
Note

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
cted agen
Prote AG.

tips.

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
seam are permitted.
ility
ot p
wit
, is n
h re
hole
Note spec
es, in part or in w
t to the co
– Weld in door aperture and windscreen aperture, RP spot weld

rrectness of i
seam (inverter).
l purpos
– Weld A-pillar to A-pillar reinforcement, SG plug weld seam.

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.

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
– Adapt retainers -1- for wing when adapting wing and secure.
ion
c
in t
or
– Check gaps/shut lines ⇒ page 10 .

his
ate
do
riv
– Weld in wing retainer, SG plug weld seam.

p
cum
for
en
g
– Install upper longitudinal member for wheel housing

n
t.
yi Co
op
⇒ page 52 . C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

RO: 51 38 55 53
AG. Volkswagen AG d
10 Renewing A-pillar reinforcement - Volkswagen oes
not
gu
part section
y
db ara
rise nte
o th eo
s au ra
c
s
WARNING
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
processes. es, in part or in w
t to the co
rrectness of i
• A-pillar part section already removed ⇒ page 183 .
l purpos
1 - A-pillar reinforcement
nf
ercia
orm
2 - Hinge reinforcement
m
atio
om
n in
c
Is part of A-pillar reinforcing

or
thi
and is removed as well.
te
sd
iva
o
r
rp
cu
3 - Bonded areas
o
m
f
en
ng
t.
yi
4 - Side member reinforcement
Co
Cop py
t. rig
gh
ht
pyri by
Vo
co lksw
by
cted agen
Prote
Note
AG.
6 - Cutting point
7 - A-pillar
Part section removed.

10.1 Tools
Note

work .
10.2 Removing
AG. Volkswagen AG d
agen oes
Note Volksw not
gu
d by ara
ise nte
r
Do not damage underlying panels whenut cutting out.
ho eo
ra
s a c
s
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
o
by c lksw
cted agen
Prote AG.
– A-pillar -1- cut out according to dimension -a-.
10. Renewing A-pillar reinforcement - part section 193

– Position parting cut -2- at A-pillar reinforcing as shown and cut
out.
– Separate original joint of A-pillar reinforcement.
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
op
– Separate original joint for hinge reinforcing for inner A-pillar C py
ht. rig
-1-. rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

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
– Remove remaining material. Prote AG.

10.3 Installing
Note

⇒ page 193 .

New part
♦ A-pillar reinforcement

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
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.

– Clip new moulded foam element -2- into hinge reinforcing
-1-.
ted.


10.3.3 Welding in
Note
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
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

tips.

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
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Weld in A-pillar reinforcement, SG plug weld seam and RP

spot weld seam (inverter).
– Recreate original joint to front wheel housing, MIG solder
seam.
– Weld in parting cut, SG continuous weld seam.
– Install A-pillar ⇒ page 185 .

RO: 51 41 55 02
11 Renewing B-pillar
WARNING

processes.

Repairs ; Safety notes G. Volkswagen A AG do
agen es n
ksw
y Vol ot g
ua
b
1 - Extended area of B-pillar ris
ed ran
tee
tho
or
Must be cut out when replacing ss
au ac
B-pillar reinforcing complete.
ce
le
un
pt
an
d
itte
2 - B-pillar
y li
rm
ab
pe
3 - Moulded foam elements
ility
ot
wit
, is n
4 - Parting cut for side member
h re
hole
spec
5 - Bonded areas
es, in part or in w
t to the co
6 - Reinforcing (roof carrier)
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.
11. Renewing B-pillar 199

11.1 Tools

agen oes
olksw not
♦ The use of different types and different thicknessesed by
V
of steel gu
ara
requires that only the welding units (inverters)
h oris authorised by nte
eo
Volkswagen AG may be used to carry out s aut repairs properly. ra
c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
work .
ility
ot p
wit
, is n
h re
11.2 Removing
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
l purpos
♦ If the B-pillar reinforcement is damaged, it must always be renewed.

♦ For safety reasons »crash safety«, it is not permissible to reweld the B-pillar reinforcement.
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.

– Make parting cut -1- as shown.

Partial renewal
A part section repair of B-pillar is possible using parting cut -2-.
– Place parting cuts -3- according to degree of damage.
Note
Keep the cutting of the replacement part in mind.
– Separate original joint to B-pillar reinforcement.
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
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Separate original joint to side member reinforcement.
Note

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
ercia

m
at

om
ion

c
in t
or
his
te
11.3 Installing
a
do
priv
cum
for
en
ng
t.
yi Co
op
Note C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
⇒ page 183 . Prote AG.

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
c
Note
or
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi
Co
Cop py
ht. rig
rig ht
by
New part copy Vo
by lksw
cted agen
Prote
♦ Subpart side panel
AG.

♦ Sealing cord -AKD 497 010 04 R10-

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
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
– Transfer parting cut to new part and cut out. atio

om
n
c

or
n thi
te
sd
va
11.3.2 Marking area where no welding work

i
o
pr
cum
r
fo
may be carried out

en
ng
t.
yi Co
op py
– Mark areas on outer B-pillar where welding for safety reasons
. C rig
ht ht
rig
»crash safety« is prohibited. py by
co Vo
by lksw
cted agen
Prote AG.
Note
The measurements given must be adhered to.

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
♦ Dimension -a- = 50 mm rrectness of i
♦ Dimension -b- = 160 mm

l purpos

nform
ercia

m
at

om
io

n
c
in t
or
his
e

at
do
priv
11.3.4 Welding in
um
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
Note pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ New part must be welded in within 90 minutes or adhesion of
adhesive will be impaired.
♦ Adhesive must be cleaned from holes for fastening hinges af‐
ter bonding in.

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
– Apply sealing cord -AKD 497 010 04 R10- to area -1-.
l purpos

the factory.
nform
mercia
at
Note
om
ion
c
in t
or
his
ate

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

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
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.

tips.

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
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.

seam are permitted.
– Weld in B-pillar, RP spot weld seam (inverter).
Note
Note prohibited weld areas -1- where welding is not allowed.

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
– Recreate remaining joint to side member reinforcement, SG

plug weld seam.
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.

RO: 51 42 55 53
12 Renewing B-pillar reinforcement -

part section
Includes: front side member reinforcement (part section) and rear
side member reinforcement (part section)
WARNING

processes.
AG. Volkswagen AG d
agen oes
ksw
• B-pillar already removed ⇒ page 199 . by Vol not
gu
d ara
ise nte
• Side member already removed ⇒ page 229 . thor eo
au ra
c
Safety notes ⇒ General Information; Body Repairs, General Body ss
ce
le

un
pt
an
d
itte
y li
erm
ab
1 - B-pillar reinforcement
ility
ot p
wit
is n
h re
ole,
spec
3 - Web plates
t to the co
4 - Rear side member rein‐
forcement parting cut
5 - Bonded areas
rrectne
6 - Front side member rein‐
forcement parting cut
ss o
cial p
f
7 - B-pillar reinforcement upper
inform
parting cut
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.

Note
♦ Parting cuts for B-pillar reinforcement, front side member re‐

inforcement and rear side member reinforcement may only be
made at positions -4, 6 and 7- as shown.
♦ Cutting or welding at points other than the ones shown is im‐
permissible due to safety reasons »crash safety«.
♦ During the repair, a section of the crash reinforcement is
placed behind the B-pillar reinforcement upper parting cut
⇒ Item 7 (page 210) as a strengthening measure.
12.1 Tools
Note

Volkswagen AG are listed AGin
. Vo⇒
lksServiceNet,
wagen AG Workshop Equip‐
agen
ment, EH catalogue,
olksw Workshop equipment,
does
nBody
ot g and paint‐
work .
V
by ua
ed ra nte
ris
ho eo
ut ra
Specialsstools and
a workshop equipment required c
ce
e
nl
♦ Mechanical door tensioner -V.A.G 1438-

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
12.2 Removing
orm
m
atio
om
n in
or c
Note
thi
te
sd
iva
o
r
rp
cu
Before cutting out B-pillar reinforcing, place a mechanical door

o
m
f
tensioner -V.A.G 1438- in door apertures to ensure that the roof

en
ng
t.
yi
cannot move.
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
12. Renewing B-pillar reinforcement - part section 211

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
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
– Position and make parting cuts as shown.
co Vo
by lksw
cted agen
Prote AG.
Dimension -c- = 100 mm

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
nform
ercia

m
at
om

ion
c

in t
or
his
ate
12.3 Installing
do
priv
cum
for
en
ng
t.
yi Co
op
Note
C py
t. rig
gh ht
pyri by
Vo
o
c by lksw
cted agen
⇒ page 211 .
Prote AG.

New part
♦ B-pillar reinforcement
♦ Front side member reinforcement
♦ Web plate for front side member reinforcement
♦ Rear side member reinforcing with web plate
♦ Moulded foam elements
♦ B-pillar crash reinforcement

Note
B-pillar reinforcement is identical for saloon and Variant.
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
– Transfer parting cuts to B-pillar reinforcing -1-, side member

nf
ercia
rear reinforcing -3- and side member front reinforcing -5- and
rm
m
cut new parts accordingly.

atio
om
n in
c
– Separate repair piece from crash reinforcing -2-, as shown.

or
thi
te
sd
a

iv
o
r
rp
cu
o
– Check fit of crash reinforcing -2- to B-pillar reinforcing -1-.

f
en
ng
t.
yi Co
op
– Apply 2K body adhesive -D 180 KD3 A2- to areas of crash C py
ht. rig
reinforcing as indicated. rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
New part must be welded in within 90 minutes or adhesion of adhesive will be impaired.

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.
– Adapt crash reinforcing -1- to fit into B-pillar reinforcing -2- and
weld in, RP spot weld seam (inverter).
Distance between weld points:
– Secure side member front reinforcing -5- and side member
rear reinforcing -3- along with web plates -4- on B-pillar rein‐
forcing.
12.3.2 Marking areas where no welding work

may be carried out
Note
♦ Welding work must not be carried out in areas marked on fol‐

lowing illustrations due to safety reasons »crash safety« when
welding in B-pillar reinforcement.
♦ The measurements given must be adhered to.
♦ Before welding in outer B-pillar, transfer dimensions of area
where no welding work may be carried out to outer B-pillar.

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
– Mark areas where welding is not permitted.
♦ Dimension -a- = 50 mm rrectness of i

l purpos
– Adapt new parts with vehicle positioned on alignment bracket

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.

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
– Tack weld front and rear side member reinforcements

-1 and 2- centrally at top and bottom -shaded areas- to B-pillar
nform
ercia
reinforcement -3- using one small SG weld at each point. Re‐

move B-pillar reinforcement with side member reinforcements
m
at
om
again.
on
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by
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Prote AG.

AG. Volkswagen AG d
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spec
t to the co
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cial p
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mer
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n
c
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– Weld rear web plate -1- to B-pillar reinforcement -2- at existing

iv
o
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elongated holes, SG continuous seam.

um
r
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t.
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Cop py
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Prote AG.

AG. Volkswagen AG d
agen oes
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d by ara
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or eo
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ce
le
un
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pe
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wit
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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
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
– Adapt web plate -2- to side member front reinforcement -1-.
AG.
Note
The holes -3- must align.
– Weld web plate to side member front reinforcement -1- and to

B-pillar reinforcement -4-, RP spot weld seam.


12.3.4 Welding in
Note

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nf
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– Drill 8 mm ∅ holes in B-pillar reinforcement on vehicle for SG
AG.
plug weld seam.

Distance between holes:
– Renew moulded foam element -1-, if necessary.
ted.

Note
AG. Volkswagen AG d
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In the area of the A, B and C-pillars, byhigh tensile, highest tensile and hot gu formed steels are used. The weld
o
♦ d
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e nte
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♦ If spot welds are located atssthe edge of hot formed steel panels, the high temperature
a c will cause the bond
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r
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tips.

AG. Volkswagen AG d
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nform
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tion in
r
te o
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t.
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Note Cop py
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pyri by
Note areas -1- where welding is not permitted.
co Vo
by lksw
cted agen
Prote AG.
– Weld in B-pillar reinforcement, RP spot weld seam (inverter).

– Weld crash reinforcement to B-pillar reinforcement, SG plug
weld seam.
– Weld in parting cut for side member front and rear reinforce‐
ments, SG continuous weld seam.
– Weld in parting cut for upper B-pillar reinforcement, SG con‐
tinuous weld seam.
– Install B-pillar ⇒ page 202 .
– Install side member ⇒ page 232 .

RO: 51 44 55 50
13 Renewing inner B-pillar
WARNING

• B-pillar reinforcement already removed ⇒ page 210 .
1 - Remaining section of B-pil‐

lar reinforcement
2 - Inner B-pillar
3 - Inner side member
4 - Bonded areas
AG. Volkswagen AG d
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13. Renewing inner B-pillar 223

13.1 Tools
Note

work .
AG. Volkswagen AG d
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Special tools and workshop equipment requiredby V o gu
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♦ Mechanical door tensioner -V.A.G 1438/-
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13.2 Removing
nf
ercia
or
Note
m
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atio
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n in
Before cutting out inner B-pillar, place a mechanical door ten‐
or c
thi
sioner -V.A.G 1438- in door apertures to ensure that the roof
te
sd
a
cannot move.
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Vo
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by
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Prote AG.

AG. Volkswagen AG d
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t to the co
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mercia
a
com
tion in
r
te o
thi
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iva
do
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cum
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en
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t.
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Cop py
t. rig
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Vo
co lksw
by
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Prote AG.

AG. Volkswagen AG d
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ara
Passat 2011 ➤ , Passat Variantrised
2011 ➤ nte
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du
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ab
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nf
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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.

13.3 Installing
Note

⇒ page 224 .
13.3.1 Welding in
New part
♦ Inner B-pillar

Note
♦ New part must be welded in within 90 minutes or adhesion of adhesive will be impaired.
♦ Before installing inner B-pillar, adapt B-pillar reinforcement to fit to assure the welding period in the bonded
areas is kept as short as possible.
AG. Volkswagen AG d
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un
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es, in part or in w
t to the co
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l purpos
ted.
nform
ercia

m

com
tion in
r
te o
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Cop py
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Prote AG.

AG. Volkswagen AG d
agen oes
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ab
ility
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, is n
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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
in t
or
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ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote
– Weld in new part, SG continuous weld seam and RP spot weld
AG.
seam (inverter).
Note
♦ The joint to inner side member is welded when installing B-pillar reinforcing.
♦ The B-pillar reinforcement must be welded in within 90 minutes or adhesion of adhesive to inner B-pillar will
be impaired.
– Install B-pillar reinforcement ⇒ page 213 .

RO: 51 45 55 10
14 Renewing side member
WARNING

processes.

1 - Parting cuts
2 - Side member
4 - Lower wing retainer
5 - Bonded area
AG. Volkswagen AG d
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es, in part or in w
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mercia
a
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tion in
r
te o
thi
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t.
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Cop py
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Vo
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229
cted agen
Prote AG.
14. Renewing side member
14.1 Tools
Note

♦ The welding units (inverters) and body
agen
AG. Votools
lkswagauthorised
en AG
d by
Volkswagen AG are listedVoinlks⇒
w ServiceNet, Workshop
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equipment, Body and paint‐ ua
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work . thori tee
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14.2 Removing
ce
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nl
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ab
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Note
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spec
♦ Wing retainer -1- is renewed as well.
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
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Prote AG.

– Mark parting cuts according to dimensions -a and b- and cut.

Partial renewal
A part replacement is possible with parting cut -2-.
– Make cuts as shown.
Note
Dimensions -a- and -b- must be strictly adhered to.

– Grind through outer edge at rear wheel arch.
swage es n
Note byV
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ua
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Remove as muchauof the moulded foam element -1- as possible before
th or
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ss
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ab
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es, in part or in w
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nf
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t.
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14. Renewing side member 231


– Clean any dust and grease off flange area on wheel arch.
14.3 Installing
Note

⇒ page 230 .
AG. Volkswagen AG d
agen oes
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nl
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du
an
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erm
ab
ility
ot p
wit
, is n
h re
hole
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es, in part or in w
t to the co
rrectness of i
l purpos
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mercia
at
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ion
c
in t
or
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ate
do
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for
en
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t.
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Note p by
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New part
♦ Side panel
♦ Wing bracket
♦ Sealing cord -AKD 497 010 04 R10-
AG. Volkswagen AG d
agen oes
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d b ara
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d
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ab
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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.
– Transfer parting cuts to side panel and cut out.

– Drill 8 mm ∅ holes in side panel -1- and wing retainer -2- for
SG plug weld seams.

14.3.2 Marking areas where no welding work

may be carried out
Note
♦ Mark areas on outer side member where welding is not per‐

mitted due to safety reasons »crash safety«.
♦ The measurements given must be adhered to.
– Mark areas where welding is not permitted.

♦ Dimension -a- = 50 mm
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es, in part or in w
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14.3.4 Welding in
rrectness of i
l purpos
Note
nform
ercia
♦ The new part must be welded in within 90 minutes, or adhesion

of adhesive will be impaired.
m
a
com
tion in
♦ Adhesive must be cleaned from holes for fastening hinges af‐
r
te o
thi
ter bonding in.
s
iva
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by
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Prote AG.

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es, in part or in w
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– Apply sealing cord -AKD 497 010 04 R10- in area -1-.

rrectness of i

l purpos
ted.
nform
ercia
Note
m
at
om
ion
c
in t
or
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e

at
do
priv
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for
en
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t.
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Cop py
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by
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Prote AG.

AG. Volkswagen AG d
agen oes
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es, in part or in w
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l purpos
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mercia
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tion in
r

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tips.
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– Adapt new part with vehicle standing on its wheels or on align‐ Cop py
. rig
ment bracket set and hold in position.
ht ht
rig by
copy Vo
by lksw
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Prote AG.
Note
Note prohibited weld areas -1- where welding is not allowed.

AG. Volkswagen AG d
agen oes
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y V gu
d b ara
rise nte
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un
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an
d
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ab
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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.
– Weld in parting cuts, MIG-L stepped seam or SG continuous

weld seam are permitted.
– Weld in door aperture, RP spot weld seam.
– Weld in remaining joint, SG plug weld seam and RP spot weld
seam.
– Adapt wing retainer -2- and weld in, SG plug weld seam.
– Reform wheel housing flange.
– Wipe away excess adhesive and seal wheel arch.

RO: 51 48 55 50
15 Renewing front side member rein‐

forcement AG. Volkswagen A n G do
wage es n
Volks ot g
by ua
WARNING ris
ed ran
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Observe safety notes!ss
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ab
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• Side member already removed ⇒ page 229 .
h re
hole
spec
es, in part or in w
1 - Front side member rein‐
t to the co
forcement
2 - Cutting point
rrectness of i
3 - Remaining section of front
l purpos
side member reinforcement

(remains)
nform
ercia
4 - Web plate
m
a
5 - Bonded area
com
tion in
r
6 - A-pillar reinforcement
te o
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Prote AG.

15.1 Tools
Note

work .
15.2 Removing
AG. Volkswagen AG d
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t to the co
rrectness of i
l purpos
nform
mercia
at
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ion
c
in t
or
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do
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or
– Position and make parting cut as shown.

f
en
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t.
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15. Renewing front side member reinforcement 239

AG. Volkswagen AG d
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agen04.2011 oes
n
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Dimension -a- = 100ris mm
e
tee
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Note
nl
pt
du
an
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Web plate -2- must not be damaged.
ab
ility
ot p
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– Separate original joint to A-pillar reinforcement -1- and to inner
h re
side member.
hole
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
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
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co Vo
by lksw
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Prote AG.

15.3 Installing
Note

⇒ page 239 .

AG. Volkswagen AG d
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byV gPassat
ua 2011 ➤ , Passat Variant 2011 ➤
ed ran
oris tee Body Repairs - Edition 04.2011
th or
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New part
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n
c
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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.

– Drill holes for SG plug weld seam (8 mm ∅) in area of factory-
fitted weld points.
15.3.2 Welding in
Note
The new part must be welded in within 90 minutes, or adhesion


AG. Volkswagen AG d
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Note
m
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Prote AG.

AG. Volkswagen AG d
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es, in part or in w
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– Check fit to side member.

rrectness of i
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c
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do
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for
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t.
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Prote AG.

AG. Volkswagen AG d
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Cop py
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– Weld in side member front reinforcement, SG plug weld seam

and RP spot weld seam (inverter).
– Weld in transition to A-pillar reinforcement, SG continuous
weld seam (qty 3).
Length of seam 20 mm, distance between seams 20 mm.

RO: 51 48 55 53
16 Renewing rear side member rein‐

forcement
WARNING

• Side member already removed ⇒ page 229 .
1 - Remaining section of rear

side member reinforcement
(remains)
2 - Cutting point
wage
3 - Outer wheel housing liner olks es n
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4 - Rear side member rein‐ ho
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7 - B-pillar reinforcement
hole
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rrectness of i
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c
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or
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16. Renewing rear side member reinforcement 245

16.1 Tools
Note

work .
16.2 Removing
lkswage es n
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– Separate original joint to inner side member and to outer wheel

te
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nf
ercia
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m
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o
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or c

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16.3 Installing
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t.
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Note co Vo
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⇒ page 246 .

New part
♦ Rear side member reinforcement

16.3.2 Welding in
AG. Volkswagen AG d
New part agen oes
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r
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– Apply 2K body adhesive -D 180 KD3 A2- to area indicated.

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mer
– Weld in rear side member reinforcement, SG continuous weld

atio
seam and RP spot weld seam.

om
n
c
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or

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AG. Volkswagen AG d
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RO: 51 87 55 50 by
V gu
ara
d
17 Renewing seat middle cross member
ise nte
or eo
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WARNING
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• Outer seat cross member mounting already removed
⇒ page 260 .
rrectness of i
17.1 Tools
l purpos
Note
nform
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17.2 Removing
AG. Volkswagen AG d
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nform
mercia
at
om
– Separate original joint to inner mounting for seat cross mem‐

ion
c
ber and to floor panel.

in t
or
his
ate
– Separate bonded connection -1- to floor panel.

do
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for
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17. Renewing seat middle cross member 251

lkswage es n
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17.3 Installing
co lksw
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Prote AG.
Note

⇒ page 250 .

New part
♦ Seat mounting

AG. Volkswagen AG d
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nf
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Cop py
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Vo
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Prote AG.
17.3.2 Welding in
– Adapt new part and fix in position.
17. Renewing seat middle cross member 253

– Check fit to outer mounting for seat cross member and seat.
AG. Volkswagen AG d
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tion in
r
te o
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fo
en
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t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.

the factory.
– Weld seat cross member to inner mounting for seat cross
member and to floor panel, SG plug weld seam.
– Install outer cross member for seat ⇒ page 263 .

RO: 51 87 55 53
18 Renewing inner mounting for seat

cross member
WARNING

Note
If a thread in the inner mounting for the seat cross member is

damaged, the component must be replaced.
18.1 Tools

agen oes
olksw not
♦ The use of different types and differentedthicknesses
by
V
of steel gu
ara
requires that only the welding unitsth(inverters)
oris authorised by nte
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au out repairs properly. ra
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pe
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r
te o
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t.
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Cop py
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18. Renewing inner mounting for seat cross member 255

18.2 Removing
lkswage es n
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u or
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nl
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c
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– Separate original joint to centre tunnel, to floor panel and to C py
t. rig
middle seat cross member -1-. gh ht
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AG. Volkswagen AG d
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olksw s no
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V
d by ara Body Repairs - Edition 04.2011
e nte
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c
i
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t.
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Cop py
t. rig
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co lksw
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18.3 Installing
Note

⇒ page 255 .

New part
♦ Inner mounting for seat cross member

AG. Volkswagen AG d
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m
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ti
18.3.2 Welding in
on in
r
te o
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– Adapt new part and fix in position.

s
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– Check fit to middle seat cross member and to seat.

fo
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t.
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Cop py
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Vo
co lksw
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AG. Volkswagen AG d
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nl
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es, in part or in w
t to the co
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l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
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– Weld inner mounting of seat cross member to centre tunnel

t
sd
iva
and middle seat cross member, SG plug weld seam.

o
r
rp
cu
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m
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en
– Weld in remaining joint, SG staggered continuous weld seam.

ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

RO: 51 87 55 56
19 Renewing outer mounting for seat

cross member G. Volkswagen
nA AG do
wage es n
Volks ot g
WARNING by ua
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au
Observe safety
ss notes! ac
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nl
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hole
Note
spec
es, in part or in w
t to the co
♦ If a thread in the outer mounting for the seat cross member is
damaged, the component must be replaced.
♦ If outer mounting for seat cross member (with vehicle identity
rrectness of i
number) has to be renewed, repair must be documented ac‐
l purpos
cording to market-specific legislation.

♦ The vehicle identification number should be reinstalled/re‐
nform
ercia
stamped before the outer mounting for the seat cross member
is welded in.
m
at
om
ion
c
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or
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ate
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for
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Cop py
t. rig
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pyri by
Vo
co lksw
by
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Prote AG.

1 - Outer mounting for seat

cross member
2 - Vehicle identification num‐
ber (only on right-hand side of
vehicle)
3 - Inner side member assem‐ AG. Volkswagen AG d
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4 - Inner side member orise nte
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5 - Middle seat cross member ss a c
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6 - Floor panel nl
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mercia
at
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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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Vo
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by c lksw
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Prote AG.
19.1 Tools
Note

work .
19. Renewing outer mounting for seat cross member 261

19.2 Removing
AG. Volkswagen AG d
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nform
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tion in
r
te o
thi
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iva
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en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Separate original joints to middle cross member -1- for seat,

to floor panel -2- and to side member -3-.

lkswage es n
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spec
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19.3 Installing
t to the co
rrectness of i
Note
l purpos

⇒ page 261 .
nform
mercia

a
com
tion in
r
New part
te o
thi
s
iva
do
♦ Outer mounting for seat cross member

r
rp
cum
fo
en
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t.
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Note
C py
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co
Before installing, reinstate vehicle identification number if necessary.
by lksw
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t to the co
19.3.2 Welding in
rrectne
– Adapt new part to fit and fix in position.

ss o
cial p
f inform
mer
atio
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n
c
i
or
n thi
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fo
en
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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.

– Check fit to seat.
lkswage es n
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es, in part or in w
t to the co
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– Weld outer mounting for seat cross member to floor panel
-1-, to middle cross member -2- for seat and to inner side
l purpos
member -3-, SG plug weld.

nform
mercia
a
com
tion in
r
te o
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t.
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Cop py
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co lksw
by
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lkswage es n
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Passat 2011 ➤ , Passat Variant 2011au ➤
th or
ac
Body Repairs - Edition 04.2011 ss
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53 – Body - rear
erm
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ility
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RO: 53 05 55 50
spec
1 Renewing rear cross panel
es, in part or in w
t to the co
Includes: cross member for rear cross panel, left and right exhaust
system retainers and lock carrier
rrectness of i
l purpos
WARNING
nform
mercia
at
om
io
n
c
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or
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• Spare wheel well already removed ⇒ page 370 .

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1 - Cross panel
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2 - Lock carrier cop Vo
by lksw
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3 - Right exhaust system re‐
AG.
tainer
4 - Cross member for rear
cross panel
5 - Left exhaust system retain‐
er
266 Rep. gr.53 - Body - rear

1.1 Tools
Note

work .
1.2 Removing
AG. Volkswagen AG d
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nform
mercia
at
– Separate original outer joint.

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Cop py
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267
AG.
1. Renewing rear cross panel
lkswage es n
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c
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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.
– Separate original joint for lock carrier.

– Separate bonded areas -1-.
– Separate original joints of left and right exhaust system re‐
tainers -2 and 3-.

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tion in
r
te o
thi
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iva
do
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cum
fo
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.
1.3 Installing
Note

⇒ page 267 .

New part
♦ Lock carrier
♦ Cross panel
♦ Cross member for rear cross panel
♦ Left exhaust system retainer
♦ Right exhaust system retainer
1. Renewing rear cross panel 269

AG. Volkswagen AG d
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n
c
i
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fo
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Cop py
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Vo
co lksw
by
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Prote AG.

– Grind bonding surfaces back to bare metal.
the factory.
1.3.2 Welding in
Note



AG. Volkswagen AG d
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or c
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Cop py
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– Weld in rear cross panel, RP spot weld seam and SG plug
gh ht
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weld seam or MIG solder seam.
o Vo
by c lksw
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1. Renewing rear cross panel 271

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nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op
– Weld in exhaust system retainers and cross member for rear C py
t. rig
cross panel, SG plug weld seam and RP spot weld seam.
gh ht
pyri by
Vo
co lksw
by
– Weld in lock carrier, RP spot weld seam and SG staggered cted agen
Prote AG.
continuous weld seam or MIG staggered continuous weld
seam.
Note
Spare wheel well may only be installed after reinstating paintwork

finish.
– Install spare wheel well ⇒ page 373 .

RO: 53 05 55 60
2 Renewing rear cross panel (Variant)

Includes: cross member for rear cross panel, left and right exhaust
system retainers and lock carrier
WARNING

• Spare wheel well already removed ⇒ page 370 .
1 - Cross panel
2 - Lock carrier
3 - Bonded area
4 - Right exhaust system re‐
tainer
AG. Volkswagen AG d
5 - Cross member ofor
lkswrear
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not
cross panel d by V gu
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6 - Left exhaust
tho system retain‐ eo
au ra
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mer
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n
c
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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
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Prote AG.
2. Renewing rear cross panel (Variant) 273

Passat 2011 ➤ , Passat Variant 2011 ➤ AG. Volkswagen AG d
agen
Body Repairs - Edition 04.2011 Volksw
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not
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2.1 Tools
r
tho eo
au ra
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pt
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Note
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requires that only the welding units (inverters) authorised by , is n
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rrectness of i
2.2 Removing
l purpos
nform
mercia
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ion
c
in t
or
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do
priv
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for
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t.
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Cop py
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o
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Prote AG.


Note
It is advisable to additionally open a section of the original joint to left and right tail light mountings -1- and to
pull the tail light mounting outwards slightly, to ease the removal of the old rear cross panel and the installation
of the new rear cross panel.
AG. Volkswagen AG d
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nl
pt
du
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nform
mercia
at
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c
in t
or
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do
priv
cum
for
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t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.
– Separate inner original joint.

– Separate original joints of left and right exhaust system re‐
tainers -1 and 2-.

AG. Volkswagen AG d
agen oes
olksw not
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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nform
mercia
at
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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
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

2.3 Installing
Note

⇒ page 274 .

New part
♦ Cross panel with lock carrier
♦ Cross member for rear cross panel
♦ Left exhaust system retainer
♦ Right exhaust system retainer

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
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ab
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nf
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m
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c

or
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f
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the factory.
yi Co
Cop py
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2.3.2 Welding in
gh ht
pyri by
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by
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– Adapt new part with vehicle standing on its wheels or align‐ Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
Passat 2011 ➤ , PassatriVariant
sed
2011 ➤ nte
o eo
Body Repairs - Editionaut 04.2011
h
ra
s s c
ce
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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
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nf
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orm
m
atio
om
n in
or c
thi
te
sd
iva
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rp
cu
o
m
f
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ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Weld in rear cross panel, RP spot weld seam and SG plug

weld seam or MIG solder seam.

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
le
un
pt
an
d
itte
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ab
ility
ot p
wit
is n
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ole,
spec
t to the co
– Weld in exhaust system retainers and cross member for rear

rrectne
cross panel, SG plug weld seam and RP spot weld seam.

– Weld in lock carrier, SG staggered continuous weld seam or
ss o
MIG staggered continuous weld seam.

cial p
f inform
mer
atio
Note
om
n
c
i
or
n thi
Spare wheel well may only be installed after reinstating paintwork

te
sd
va
finish.
i
o
pr
cum
r
fo
en
ng
t.
– Install spare wheel well ⇒ page 373 .
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

RO: 53 09 55 50
3 Renewing lock carrier
WARNING

3.1 Tools
Note

ment, EH catalogue, Workshop equipment, Body and paint‐ n AG. Volkswagen A
work . olks
wage
G do
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o
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db ara
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nl
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ab
ility
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, is n
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
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m
atio
om
n in
or c
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te
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cu
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m
f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

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3.2 Removing
ol ot g
byV ua
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ir se tee
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u or
a ac
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nl
pt
du
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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.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

3. Renewing lock carrier 281

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
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

3.3 Installing
Note

⇒ page 280 .

New part
♦ Lock carrier


the factory.
3.3.2 Welding in
– Adapt new part with vehicle standing on its wheels and fix in
place.
lkswage es n
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un
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pe
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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
en
g
– Weld in lock carrier, RP spot weld seam and SG staggered

n
t.
yi Co
continuous weld seam or MIG staggered solder seam. Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Renewing lock carrier 283

RO: 53 10 55 50
4 Renewing tail light mounting
WARNING
Observe safety notes! agen

AG. Volkswagen AG d
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olksw not
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ara
ed
ris nte
Safety notes ⇒ General Information;
ut
ho Body Repairs, General Body eo
ra
Repairs ; Safety notes ss a c
ce
e
nl
pt
du
an
itte
1 - Bonded areas
y li
erm
ab
ility
2 - Sealing channel
ot p
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3 - Tail light mounting
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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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.

AG. Volkswagen AG d
agen oes
olksw not
yV gu
ed b ara
nte
ris
ut
ho eo
ra
s a c
s
4.1 Tools
ce
e
nl
pt
du
an
itte
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erm
ab
ility
Note
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
work .
l purpos
4.2 Removing
nf
ercia
orm
m
atio
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n in
or c
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sd
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cu
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m
f
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ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Separate bonded areas -1- on sealing channel.
4. Renewing tail light mounting 285

lkswage es n
o ot g
byV ua
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a ac
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un
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an
d
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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
r
fo
en
ng
– Release original joint to lock carrier -2-.

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
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nl
pt
du
an
itte
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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
m
atio

om
n in

or c
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4.3 Installing
sd
iva
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cu
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m
f
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t.
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op
Note C py
t. rig
gh ht
pyri by
Vo
o
c by lksw
cted agen
⇒ page 285 . Prote AG.

New part
♦ Tail light mounting


the factory.
4.3.2 Welding in
Note


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
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

lkswage es n
o ot g
byV ua
d ran
ir se tee
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
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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rp
cu
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f
en
ng
– Weld in new part, SG plug weld seam and RP spot weld seam.
t.
yi Co
Cop py
– Weld in remaining joints to side panel and sealing channel, SG
t. rig
gh ht
yri
staggered continuous weld seam or MIG staggered continu‐
p by
co Vo
by lksw
ous weld seam. Prote
cted AG.
agen

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
cted agen
Prote AG.
– Weld in remaining joints to lock carrier, SG staggered contin‐

uous weld seam or MIG staggered continuous weld seam.

RO: 53 10 55 60
5 Renewing tail light mounting (Var‐

iant)
WARNING

• Side panel already removed ⇒ page 342 .
1 - Tail light mounting

2 - Sealing channel
3 - Cross panel
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
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ce
le
un
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d
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ab
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wit
, is n
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hole
spec
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t to the co
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l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
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t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
5. Renewing tail light mounting (Variant) 291

5.1 Tools
Note

work .
5.2 Removing
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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, is n
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com
tion in

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

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
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nl
pt
du
an
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5.3 Installing
wit
, is n
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hole
spec
es, in part or in w
Note
t to the co

⇒ page 292 .
rrectness of i
l purpos

New part
nf
ercia
orm
♦ Tail light mounting

m
atio
om
n in
or c
thi
te
sd
iva
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r
rp
cu
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m
f
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.

lkswage es n
o ot g
byV ua
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ir se tee
tho
u or
a ac
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ab
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ility
ot
wit
, is n
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spec
es, in part or in w
t to the co
rrectness of i
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5.3.2 Welding in
nform
ercia

m
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.

lkswage es n
o ot g
byV ua
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tho
u or
a ac
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nl
pt
du
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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
– Weld in new part, SG plug weld seam and RP spot weld seam.
his
ate
do
riv
– Weld in remaining joints to sealing channel, MIG continuous

p
cum
for
weld seam.
en
ng
t.
yi Co
op
– Install side panel for Variant, ⇒ page 345 .
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
Passat 2011 ➤ , Passataut Variant 2011 ➤
ho eo
ra
s s 04.2011 c
ce
e
nl
pt
du
an
itte
y li
erm
ab
RO: 53 29 55 50
ility
ot p
6 Renewing C-pillar reinforcement
wit
, is n
h re
hole
spec
WARNING
es, in part or in w
t to the co
rrectness of i
l purpos
processes.
nf
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orm
m
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o
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or c
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en
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t.
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op py
2 - C-pillar reinforcement t. C rig
gh ht
pyri by
3 - Inner side panel
co Vo
by lksw
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Prote AG.
5 - Side panel
Part section removed.

6.1 Tools
Note

work .
6.2 Removing
Note
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
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pt
du
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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.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Position parting cut -1- as shown and cut out.
6. Renewing C-pillar reinforcement 297

lkswage es n
Vo ot g
Passat 2011 e➤ d , Passat Variant 2011 ➤
by ua
ran
ir s
Body Repairs
tho - Edition 04.2011 tee
or
au ac
ss
ce
e
nl
pt
du
an
– Separate original joints to inner side panel and to wheel hous‐
itte
y li
erm
ing.
ab
ility
ot p
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spec
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nf
ercia
orm
m
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n in
or c
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f
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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.
6.3 Installing
Note

⇒ page 297 .

New part
♦ C-pillar reinforcement


Follow repair instructions. AG. Volkswagen AG d
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Moulded foam element ⇒ General iInformation;
se
d b Body Repairs, ara
nte
General Body Repairs ; GeneralthNotes;
or
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au ra
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nl
pt
du
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erm
ab
ility
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or c
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Cop py
t. rig
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Vo
co lksw
by
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Prote AG.

6.3.3 Welding in
Note
AG. Volkswagen AG d
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cum
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en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

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
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Weld in C-pillar reinforcement, RP spot weld seam and SG

plug weld seam.
– Install side panel ⇒ page 335 .

RO: 53 29 55 60
7 Renewing C-pillar reinforcement

(Variant)
Includes: lock reinforcement
WARNING

processes.

AG. Volkswagen AG d
agen oes
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1- C-pillar reinforcement by
Vol
gu
ara
ed
is nte
2- Water drain hose hor eo
aut ra
s c
For models with panorama s
ce
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sliding sunroof.
un
pt
an
d
itte
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3 - Cutting point
rm
ab
pe
ility
ot
wit
, is n
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With opening for water drain

hole
spec
hose.
es, in part or in w
t to the co
5 - Lock reinforcement
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
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7.1 Tools
Note n AG. Volkswagen AG do

lkswage es n
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♦ The use of different
ir se
d b types and different thicknesses of ua
rsteel
an
requires thatthonly the welding units (inverters) authorisedteeby
o
o
Volkswagen
ss
au AG may be used to carry out repairs properly. r ac
ce
e

nl
pt
du
an
itte
y li
erm
ab
work .
ility
ot p
wit
, is n
h re
7.2 Removing
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.
– Release adhesive joint -1- between lock reinforcing, C-pillar

reinforcing and wheel housing liner.
– Separate original joint between lock reinforcing and rear door
aperture.
7. Renewing C-pillar reinforcement (Variant) 303

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
Note thor eo
au ra
ss c
ce
le
un
pt
an
d
♦ Do not damage water drain hose -1- on models with a panorama sliding sunroof.
itte
y li
rm
ab
pe
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
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.
– Make parting cut -2- according to degree of damage.

Note
Remove as much of the foam residue as possible at the water drain hose opening -1- before starting grinding
work.

lkswage es n
o ot g
byV u
ir se
d Passat 2011 ➤ar,anPassat
tee Variant 2011 ➤
o
auth Body Repairs
or - Edition 04.2011
ac
ss
ce
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un
pt
an
d
itte
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erm
ab
ility
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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
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

7.3 Installing
Note

⇒ page 303 .

New part
♦ C-pillar reinforcement
♦ Lock reinforcement

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
o eo
Passat 2011 ➤ , Passat Variant 2011 ➤ aut
h
ra
s c
Body Repairs - Edition 04.2011 s
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
nform
7.3.2 Moulded foam elements mercia
at
om
ion
c
in t
or
his
te
Moulded foam element ⇒ General Information; Body Repairs,

a
do
riv

p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

7.3.3 Welding in
Note
AG. Volkswagen
flanges in these areas are aboutlk13mm
swa
gen wide. AG do
es n
ot g
Vo
by ua
♦ If spot welds are located ratisedthe edge of hot formed steel panels, the
ran high temperature will
tee
cause the bond
between the panels toutchange,
ho which will subsequently have an effect or on crash safety.
s a ac
s
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
cted agen
Prote AG.

tips.

Body Repairs - Edition 04.2011 agen
AG. Volkswagen AG d
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.
– Weld in C-pillar reinforcement, RP spot weld seam.

Lock reinforcing plate -1- must be welded in within 90 minutes or
adhesion of adhesive will be impaired.
– Check fit with side panel.

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
the factory.
his
ate
do
riv
– Weld in lock reinforcement -1-, RP spot weld seam.

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

RO: 53 30 55 50
8 Renewing D-pillar reinforcement -

part section
Includes: sealing channel - part section
WARNING

processes.

• Tail light mounting already removed ⇒ page 291 .

2 - Cutting point
3 - D-pillar reinforcement
4 - Sealing channel
AG. Volkswagen AG d
agen oes
5 - Bonded area 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
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
o
by c lksw
cted agen
Prote AG.

8.1 Tools
Note

work .
8.2 Removing
Note agen
AG. Volkswagen AG d
oes
olksw not
byV gu
Do not damage underlying
rised panels when cutting out. ara
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
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.
– Position parting cut on sealing channel -1- as shown and cut

out.
8. Renewing D-pillar reinforcement - part section 311

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
– Position parting cut at D-pillar reinforcing as shown and cut

y li
rm
ab
out.
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
312
agen
Prote AG.
Rep. gr.53 - Body - rear
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
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.

8.3 Installing
Note

⇒ page 311 .

New part
♦ Inner side panel
♦ Sealing channel

– Transfer parting cut to sealing channel -1- and to D-pillar re‐

inforcing -2- and cut to size.
– Separate original joint from D-pillar reinforcement part section.
8.3.2 Welding in
Note

– Adapt new part with vehicle positioned on alignmentagbracket

en AG. V
olkswagen AG
does
set and fix in place. yV
olksw not
g b ua
ed ran
– Check fit with bolt-on parts. horis tee
t 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
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r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

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
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.
the factory.
– Adapt D-pillar reinforcing to fit and secure in position.
– Weld in D-pillar reinforcing, RP spot weld seam.
– Adapt sealing channel -1- to fit and fix in position.

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
– Weld in parting cut on sealing channel -1-, MIG continuous

weld seam or SG continuous weld seam are permitted.
rrectness of i
– Spot weld remaining joint in, RP spot weld seam.

– Install tail light mounting ⇒ page 293 .
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.

RO: 53 30 55 52
9 Renewing inner D-pillar
WARNING

• Cross panel already removed ⇒ page 273
1 - Sealing channel
2 - Inner D-pillar
3 - Rear longitudinal member
4 - Bonded area
5 - D-pillar reinforcement
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
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
9. Renewing inner D-pillar 317

9.1 Tools
Note

work .
9.2 Removing
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
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
a
– Separate original joint to inner side panel and to rear longitu‐

iv
o
r
rp
cu
dinal member.
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

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

rrectne
9.3 Installing
ss o
cial p
f inform
Note
mer
atio
om

n
c
i
or
⇒ page 318 .
thi
te
sd
iva
o
pr
cum

r
fo
en
ng
t.
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op
New part C py
ht. rig
rig ht
py by
♦ Inner D-pillar (parts designation: reinforcement) co Vo
by lksw
cted agen
Prote
AG.


the factory.
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
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erm
ab
ility
ot p
wit
, is n
9.3.2 Welding in
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
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m
f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

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
– Weld new part to longitudinal member and inner side panel,

RP spot weld seam and SG continuous weld seam.
rrectness of i
– Install tail light mounting ⇒ page 293 .

l purpos
– Install rear cross panel with lock carrier ⇒ page 276 .

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.

RO: 53 48 55 50
10 Renewing rear longitudinal member -

part section
Includes: floor panel, rear cross panel, longitudinal member cover
plate and bumper mounting
WARNING

AG. Volkswagen AG d
Saloon lksw
agen oes
not
Vo gu
y
• Cross panel already removed ⇒ page 266 rise
d b ara
nte
tho eo
• Side panel already removed ⇒ page 332 . s au ra
c
s
ce
e

nl
pt
du
an
itte
Variant
y li
erm
ab
ility
• Cross panel already removed ⇒ page 273
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.


2 - Part section parting cut
with cover plate
4 - Bumper mounting
5 - Floor panel
Note
6 - Connecting plate
lkswage es n
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byV ua
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10.1 Tools
un
pt
an
d
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erm
ab
ility
ot p
Note
wit
is n
h re
ole,

spec

t to the co

rrectne

work .
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
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pr
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fo
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ng
t.
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Cop py
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Vo
co lksw
by
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Prote AG.
10. Renewing rear longitudinal member - part section 323

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
Passat aut2011 ➤ , Passat Variant 2011 ➤
ho eo
ra
Bodys Repairs - Edition 04.2011
s c
ce
e
nl
pt
du
an
10.2 Removing
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.
– Release original joint to floor panel and connecting plate.

– Roughly cut floor panel out using parting cut -1-.

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
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un
pt
an
d
itte
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ab
– Position offset parting cuts on longitudinal member -2- and on

ility
ot p
longitudinal member cover part -1- and cut out.

wit
is n
h re
Dimension -a- approx. 50 mm

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
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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.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
– Remove remaining material. uthor eo
ra
s a c
10.3 Installing
s
ce
le
un
pt
an
d
itte
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rm
ab
Note
pe
ility
ot
wit
, is n

h re
hole
⇒ page 323 .
spec
es, in part or in w
t to the co

New part
rrectness of i
♦ Rear longitudinal member

l purpos
♦ Cover plate for longitudinal member

nform
ercia
♦ Bumper mounting
m
♦ Floor panel (not illustrated)

com
tion in
r
♦ Connecting plate (not illustrated)

te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
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326
cop Vo
by lksw
Rep. gr.53 - Body - rear Prote
cted AG.
agen
lkswage es n
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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
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.
– Transfer parting cuts to new parts and cut out.

10.3.2 Welding in
Note
♦ In the area of the A, B and C-pillars, high tensile, highest tensile

wage
n AG. Voand
lkswahot
genformed
AG do steels are used. The weld
e
flanges in these areas are about 13mm wide. yV
olks s no
t gu
edb ara
♦ If spot welds are located at the edge of hot thformed
or
is steel panels, the high temperature willnte
e cause the bond
between the panels to change, which wills asubsequently
u have an effect on crash safety. or ac
s
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nl
pt
du
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ility
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at
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ion
c
in t
or
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ate
do
priv
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en
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Cop py
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Prote AG.

tips.

lkswage es n
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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
– Weld in longitudinal member part section -1-, SG continuous

weld seam.
nform
ercia
– Weld in bumper mounting -2-, RP spot weld seam.

m
a
com
tion in
r
te o
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s
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Cop py
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lkswage es n
Passat 2011 d➤by,VPassat
o
Variant 2011 ➤ ot g
ua
ran
Body Repairs
horise
- Edition 04.2011 tee
ut or
a ac
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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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
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.
Weld in floor panel and rear cross panel, RP spot weld seam.

AG. Volkswagen AG d
agen oes
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d by ara
ise nte
or eo
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ce
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un
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pe
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ot
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spec
Saloon
es, in part or in w
t to the co
• Install cross panel ⇒ page 269 .

• Install tail light mounting ⇒ page 287 .
rrectness of i
• Install side panel ⇒ page 335 .

l purpos
Variant
nform
ercia
• Install cross panel ⇒ page 276 .

m
• Install tail light mounting ⇒ page 293 .

a
com
tion in
• Install side panel ⇒ page 345 .

r
te o
thi
s
iva
do
r
rp
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en
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t.
yi Co
Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

RO: 53 55 55 50
11 Renewing side panel - part section
WARNING

processes.

1 - Side panel
wage es n
2 - Bonded area yV
olks ot g
d b ua
ran
3 - Moulded foam elements ir se tee
tho
u or
a ac
4 - Parting cut to side member ss
ce
e
nl
pt
5 - Parting cut to roof member
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
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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cted agen
Prote AG.

11.1 Tools
Note

work .
11.2 Removing
Note
AG. Volkswagen AG d
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rise nte
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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
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.
– Position parting cuts according to degree of damage and cut

out.
11. Renewing side panel - part section 333

Recommended parting cuts:

– Grind through outer edge at wheel arch.
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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ab
ility
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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
o
pr
cum
r
fo
– Separate original joint to sealing channel and to tail light

en
ng
t.
yi
mounting.
Co
Cop py
t. rig
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pyri by
Vo
o
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cted agen
Prote AG.

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.

11.3 Installing
Note

⇒ page 333 .

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
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erm
ab
ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
t to the co

rrectness of i
New part
l purpos
♦ Side panel subpart

nf
ercia

orm
m

atio
om
n in
c
♦ 2K polyurethane adhesive -D 180 KD2 A1- (for right side pan‐

or
thi
e
el)
t
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.

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
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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t.
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Cop py
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

11.3.3 Welding in
Note

♦ When applying 2K body adhesive -D 180 KD3 A2- , do not
apply in area of SG plug weld seam for lock reinforcement.
♦ Adhesive must be cleaned from threads for fastening striker
after bonding in.
♦ Before starting welding on right-hand side panel, apply 2K
polyurethane adhesive -D 180 KD2 A1- in area of fuel filler
neck.
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
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

ted.

Note
Before starting welding on right side panel, apply sealing cord -AKD 497 010 04 R10- in area of fuel filler neck.
Note agen
AG. Volkswagen AG d
oes
o lksw not
byV gu
ara
♦ In the area of the A, B and C-pillars, high tensile,
rised
highest tensile and hot formed steels
nte are used. The weld
flanges in these areas are about 13mmawide.ut
ho eo
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.

tips.

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
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.
– Weld in side panel, RP spot weld seam and SG plug weld

seam.
seam are permitted.

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
– Weld in original joint of rear window aperture, RP spot weld

es, in part or in w
seam.
t to the co
– Weld in remaining joint, SG plug weld seam, MIG solder seam

or SG continuous weld seam.
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.

RO: 53 55 55 60
12 Renewing side panel (Variant) - part

section
WARNING

processes.

1 - Side panel
3 - Parting cut for D-pillar
4 - Bonded area
5 - Parting cut to side member
6 - Parting cut for C-pillar
lkswage es n
o ot g
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d ran
ir se tee
tho
u or
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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
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.

12.1 Tools
Note

work .
12.2 Removing
Note
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
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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
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.
– Position parting cuts according to degree of damage and cut

out.
12. Renewing side panel (Variant) - part section 343

Recommended parting cut on side member:

– Grind through outer edge at wheel arch.
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.
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Cop py
t. rig
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Vo
co lksw
by
cted agen
– Separate original joint to sealing channel and to tail light Prote AG.
mounting.

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
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.

12.3 Installing
Note

⇒ page 343 .

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
Note
l purpos
nf
ercia

rm
m
atio
om
n in
New part
or c
thi
te
♦ Side panel subpart for Variant

sd
iva
o
r
rp
cu
♦ Moulded foam elements

o
m
f
en
ng
t.
yi Co
♦ 2K body adhesive -D 180 KD3 A2- t. Cop py
rig
gh ht
♦ 2K polyurethane adhesive -D 180 KD2 A1- (for right side pan‐ pyri by
Vo
o
by c
el)
lksw
cted agen
Prote AG.

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.



AG. Volkswagen AG d
12.3.3 Welding in Volksw
agen oes
not
gu
by ara
d
rise nte
tho eo
Note ss au ra
c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
♦ When applying 2K body adhesive -D 180 KD3 A2- , do not
ot p
wit
apply in area of SG plug weld seam for lock reinforcement.
is n
h re
ole,
♦ Adhesive must be cleaned from threads for fastening striker
spec
after bonding in.
t to the co
♦ Before starting welding on right-hand side panel, apply 2K
polyurethane adhesive -D 180 KD2 A1- in area of fuel filler
neck.
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.

ted.

Note
Before starting welding on right side panel, apply sealing cord -AKD 497 010 04 R10- in area of fuel filler neck.
Note
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

nform
ercia

m
at
om
tips.
ion
c
in t
or

his
ate

do
priv
cum
or

f
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co
349
by lksw
cted agen
Prote 12. Renewing side panel (Variant) - part section
AG.
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.
– Weld in side panel, RP spot weld seam and SG plug weld

seam.
seam are permitted.

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
rrectne
– Weld in remaining joint to sealing channel, SG plug weld seam

and MIG staggered continuous seam or SG staggered con‐
s
tinuous weld seam.

s o
cial p
f in
– Weld in remaining joints to tail light mounting, SG plug weld

form
mer
seam.
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
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.

RO: 53 68 55 50
13 Renewing outer wheel housing liner
WARNING

processes.

1 - Wheel housing liner

2 - Reinforcing plate
3 - Bonded areas
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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Vo
o
352
by c lksw
cted
Rep. gr.53 - Body - rear
agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e nte
horis Passat 2011 ➤ , Passate o Variant 2011 ➤
ut
ss a Body Repairs -r aEdition
c 04.2011
ce
e
nl
pt
du
13.1 Tools
an
itte
y li
erm
ab
ility
ot p
wit
Note
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
work .
nform
ercia
13.2 Removing
m
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
o
by c lksw
cted agen
Prote AG.
– Separate original joint to C-pillar reinforcing and to inner wheel

housing liner.
– Separate bonded areas -1- between lock reinforcing and
wheel housing liner.
13. Renewing outer wheel housing liner 353

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
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Separate remaining joint to rear side member reinforcement

-1- and to rear connecting plate -2-.

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
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

13.3 Installing
Note

⇒ page 353 .

AG. Volkswagen AG d
agen oes
13.3.1 Preparing new part d byV
olksw not
gu
ara
ise nte
r
New part ut
ho eo
ra
s a c
♦ Outer wheel housing liner -1- s
ce
le
un
pt
♦ Reinforcing plate -2-
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness
13.3.2 Welding in
o
cial p
f inform
mer
atio
m
Note
o
n
c
i
or
n thi
e

t
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.

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
the factory.
nform
ercia

m

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.

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
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
– Weld outer wheel housing liner to C-pillar reinforcement and

en
ng
t.
yi
inner wheel housing, RP spot weld seam and SG plug weld
Co
Cop py
seam. ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

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
– Recreate original joint to side member rear reinforcement -1-

thi
te
sd
a
and to rear connecting plate -2-, RP spot weld seam.

iv
o
r
rp
cu
o

f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

RO: 53 68 55 60
14 Renewing outer wheel housing liner

(Variant)
Includes: lock reinforcement
WARNING

processes.

AG. Volkswagen AG d
agen
• Side panel already removed ⇒ page 342 . Volksw
oes
not
by gu
d ara
ise nte
or eo
h
1 - Wheel housing liner s aut ra
c
s
2 - Reinforcing plate
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
4 - Bonded areas
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
o
by c lksw
cted agen
Prote AG.

14.1 Tools
Note

work .
14.2 Removing
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
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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
cted agen
Prote AG.
– Separate bonded areas -1- between lock reinforcing and

wheel housing liner.
– Separate original joint of lock reinforcing to inner C-pillar.
14. Renewing outer wheel housing liner (Variant) 361

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
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.
– Separate original joint to C-pillar reinforcing and to inner wheel

housing liner.

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
– Separate remaining joint to rear side member reinforcement Prote AG.
-1- and to rear connecting plate -2-.

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
ercia

m
a
com

tion in

r
te o
thi
s
iva
14.3 Installing
do
r
rp
cum
fo
en
ng
t.
yi Co
op
Note
C py
t. rig
gh ht
pyri by
Vo
o
c by lksw
cted agen
⇒ page 361 .
Prote AG.


New part
♦ Outer wheel housing liner -1-
. Volkswagen AG
wa gen AG does
♦ Reinforcing Vplate
olks -2- not
gu
y b ara
d
♦ Lock reinforcement
oris
e nte
eo
th
u ra
♦ 2K
ss body adhesive -D 180 KD3 A2-
a 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
14.3.2 Welding in
rrectness of i
Note
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.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e nte
Passat 2011 ➤ , Passat Varianthoris
2011 ➤ eo
ut
ss a ra
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.

the factory.

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
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.
– Weld outer wheel housing liner to C-pillar reinforcement and

inner wheel housing, RP spot weld seam and SG plug weld
seam.

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
– Recreate original joint to side member rear reinforcement -1-
f
en
ng
t.
yi
and to rear connecting plate -2-, RP spot weld seam.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

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
– Apply 2K body adhesive -D 180 KD3 A2- in areas shown be‐

y li
erm
ab
tween lock reinforcement and wheel housing liner.

ility
ot p
wit

, is n
h re
hole
– Weld in lock reinforcing, RP spot weld seam.

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
cted agen
Prote AG.

RO: 53 80 55 00
15 Renewing spare wheel well
WARNING
Observe safety notes! AG. Volkswagen AG d

agen oes
olksw not
byV gu
ara
ed
Safety notes ⇒ General Information;
thoris
Body Repairs, General Body nte
eo
Repairs ; Safety notes s au ra
c
s
ce
e
nl
pt
du
an
1 - Spare wheel well (bonded)
itte
y li
erm
ab
ility
ot p
wit
, is n
3 - Floor panel
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.
15.1 Tools

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
♦ Electric cutter -V.A.G 1561/A-

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.
15. Renewing spare wheel well 371

15.2 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
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
cted agen
Prote AG.
– Roughly cut out spare wheel well at edge -parting line- using
pneumatic sabre saw -V.A.G 1523/A- .
– Leave bonding flange -1-.

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
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove residual material of spare wheel well (bonding flange

-1-) using electric cutter -V.A.G 1561/A- and a suitable blade,
e.g. offset blade (25 mm) -V.A.G 1561/4- or offset blade -
V.A.G 1561/10- .
Note
♦ Do not remove all adhesive, residual material is used as a base for the new adhesive.
♦ Keep adhesive surface clean and free of grease.
15.3 Installing

New part
♦ Spare wheel well (for front or four-wheel drive)
♦ 2K window adhesive -DA 004 600 A2-
♦ Glass and paint primer -D 009 200 02-
♦ Primer applicator -D 009 500 25-

♦ Cleaning solution -D 009 401 04-

♦ Activator -D 181 801 A1-
♦ Adhesive remover -D 002 000 10-
– The circumferential adhesive bead -1- on the new part must
be cut back to approx. 1 mm.
Note
For bonding reasons, the adhesive bead on the new part should
be cut back only just before it is to be fitted.
15.3.2 Bonding in
Note
For damaged paintwork or new body parts, apply corrosion pro‐

tection measures according to guidelines in ⇒ Paint workshop
manual: Corrosion and corrosion protection, attached and welded
parts, materials .
Prepare bonding surface on body for spare wheel well

-shaded area-.
Areas with new paint work structure:
. Volkswagen AG
– Clean respective areas with cleaning solution -D 009 401 04- kswagen AG does
not
and then dry with a lint-free cloth. by
Vol gu
ara
d
ise nte
– Then apply glass/paint primer -D 009 200 02- evenly using
ho
r eo
ut
primer applicator -D 009 500 25- . ss
a ra
c
ce
e
♦ Drying time approx. 10 minutes

nl
pt
du
an
itte
y li
Areas with residual adhesive:
erm
ab
ility
ot p
– If bonding is not performed immediately after cutting back, the wit

, is n
remaining residual material must be activated with activator - h re

D 181 801 A1- .
hole
spec
es, in part or in w
t to the co
WARNING
Activator must not come into contact with the paintwork, oth‐
rrectness of i
erwise paint surface will be damaged.

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
o
by c lksw
cted agen
Prote AG.

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
m
WARNING
o
n in
or c
thi
e
Spare wheel well must be welded in within 10 minutes or ad‐

t
sd
iva
hesion of glass adhesive will be impaired.

o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op py
– Apply 2K glass adhesive -DA 004 600 A2- -A- to bonding sur‐ t. C rig
gh ht
face -1-. yri
p by
co Vo
by lksw
cted
– Fit new part and align.
agen
Prote AG.
– Fit spare wheel or other suitable weight to press on.

– Remove excess adhesive with a dry cloth.
– Remove residual soiling using adhesive remover -D 002 000
10- .
Safety precautions must be observe for all work procedures.
Note
Minimum curing period for 2K glass adhesive -DA 004 600 A2- is
4 hours.

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Service

Service Department. Technical Information

All rights reserved.

Copyright © 2011 Volkswagen AG, Wolfsburg D3E80312527

2 Renewing right console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

5 Renewing upper wheel housing longitudinal member . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

10 Renewing A-pillar reinforcement - part section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

16.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

16.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

17 Renewing seat middle cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

17.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

17.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

17.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252

18 Renewing inner mounting for seat cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255

18.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

19 Renewing outer mounting for seat cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

19.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

19.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

19.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

53 - Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

1 Renewing rear cross panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

2.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

4 Renewing tail light mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284

10.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324

10.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326

11 Renewing side panel - part section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ab 332

11.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335

12 Renewing side panel (Variant) - part section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342

12.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345

13 Renewing outer wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352

13.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353

13.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355

14 Renewing outer wheel housing liner (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360

14.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361

14.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361

14.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364

00 – Technical data olksw

The vehicle identification number -1- is located in the area of the

♦ The vehicle identification number is also stamped at three oth‐

1. Vehicle identification data 1

♦ The vehicle identification number -arrow A- is located on the

wing mounting on the right in the luggage compartment (driv‐

♦ The vehicle identification number -arrow B- is located on the

The numbers are located at the same points on the Variant.

2 Rep. gr.00 - Technical data

Before beginning any cutting, alignment or dent removal, refer

Safety notes ⇒ General Information; Body Repairs, General Body

The exact location of these moulded foam elements are shown

The replacement moulded foam elements expand first at ap‐

4 Rep. gr.00 - Technical data

As these temperatures cannot be achieved under normal work‐

Secure new part in position. Gently press new part, in vicinity of

The foam filler hardens within 25 minutes.

3. Moulded foam elements 5

4 Galvanized body parts, high/higher- agen

strength than conventional high-strength panels for less weight.

Work on strengthened body panels must comply with guide lines

The body of the vehicle is predominantly manufactured from

galvanized steel panels.

This illustration shows those parts of the body manufactured from

6 Rep. gr.00 - Technical data