Body Repairs

Service
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Passat CC 2009 ➤
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Edition 11.2011
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Service Department. Technical Information

Service
Repair Group overview for Body Repairs
Repair Group
00 - Technical data
50 - Body - front
51 - Body - centre
53 - Body - rear
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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 K0059040920

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Body Repairs - Edition 11.2011
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Vehicle identification data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Identification plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Moulded foam elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 Galvanized body parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.1 Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.2 High- and higher-strength body panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.3 Hot-formed body panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5 Laser welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6 Body panel gaps/shut lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.1 Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.2 Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.3 Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7 Body dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7.1 Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7.2 Body - centre . V.ol.ks. w. a.g.en. A
..................................................... 15
gen AG G
7.3 Body ksw- arear . . . . . . . . . . . d. o.e.s n. o. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Vol tg
7.4 sed bFloor group - front . . . . . . . . . . . .ua. ra. n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
y
25
ri t
7.5
ut
ho Floor group - centre . . . . . . . . . . . . . .ee.o.r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
a a
ss 7.6 Floor group - rear . . . . . . . . . . . . . . . . . . c. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
ce
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nl
8 Alignment bracket set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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8.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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erm
ab
9 Portal gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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9.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
, is n
h re
hole
50 - Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
spec
es, in part or in w
t to the co
1 Renewing right console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
rrectness of i
1.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
l purpos
2 Renewing left console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
nform
ercia
2.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
m
at
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ion
3 Renewing retaining bracket (for subframe) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

c
in t
or
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
his
ate
do
riv
3.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
p
cum
or
3.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
f
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ng
t.
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4 Renewing bumper bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Cop py
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4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
gh ht
pyri by
Vo
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4.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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Prote AG.
4.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5 Renewing upper wheel housing longitudinal member . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6 Renewing front wheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Contents i
CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
6.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7 Renewing front longitudinal member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
7.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
7.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
7.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
8 Renewing front longitudinal member - part section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
8.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
9 Repairing threads for securing subframe (suspension subframe) . . . . . . . . . . . . . . . . . . . . 93
9.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
9.2 Contents of thread repair kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
9.3 Repairing thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
51 - Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1 Renewing roof - vehicles with no panorama tilting sunroof . . . . . . . . . . . . . . . . . . . . . . . . 99
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .V.o.lk.sw. a. . . . . . . . . . . . . . 100
AG. gen A
1.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .lk.sw. a.g.e.n . . . . . . . . . . . .G.d.oe. s.n.o . . . . 102
V o t
1.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ed. b.y. . . . . . . . . . . . . . . . . . . . . . . . . .g.ua. ra. 104
ris nte
2 Renewing roof - vehicles with panorama tilting sunroof ut
ho . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 eo
ra
a
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 c
s
ce
le
2.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

un
pt
an
d
2.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

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erm
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3 Renewing roof side member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
ility
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3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
wit
is n
h re
3.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
ole,
spec
3.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
urposes, in part or in wh
t to the co
4 Renewing front cross member for roof - vehicles with no panorama tilting sunroof . . . . . . 142
4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
4.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
rrectne
4.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
5 Renewing front cross member for roof - vehicles with panorama tilting sunroof . . . . . . . . 146
ss o
5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
cial p
f inform
5.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
mer
5.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

atio
om
6 Renewing roof reinforcement, vehicles with panorama tilting sunroof . . . . . . . . . . . . . . . . 150 n

c
i
or
n thi
e
6.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

t
sd
iva
6.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

pr
cum
r
fo
6.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

en
ng
t.
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op
7 Renewing rear roof cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 C py
t. rig
gh
7.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
ht
pyri by
Vo
o
by c
7.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
lksw
cted agen
Prote AG.
7.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
8 Renewing A-pillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
8.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
8.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
8.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
9 Renewing A-pillar reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
9.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
9.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
9.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
10 Renewing B-pillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
10.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
ii Contents
CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
10.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

10.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
11 Renewing inner B-pillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
11.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
11.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
11.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
12 Renewing B-pillar reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
12.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
12.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
12.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
13 Renewing side member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
13.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
13.2 Removing . . . . . . . . . .en. A. G . ..V.o.lk.sw
. a. g.e.n.A.G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
ag do
13.3 Installing . . . . . V. o.lk.sw
. . . . . . . . . . . . . . . . . . .es. n.o.t g. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
by ua
14 Renewing ofront
ris
ed side member reinforcement . . . . . r.an. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
tee 215
h
14.1 Tools .au.t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o.r a.c. . . . . . . . . . . . . . . . . . . . . . . . . . 216
ss
14.2 Removing .............................................................. 216
ce
le
un
pt
14.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
an
d
itte
y li
15 Renewing rear side member reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
rm
ab
pe
ility
15.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
ot
wit
, is n
15.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
h re
15.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
hole
spec
es, in part or in w
53 - Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
t to the co
1 Renewing cross panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
rrectness of i
1.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
l purpos
1.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

2 Renewing lock carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
nform
ercia
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

m
2.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

a
com
tion in
2.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

r
te o
thi
3 Renewing tail light mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

s
iva
do
r
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

rp
cum
fo
3.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

en
ng
t.
yi Co
3.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Cop py
t. rig
gh ht
4 Renewing rear longitudinal member - part section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
yri
244
p by
co Vo
by lksw
4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prote
cted AG.
agen
245
4.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
4.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
5 Renewing side panel - part section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
5.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
5.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
6 Renewing outer wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
6.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
6.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
6.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
7 Renewing spare wheel well . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
7.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
7.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Contents iii
CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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.
iv Contents
CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
00 – Technical data
1 Vehicle identification data
1.1 Vehicle identification number

The vehicle identification number (chassis number) -arrow- is lo‐
cated on the right wing mounting (upper longitudinal member for
wheel housing) as seen when sat behind the steering wheel look‐
ing forwards.
Note
If the wing mounting (upper longitudinal member for wheel hous‐

ing) must be renewed, the repairs must be documented according
to the market-specific legislation.
n AG. Volkswagen AG do
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1.2 Identification plate
h re
hole
spec
The identification plate -arrow- is located on the left outer B-pillar
es, in part or in w
(as seen when sat behind the steering wheel looking forwards)
t to the co
and it is visible when the left front door is opened.
rrectness of i
l purpos
nform
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c
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co lksw
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1. Vehicle identification data 1

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
1.3 Vehicle data sticker

The vehicle data sticker -arrow- is stuck on the right of the spare
wheel wheel.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
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ho eo
aut ra
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
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pr
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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.
2 Rep. gr.00 - Technical data

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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.
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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rm
ab
pe
ility
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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
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com
tion in
r
te o
thi
s
iva
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Cop py
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pyri by
Vo
o
by c lksw
cted
3
agen
Prote AG.
2. Safety instructions
CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
3 Moulded foam elements

On this vehicle, various bodywork cavities are fitted with moulded
foam elements.
The moulded foam elements reduce the amount of driving noise
that is transmitted into the interior.
The exact location of these moulded foam elements are shown
at the beginning of the respective repair description.
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
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es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
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n in
or c
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f
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Cop py
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gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
4 Galvanized body parts

Working on galvanized body panels ⇒ General Information; Body
Repairs, General Body Repairs ; Steel panel repairs; galvanized
body parts .
4.1 Body
The body of the vehicle is predominantly manufactured from
galvanized steel panels of various strength.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
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nl
pt
du
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Prote AG.
This illustration shows the body parts which are not galvanized
-blue-.
Note
The outer side panel and roof panel are only shown for orientation
purposes.
4. Galvanized body parts 5

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
4.2 High- and higher-strength body panels
Note
♦ High- and higher-strength body panels are primarily fitted on

this vehicle.
♦ The rear wheel housing liners, the outer side panels and the
roof are manufactured from »normal« body panels.
Fundamentally when working with high strength body panels

⇒ General Information; Body Repairs, General Body Repairs ;
Steel panel repairs; galvanized body parts .
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
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wit
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es, in part or in w
t to the co
rrectness of i
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nf
ercia
4.3 Hot-formed body panels

orm
m
atio
om
n in
c
Note
or
thi
te
sd
iva
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r
Higher-strength body panels are primarily fitted on this vehicle

rp
cu
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⇒ page 6 .
f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
6
cted agen
Prote AG.
Rep. gr.00 - Technical data
CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
To show the body better, the outer side panel and the roof are not
illustrated.
Fundamentally when working with high strength body panels
Steel panel repairs; galvanized body parts .
This illustration shows those parts of the body manufactured from
hot-formed body panels.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
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es, in part or in w
t to the co
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c
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Cop py
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Vo
co lksw
by
cted agen
Prote AG.
4. Galvanized body parts 7

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
5 Laser welding
On this vehicle, some sections of the roof and body are welded
by laser.
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 with or without
the need of additional material.
For repairs (except for roof repairs), the laser weld seam is re‐
placed by a SG plug weld seam or RP spot weld seam.
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
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
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m
atio
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n in
or c
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iva
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cu
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f
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t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
6 Body panel gaps/shut lines
Note
Use setting gauge -VAS 3371- for checking or adjusting.
lkswage es n
o ot g
byV ua
6.1 Body - front
d ran
ir se tee
tho
u or
a ac
Dimension -a- - 6.0 mm ± 1 mm
ss
ce
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nl
pt
Dimension -b- - 6.0 mm ± 1 mm
du
an
itte
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Dimension -c- - 3.5 mm ± 1 mm
ab
ility
ot p
Dimension -d- - 3.5 mm ± 1 mm
wit
, is n
h re
Dimension -e- - 4.0 mm ± 1 mm
hole
spec
es, in part or in w
t to the co
rrectness of i
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6.2 Body - centre

n
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Dimension -c- - 3.5 mm ± 1 mm C py
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Dimension -d- - 5.5 mm ± 1 mm cop Vo
by lksw
cted agen
Prote AG.
6. Body panel gaps/shut lines 9

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
6.3 Body - rear

Dimension -c- - 3.5 mm ± 1 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
y li
erm
ab
ility
ot p
wit
, is n
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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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rp
cu
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f
en
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t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
7 Body dimensions
Note
♦ Dimensions only given for checking purposes. The alignment

bracket set is definitive. Bolts, screws, plugs, trim and attached
components must be removed before taking measurements.
♦ Use Telescopic gauge -VAS 5159- or Telescopic gauge -VAS
5160- to determine body dimensions.
7.1 Body - front

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
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erm
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ility
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wit
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hole
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es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
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n in
or c
thi
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rp
cu
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f
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t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Dimension -a- = 990 mm ± 1 mm
7. Body dimensions 11
CC 2010 ➤ , CC 2012 ➤ , Passat ACC 2009 ➤
n G. Volkswagen AG do
lkswage es n
o o t gu
yV
db ara
ir se nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
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ility
ot p
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es, in part or in w
t to the co
rrectness of i
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nf
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or c
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f
en
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t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
Dimension -a- = 1,510 mm ± 1 mm

mer
atio
om
n
c
i
or
n thi
te
sd
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CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤

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CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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Dimension -a- = 715 mm ± 1 mm Prote AG.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
7.3 Body - rear
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CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤

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Dimension -a- is measured on floor at a height of the left and right B-pillar
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Dimension -b- = 1,327 mm ± 1 mm

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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Setup of entire alignment bracket set -VAS 6325- .

– Detailed information on setting up the alignment bracket set
can be found in the setup plan enclosed with the equipment.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
9 Portal gauge
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– Detailed information on setting up the portal gauge can be

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9. Portal gauge 31
CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
9.1.2 Rear door aperture

Set up for portal gauge -VAS 5007/38- , rear door aperture
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CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
50 – Body - front
RO: 50 40 55 53
1 Renewing right console
WARNING
Observe safety notes!
Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes
1.1 Tools
Note
♦ The use of different types and different thicknesses of steel . Volkswagen AG

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Volkswagen AG may be used to carry out repairs properly. by
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1. Renewing right console 33

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
1.2 Removing
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34 Rep. gr.50 - Body - front

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– Remove remaining material.
1.3 Installing
Note
Only welding units authorised by Volkswagen AG may be used

⇒ page 33 .
1.3.1 Welding in
Replacement part
♦ Right engine bracket
– Using alignment bracket set, adapt new part to fit and fix in
place.
1. Renewing right console 35

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– Weld in console, RP spot weld seam.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
RO: 50 40 55 50
2 Renewing left console
WARNING
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2. Renewing left console 37

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
2.2 Removing
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CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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– Separate rear original joint.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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2.3 Installing
Note
The use of different types and different thicknesses of steel re‐

quires that one of the welding units (inverter) listed under Tools
must be used for proper spot welding ⇒ page 37 .
2.3.1 Preparing new part

Replacement part
♦ Left engine console
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2.3.2 Welding in
– Using alignment bracket set, adapt new part to fit and fix in
place.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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Prote AG.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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‐
AG. Volkswagen AG d
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agen oes
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3.1 Tools tho
ris tee
or
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Note
an
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pe
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wit
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spec
es, in part or in w
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paintwork .
rrectness of i
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tion in
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
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Prote AG.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
3.2 Removing
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
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tho eo
au ra
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nl
pt
du
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ab
ility
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spec
es, in part or in w
t to the co
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Renewing retaining bracket (for subframe) 43

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
lkswage es n
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tho
u or
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ss
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nl
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ility
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wit
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es, in part or in w
t to the co
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3.3 Installing
t
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Note Cop py
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agen
Prote AG.

Replacement part
♦ Front retaining bracket for subframe (parts designation: sub‐
frame retaining bracket)

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
– Drill holes for SG plug weld seam (7 mm ∅).
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
3.3.2 Welding in
ed
ris nte
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– Adapt new part to vehicle standing on alignment bracket set
ss c
ce
e
and fix in place.

nl
pt
du
an
itte
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erm
ab
ility
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wit
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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
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
– Weld in new part, SG plug weld seam.
3. Renewing retaining bracket (for subframe) 45

AG. Volkswagen AG d
agen oes
olksw not
CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤ d byV gu
ara
e
Body Repairs - Edition 11.2011 horis nte
eo
aut ra
ss c
ce
e
nl
pt
du
RO: 50 65 55 00
an
itte
4 Renewing bumper bracket
y li
erm
ab
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wit
, is n
WARNING
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
1 - Bumper bracket
nf
ercia
o
2 - Longitudinal member with
rm
cover plate
m
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n in
or c
thi
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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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
4.1 Tools
Note

paintwork .
4.2 Removing
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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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
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
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 bumper bracket 47

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
4.3 Installing es, in part or in w
t to the co
rrectness of i
Note
l purpos

nform
ercia

m
at
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io
4.3.1 Welding in
n
c
in t
or
his
te
Replacement part
a
do
priv
cum
or
♦ Front bumper bracket

f
en
ng
t.
yi Co
– Adapt new part with vehicle standing on its wheels or on align‐ t. Cop py
ment bracket set and hold in position.
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
– Weld in bumper bracket, SG continuous weld seam.

ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
4. Renewing bumper bracket 49

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
RO: 50 72 55 00
5 Renewing upper wheel housing lon‐

gitudinal member
Comprises: upper outer longitudinal member and upper inner
longitudinal member
Note
The chassis number is located on the right upper longitudinal

member for the wheel housing. If this component has to be re‐
placed during accident damage repair, an impartial expert is to be
consulted prior to the work being carried out.
WARNING

1 - Parting cut for partial re‐

placement
2 - Upper inner longitudinal
member
3 - Bonded section
Note
AG. Volkswagen AG d
agen oes
olksw not
Partial renewal ed byV gu
ara
A partial replacement can also horis nte
eo
be made with the specified s aut ra
c
parting cut -1-. s
ce
le
un
pt
an
Dimension -a- = 260 mm

d
itte
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ab
pe
4 - Upper outer longitudinal

ility
ot
member
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
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t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
5.1 Tools
lkswage es n
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Note ir se
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th or
u
♦ The use of different types and differentss thicknesses of steel
a ac
ce
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nl
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du
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erm
ab
ility
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wit
, is n
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paintwork .
hole
spec
es, in part or in w
t to the co
5.2 Removing
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.
5. Renewing upper wheel housing longitudinal member 51

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
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rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
Note
t. rig
gh ht
pyri by
Vo
o
by c lksw
The suspension strut mounting is welded using SG continuous weld seam in area -1-.
cted agen
Prote AG.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
5.3 Installing atio

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

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤

Replacement part
♦ Upper inner longitudinal member
♦ Upper outer longitudinal member
♦ 1K assembly adhesive -D 190 MKD A3-
– Drill 7 mm ∅ holes in upper inner longitudinal member for SG
plug weld seam.
– Using alignment bracket set, adapt upper inner longitudinal
member to fit and fix in place.
– Check fit with upper outer longitudinal member.
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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
5.3.2 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
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
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Weld in upper inner longitudinal member, RP spot weld seam

and SG staggered continuous weld seam.
– Apply 1K adhesive adhesive -D 190 MKD A3- to bonding area.
– Adapt upper outer longitudinal member to fit with upper inner
longitudinal member and check fit with adjacent parts.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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 upper outer longitudinal member -1- to upper inner lon‐

gitudinal member, SG plug weld seam and RP spot weld
seam.
– Recreate remaining joint to A-pillar -2-, SG plug weld seam.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
RO: 50 74 55 00
6 Renewing front wheel housing

Includes: suspension strut mounting
WARNING

1 - Wheel housing with sus‐

pension strut mounting
2 - Front longitudinal member
3 - Cover plate for longitudinal
member
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
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.
6. Renewing front wheel housing 57

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
6.1 Tools
Note

paintwork .
6.2 Removing
• Upper longitudinal member for wheel housing already re‐
moved
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
– Separate original joint to front longitudinal member cover

sd
iva
o
r
plate, to interior and to plenum chamber from wheel housing

rp
cu
o
side.
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
58
AG.
Rep. gr.50 - Body - front
CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
– Separate remainder of joint to plenum chamber. Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
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CC 2010 ➤ , CCby2012 Vo l ➤ , Passat CC 2009 ➤ not gu
d ara
Body Repairs oris - Edition 11.2011
e nte
h 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
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
6.3 Installing
Note

6.3.1 Preparing new parts

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

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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.
– Drill 8 mm ∅ holes in suspension strut mounting reinforcement

for SG plug weld seam.
– Drill 8 mm ∅ holes in suspension strut mounting for SG plug
weld seam.
– Drill 8 mm ∅ holes in wheel housing for SG plug weld seam.
Note
♦ Drill a double row of holes in area -1-.

♦ Distance between holes: approx. 30 mm.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
– Adapt new part with assistance of alignment bracket fixtures

-item 13-, -item 15-, -item 16- and -item 17- from alignment
nf
ercia
bracket set -VAS 6325- and to adjacent parts and fix in place.
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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
6.3.2 Welding in
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
– Weld suspension strut mounting -1- to suspension strut

ility
ot p
mounting reinforcement -2- and reinforcement extension -3-,

wit
, is n
SG plug weld seam.

h re
hole
spec
es, in part or in w
t to the co
Note
The upper inner longitudinal member -4- is attached only to position parts -1,2,3-. It can be removed for welding
rrectness of i
and drilling holes for suspension strut.

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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
– Drill holes -1- (10 mm ∅) for mounting suspension strut. Ad‐

ditionally secure suspension strut mounting and suspension spec
es, in part or in w
t to the co
strut mounting reinforcement with bolts to alignment bracket
fixture -2-.
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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
– Weld wheel housing to suspension strut mounting, SG plug

spec
weld seam and RP spot weld seam.

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
V gu
d by ara
ise nte
or eo
h
CC 2010 ➤ , CC
aut 2012 ➤ , Passat CC 2009 ➤ ra
c
s
Body Repairs - Edition 11.2011 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
o
by c lksw
cted agen
Prote AG.
– Recreate joint between wheel housing and plenum chamber;

SG plug weld seam.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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.
– Recreate remaining joint to plenum chamber, SG plug weld

seam.
– Recreate original joint between suspension strut mounting
-1- and suspension strut mounting reinforcement -2-, RP spot
weld seam.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Note
m
at
om
ion
c
in t
r
Item 17 of alignment bracket set -VAS 6325- can be used to check dimension -a-
o
his
te
⇒ „8 Alignment bracket set“, page 30 .

a
do
priv
cum
for
en
g
– Enlarge holes for suspension strut mounting cover plate.

n
t.
yi Co
op py
– Install upper longitudinal member for wheel housing
t. C rig
gh ht
yri
⇒ „5.3 Installing“, page 53 . p by
co Vo
by lksw
cted agen
Prote AG.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
RO: 50 79 55 00
7 Renewing front longitudinal member
WARNING
AG. Volkswagen AG d
agen
Observe safety notes! olksw
oes
not
byV gu
ara
ed
ris nte
ho eo
ut
Safety notes ⇒ General Information;
ss a Body Repairs, General Body ra
c
ce
e
nl
pt
du
an
itte
y li
erm
1 - Parting cut (cover plate)
ab
ility
ot p
2 - Parting cut (longitudinal
wit
, is n
member)
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. Renewing front longitudinal member 69

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
7.1 Tools
Note

paintwork .
7.2 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
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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
– Make parting cut on longitudinal member as shown.

t.
yi Co
Cop py
t. rig
Dimension -a- = 55 mm opyri
gh by
Vo
ht
by c lksw
cted agen
Prote AG.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
– Make parting cut on longitudinal member cover plate as

ercia
shown.
m
a
com
tio
n 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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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.
7.3 Installing
Note


Replacement part
♦ Longitudinal member assembly

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
– Transfer parting cuts to new part and cut out.

an
d
itte
y li

erm
ab
ility
ot p
7.3.2 Welding in
wit
is n
h re
ole,
– Adapt new part with vehicle standing on its wheels or on align‐

spec

t to the co
– Check fit with adjacent parts.

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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
– Butt weld parting cut of longitudinal member all around (SG yri
p by
o Vo
continuous weld seam).
c by lksw
cted agen
Prote AG.
– Weld parting cut of cover plate, SG continuous weld seam and
RP spot weld seam.
– Butt weld cover plate parting cut, SG continuous weld seam.
– Restore remaining joint, SG plug weld seam and RP spot weld
seam.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
7.3.3 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
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.
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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
– Assemble alignment bracket mounting for front longitudinal

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

es, in part or in w
t to the co
longitudinal member from below.

– Transfer dimensions (plus an additional 2mm) -a- to longitu‐
dinal member and cover plate and remove excessive material.
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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
– Fix front bumper bracket -1- in position in front of longitudinal
inform
member -2- with aid of -RW 1- and -RW 3-.
mer
atio
om
n
c
i
or
Note
thi
te
sd
iva
o
pr
There must be a gap of 1-2 mm between longitudinal member -2- with cover plate and bumper bracket -1-.
um
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
– Weld in bumper bracket, SG continuous weld seam.

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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
RO: 50 79 55 02
8 Renewing front longitudinal member

- part section
WARNING

1 - Cover plate
2 - Longitudinal member
3 - Laser weld seam
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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
8.1 Tools
Note

paintwork .
8.2 Removing
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
The parting cut for cover plate -1- and the parting cut for longitu‐
m
at
om
dinal member -2- must be offset.

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
o
by c lksw
cted
81
agen
Prote AG.
8. Renewing front longitudinal member - part section
CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Note
Do not cut or weld 50 mm before or after the laser weld seam

-2-.
– Position parting cuts -1 or 3- according to degree of damage

and cut out.
Caution
The parting cut for the longitudinal member is permitted only

in the area shown. If the longitudinal member is damaged be‐
yond this area, it must be renewed entirely.
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.
– Position parting cut -1- for cover plate as shown and cut out.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
– Remove 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
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Position parting cut -3- on longitudinal member -1- and longi‐

tudinal member -2- congruently and cut out. Take note of laser
t to the co
weld seam -4-.

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.
8. Renewing front longitudinal member - part section 83

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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.
– Remove residual material and remainder of longitudinal mem‐

ber reinforcement -1 shaded area-.
8.3 Installing
Note


Replacement part
♦ Longitudinal member (subpart)
♦ Cover plate for longitudinal member
♦ Longitudinal member reinforcement (parts designation: bulk‐
head plate)

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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 cut to longitudinal member and longitudinal

member cover plate and cut out.
8.3.2 Welding in
– Check fit with adjacent parts.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
– Weld in longitudinal member parting cut (all round), SG con‐

l purpos
tinuous weld seam.

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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
– Weld in longitudinal member reinforcement, RP spot weld

seam (inverter).
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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
Note
hole
spec
es, in part or in w
t to the co
Distance between weld points -a- approx. 35-40 mm
– Weld in cover plate parting cut, SG continuous weld seam.

rrectness of i
– Weld in cover plate, RP spot weld seam.

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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
8.3.3 Shortening new longitudinal member with cover plate
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
Note
s
iva
do
r
rp
cum
The longitudinal member -2- with cover plate -1- (parts designation: longitudinal member) is too long at the front
fo
en
g
-shaded area- and must be shortened when adapting and welding in the bumper bracket.
n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
– Assemble alignment bracket mounting for front longitudinal

an
d
itte
member -RW 1- with spacer -RW 3- as shown and hold against

y li
rm
ab
longitudinal member from below.

pe
ility
ot
– Transfer dimensions (plus an additional 2mm) -a- to longitu‐

wit
, is n
h re
dinal member and cover plate and remove excessive material.

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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
– Fix front bumper bracket -1- in position in front of longitudinal

r
te o
thi
member -2- with aid of -RW 1- and -RW 3-.

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

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
– Weld in bumper bracket, SG continuous weld seam. t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
RO: 50 79 49 50
9 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.
AG. Volkswagen AG d
agen oes
olksw not
V
Special tools and workshop equipment required ed by gu
ara
ris nte
o
♦ Thread repair kit -VAS 6058- aut
h eo
ra
ss c
♦ Drill -VAS 6267-
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.
9. Repairing threads for securing subframe (suspension subframe) 93

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
1 - Threaded plate (welded to

subframe retaining bracket)
Note
2 - Helicoil thread insert
lkswage es n
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9.1 Tools ss
ce
e
nl
pt
du

an
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erm
ab
♦ M12x1.5 thread repair set -VAS 6058-

ility
ot p
wit
♦ Drill -VAS 6267-

, 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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f
en
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t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
94
Prote AG.
Rep. gr.50 - Body - front
CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
9.2 Contents of thread repair kit

AG. Volkswagen AG d
agen oes
1 - Twist drill 12.5 mm ∅ olksw not
byV gu
ara
ed
nte
2 - Thread-cutting tap M12 x horis
eo
1.5 aut ra
ss c
ce
le
3 - Fitting spindle
un
pt
an
d
itte
4 - Thread insert M12 x 1.5 x
y li
rm
ab
24 ( -VAS 6058/1- ) pe
ility
ot
wit
5 - Pin breaker with magnetic
, is n
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end
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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
9.3 Repairing thread
9.3.1 Drilling thread

– Drill out thread using twist drill.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
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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
– Do not cant drill.
nform
ercia
– Use drill -VAS 6267- when drilling and shaping.

m
a
com
Note tion in
r
te o
thi
s
iva
do
The drill must be held by an assistant using an additional hand

r
rp
cum
support when drilling.

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

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
9.3.2 Cutting thread

– Cut thread with thread-cutting tap
– Clean threaded sleeve (with compressed air).
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
h re
9.3.3 Inserting thread insert
hole
spec
es, in part or in w
– Screw thread insert -3- onto fitting spindle until the fitting pin
t to the co
-2- contacts the fitting lug -1- on the fitting spindle.
– Screw thread insert into the threaded plate until the top of the
rrectness of i
thread insert is flush with the outer edge of the threaded plate
(visual check).
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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
– Then screw thread insert inwards a 1/4 turn.
Note
Thread insert must screw in easily.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
– Remove fitting spindle.
spec
es, in part or in w
– Break off drive pin of thread insert using pin breaker.
t to the co
– Install subframe (suspension subframe) (torque settings) ⇒
Suspension, axles, steering; Rep. gr. 40 ; Removing and in‐
rrectness of i
stalling subframe, torque settings
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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
51 – Body - centre
RO: 51 03 55 00
1 Renewing roof - vehicles with no pan‐

orama tilting sunroof
WARNING

1 - Roof
2 - Laser brazed seam
3 - Front and rear original joints
4 - Bonded area
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.
1. Renewing roof - vehicles with no panorama tilting sunroof 99

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Body Repairs - Edition 11.2011 AG. Volkswagen AG d
agen oes
olksw not
V gu
1.1 Tools orised by ara
nte
h eo
aut ra
ss c
ce
Note
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
paintwork .
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.

♦ Pneumatic cartridge gun -V.A.G 1761/1-
♦ Cartridge heater -V.A.G 1939 A-
♦ Double-cartridge gun -VAS 5237-
100 Rep. gr.51 - Body - centre

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
♦ Setting gauge -3371-
. Volkswagen AG
gen AG does
Special tools and workshopVequipment
olks
wa required not
y gu
db ara
♦ Securing belt (commercial
or
ise type) nte
eo
th
s au ra
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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
1.2 Removing
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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aut ra
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le
un
pt
an
d
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erm
ab
ility
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wit
is n
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ole,
Note
spec
t to the co
When cutting out, note inclined contact surfaces of roof and roof side member -1-, so that roof side member is
not damaged during processing.
rrectne
– Separate original joints in windscreen and rear window aper‐

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

o
cial p
f inform
– Roughly cut out roof.

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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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.
Note
♦ Side panel -2- must not be damaged when removing residual material of roof -1-.
♦ Use flap discs only, do not use cutting disks or rough grinding disks.

– 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 painting guide‐
lines.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
1.3 Installing
Note

must be used to carry out repairs ⇒ page 100 .

Replacement 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-
Note
♦ Following repair sequence must be adhered to in order to en‐

sure correct and long-lasting roof repairs.
agen
AG. Volkswagen AG d
o w es n
olks ot g
♦ For this repair, it is absolutely necessary
ed
by
V
to work with great ua
ran
care to prevent faults duringhoprocessing.
ris tee
t or
au 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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Roughen bonding area on vehicle and new part using fine

es, in part or in w
abrasive paper (360 graining).

t to the co
This ensures that 2K body adhesive -D 180 KD3 A2- bonds well
with bonding area.
rrectness of i
– Place roof onto roof frame and check line of roof versus side
l purpos
panels (visual check).

– Check roof fit with rear window and windscreen.
nform
mercia
at
om
Note
on
c
in t
or
his
e
♦ Securing belts must not be tightened too tightly in order to avoid damage.
at
do
priv
cum
or
♦ Securing belts prevent roof lifting off roof frame or moving during bonding process.
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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.
– In area of door apertures, tension securing belts (commercially

available) -arrows- transversely over roof to vary height of roof.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
1.3.2 Adjusting roof depth
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
Note
l purpos
♦ By tightening and loosening the tensioning belts, dimension -a- can be determined to position roof deeper
nf
ercia
relative to roof side members.

orm
m
atio
♦ Use setting gauge -3371- to check dimension -a-.

om
n in
or c
♦ If dimension -a- cannot be set at rear, rear roof cross member may have to be released, bonded again and
thi
e
welded ⇒ page 155 .

t
sd
iva
o
r
rp
cu
o
m
f
en
– Check line of roof relative to side panels.

ng
t.
yi Co
op py
Dimension -a- = 4±1 mm
. C rig
ht ht
rig by
py Vo
1.3.3 Bonding roof
co lksw
by
cted agen
Prote AG.
– Remove roof again.

– Apply corrosion protection measures according to guidelines
in ⇒ Paint workshop manual: Corrosion and corrosion pro‐
tection, attached and welded parts, materials .

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
AG. Volkswagen AG d
agen oes
lksw not
– Clean bonding areas on roof and vehicle with silicone removerd by
Vo gu
ara
-LSE 020 100 A3- . orise nte
h eo
aut ra
ss c
ce
le
Note
un
pt
an
d
itte
y li
♦ The adhesive materials must be applied very quickly.
rm
ab
pe
ility
ot
♦ Always observe the application time (pot life).
wit
, is n
h re
♦ Use pneumatic or electric cartridge guns to apply bonding ma‐
hole
spec
terials.
es, in part or in w
t to the co
– Cut approx. 2 mm off nozzle -B- to provide appropriate bead
geometry.
rrectness of i
l purpos
Note
nform
ercia

m
a
com
tio
♦ For this repair, it is absolutely necessary to work with great
n in
r
care to prevent faults during processing.

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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
– Apply 1K assembly adhesive -D190 MKD A3- to front roof

cross member -1- and rear roof cross member -2- in area of
factory-fitted bonds using pneumatic cartridge gun -
nform
ercia
V.A.G 1761/1- .
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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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.
– In the area of the roof frame, apply 1K assembly adhesive -

D190 MKD A3- -1- with the pneumatic cartridge gun -
V.A.G 1761/1- .
Dimension -b- = 14 mm

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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.
60thd
– Apply 1K assembly adhesive -D190 MKD A3- -1- 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.
♦ An assistant is required for the following work.
♦ 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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
– Cut the first step of the static mixer -A- off to achieve the cor‐
responding bead cross-section.
– Carefully operate the double cartridge gun -VAS 5237- without
static mixer until the adhesive is discharged uniformly from
both chambers of the 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
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.
– Fill area -1- with 2K body adhesive -D 180 KD3 A2- using
double cartridge gun -VAS 5237- .

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Note

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
– Coat roof flanges with 2K body adhesive -D 180 KD3 A2- -1-. . Cop py
rig
ht ht
rig
– Immediately position and align roof. py by
co Vo
by lksw
cted
– Secure roof in area of rear window and windscreen aperture
agen
Prote AG.
using vice-grip pliers and secure centre of roof using securing
belts.
– Remove excessive adhesive at side of roof immediately using
a cloth soaked in silicone remover -LSE 020 100 A3- .
– Check roof depth dimension -a- and adjust if necessary
⇒ „1.3.2 Adjusting roof depth“, page 107 .

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
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.
– Weld roof to front and rear apertures, RP spot weld seam

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
rrectne
– Apply adhesive sealant -AKD 476 KD5 05- from above to fully
ss
seal bonding seam -1-.
o
cial p
f in
– After painting, preserve roof cavities -arrow- with cavity seal‐
form
mer
ant -AKR 321 M15 4- . 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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
RO: 51 03 55 03
2 Renewing roof - vehicles with panor‐

ama tilting sunroof
WARNING

1 - Roof
2 - Laser brazed seam
3 - Front and rear original joints
4 - Bonded area 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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
2.1 Tools
Note

equipment, EH catalogue,
en AG. V
olkWorkshop
swagen AG equipment, Body and
paintwork . olkswag does
not
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du
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ab
ility
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wit
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hole
spec
es, in part or in w
t to the co
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nf
ercia
orm
m
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om
n in
or c
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te
sd
iva
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cu
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f
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.

♦ Pneumatic cartridge gun -V.A.G 1761/1-
♦ Cartridge heater -V.A.G 1939 A-
♦ Double-cartridge gun -VAS 5237-
2. Renewing roof - vehicles with panorama tilting sunroof 117

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
♦ Setting gauge -VAS 3371-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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ris nte
ho eo
aut 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
♦ Securing belt (commercial type)
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.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
2.2 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
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
When cutting out, note inclined contact surfaces of roof and roof side member -1-, so that roof side member is
not damaged during processing.
– Separate original joint to front and rear parts of roof.

– Separate bonded joints to front and rear roof cross members.
– Roughly cut out roof.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
Note
wit
, is n
h re
hole
♦ Side panel -2- must not be damaged when removing residual material of roof -1-.
spec
es, in part or in w
♦ Use flap discs only, do not use cutting disks or rough grinding disks.
t to the co

rrectness of i
– Remove all adhesive and sealant residues from front and rear
roof cross members.
l purpos
– Remove all adhesive residues from left and right roof side
nform
ercia
members.
m
– Touch up paint damage in accordance with painting guide‐

at
om
io
lines.
n
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.

n AG. Volkswagen AG do CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
wage es n
Volks ot g Body Repairs - Edition 11.2011
by ua
ed ran
ris tee
2.3 Installing
tho
u or
a ac
ss
ce
e
nl
pt
du
an
Note
itte
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ility
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spec
es, in part or in w
t to the co
Replacement part
rrectness of i
♦ Roof
l purpos
♦ 1K assembly adhesive -D 190 MKD A3- (2 cartridges)

♦ 2K body adhesive -D 180 KD3 A2- (2 cartridge sets)
nform
ercia
♦ Adhesive sealant -AKD 476 KD5 05-

m
at
om
ion
c
♦ Cavity sealant -AKR 321 M15 4-
in t
or
his
ate
do
priv
cum
Note
for
en
ng
t.
yi Co
op
C py
t. rig
gh
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Body Repairs - Edition 11.2011 wage
e ks s no
Vol t gu
d by ara
e nte
ris
utho eo
ra
a 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
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.
– Roughen bonding area on vehicle and new part using fine

abrasive paper (360 graining).
This ensures that 2K body adhesive -D 180 KD3 A2- bonds well
with bonding area.
– Place roof onto roof frame and check line of roof versus side
panels (visual check).
– Check roof fit with rear window and panorama tilting sunroof.
Note
♦ To prevent damage, do not over tighten the securing belt.

♦ The securing belt prevents the roof lifting off the roof frame or moving during the bonding process.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Body Repairs
- Edition 11.2011
lkswage es n
o ot g
yV ua
db 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.
– To adjust height of roof, position securing belt (commercial

type) through rear door apertures -arrow- and over roof and
tension.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
2.3.2 Adjusting roof depth
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.
– Check line of roof relative to side panels.

Dimension -a- = 4±1 mm
Note
♦ By tightening and loosening the tensioning belts, dimension -a- can be determined to position roof deeper
relative to roof side members.
♦ Use setting gauge -3371- to check dimension -a-.
♦ If dimension -a- cannot be set at rear, rear roof cross member may have to be released, bonded again and
welded ⇒ page 155 .
2.3.3 Bonding roof

– Remove roof again.
– Apply corrosion protection measures according to guidelines
in ⇒ Paint workshop manual: Corrosion and corrosion pro‐
tection, attached and welded parts, materials .

AG. VolkswageCC
n AG2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
agen does
olksw not
yV gu
edb ara
ris and vehicle with silicone remover nte
– Clean bonding areas onthoroof eo
-LSE 020 100 A3- . ss au ra
c
ce
le
un
pt
an
d
itte
Note
y li
rm
ab
pe
ility
♦ The adhesive materials must be applied very quickly.
ot
wit
, is n
h re
♦ Always observe the application time (pot life).
hole
spec
♦ Use pneumatic or electric cartridge guns to apply bonding ma‐
es, in part or in w
t to the co
terials.
– Cut approx. 2 mm off nozzle -B- to provide appropriate bead
rrectness of i
geometry.
l purpos
Note
nform
ercia

m
a
com
ti
on 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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
– Apply 1K assembly adhesive -D190 MKD A3- to roof rein‐

mer
forcement -1- and rear roof cross member -2- in area of

atio
m
factory-fitted bond using pneumatic cartridge gun -

o
n
c
V.A.G 1761/1- .
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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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.
– In the area of the roof frame, apply 1K assembly adhesive -

D190 MKD A3- -1- with the pneumatic cartridge gun -
V.A.G 1761/1- .

. Volkswagen AG
gen AG does
swa
CC 2010 ➤y ,V CC 2012 ➤ , Passat CC 2009
olk not ➤
gu
b ara
Body Repairs
rised
- Edition 11.2011 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 -D190 MKD A3- -1- 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.
♦ An assistant is required for the following work.
♦ 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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
– Cut the first step of the static mixer -A- off to achieve the cor‐
responding bead cross-section.
– Carefully operate the double cartridge gun -VAS 5237- without
static mixer until the adhesive is discharged uniformly from
both chambers of the 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.
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.
– Fill area -1- with 2K body adhesive -D 180 KD3 A2- using
double cartridge gun -VAS 5237- .

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
– Coat roof flanges with 2K body adhesive -D 180 KD3 A2- -1-.
om
ion
c
in t
r
– Immediately position and align roof.

o
his
ate
do
riv
– Secure front and rear of roof using vice-grip pliers and secure
p
cum
or
centre of roof using a securing belt.

f
en
ng
t.
yi Co
– Remove excessive adhesive at side of roof immediately using Cop py
t. rig
a cloth soaked in silicone remover -LSE 020 100 A3- . opyri
gh by
Vo
ht
c
– Check roof depth dimension -a- and adjust if necessary
by lksw
cted agen
Prote
⇒ „2.3.2 Adjusting roof depth“, page 124 .
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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
2.3.4 Welding in
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
– Weld roof at front and rear, RP spot weld seam.

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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
– Apply adhesive sealant -AKD 476 KD5 05- from above to fully
un
pt
an
d
seal bonding seam -1-.

itte
y li
rm
ab
– After painting, preserve roof cavities -arrow- with cavity seal‐

pe
ility
ot
ant -AKR 321 M15 4- .

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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
RO: 51 05 55 60
3 Renewing roof side member

AG. Volkswagen AG d
agen oes
WARNING olksw not
byV gu
ara
ed
ris nte
Observe safety notes! ut
ho eo
ra
s a c
Welding, parting using spark generating machines/tools or tin‐ s
ce
le
ning in foam treated areas creates gases which are hazardous
un
pt
an
d
to health and environment. Please refrain from using these

itte
y li
processes under any circumstances.
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
Safety instructions
t to the co
1 - Moulded foam elements
rrectne
2 - Roof member
3 - Roof rack reinforcement
ss o
4 - Bonded area
cial p
f inform
5 - Parting cut on roof
mer
atio
m
6 - Parting cuts at A, B and C-

o
n
c
pillars
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.
3. Renewing roof side member 133

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
3.1 Tools
Note

paintwork .
3.2 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
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
– Make parting cuts -1- and -4- in front of the moulded foam
t.
yi Co
op
elements -2-. C py
ht. rig
rig ht
by
– Separate original joint in door apertures and front and rear copy Vo
by lksw
window apertures. cted agen
Prote AG.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Note
Make parting cut -3- in area of roof rack reinforcement with caution, do not damage them.
Parting cut measurements
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
– Position parting cuts from upper edge of windscreen aperture

according to dimension -a- and from upper edge of rear win‐
rrectness of i
dow aperture according to dimensions -b-, -c-, -d- and -e- and
cut out.
l purpos

nform
ercia
m
Dimension -c- = 140 mm

at
om
ion
c
Dimension -d- = 50 mm
in t
or
his
ate
Dimension -e- = 30 mm
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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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 i
– Remove remaining adhesive completely and grind bonded

nform
surface back to bare metal.

mer
atio
m
3.3 Installing
o
n
c
i
or
n thi
te
sd
iva
o
pr
Note
um
r
fo
en
ng
t.
yi Co
The use of different types and different thicknesses of steel re‐ Cop py
t. rig
quires that one of the welding units (inverter) listed under Tools gh ht
yri by
must be used for proper spot welding ⇒ page 134 . cop Vo
by lksw
cted agen
Prote AG.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
g
Note
n
t.
yi Co
Cop py
t. rig
gh
MIG brazed seams are permitted at the parting cuts shown in the illustration.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Replacement part
♦ Side panel
♦ Repair kit for treating roof side member with foam -D 506 110
A2- (one kit for each front and rear section).
♦ 2K body adhesive -D 180 KD3 A2-
♦ Blind rivet nut
♦ Zinc foil -D 381 ZN1 A2-

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
– Transfer parting cuts to new part and remove

om
n in
-shaded areas-.
or c
thi
te
sd
3.3.2 Moulded foam elements

iva
o
r
rp
cu
o
m
f
Follow repair instructions.

en
ng
t.
yi Co
op py
Moulded foam elements ⇒ General Information; Body Repairs, t. C rig
gh ht
General Body Repairs ; General Notes; Moulded foam elements yri
p by
co Vo
by lksw
cted agen
Prote AG.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
3.3.3 Welding in
or
thi
te
sd
iva
o
r
rp
cu
o
m
f
Note
en
ng
t.
yi Co
Cop py
ht. rig
To ensure sufficient sturdiness, the RP weld points must be set rig ht
py by
as far as possible from the outer edge of the welding flange. co Vo
by lksw
cted agen
Prote AG.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
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spec
t to the co
rrectness o
cial p
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mer
atio
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c
i
or
n thi
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fo
en
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t.
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Cop py
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pyri by
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co lksw
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cted agen
Prote AG.
Note
New part must be welded-in within 90 minutes or adhesion properties of adhesive will be impaired.
– Apply 2K body adhesive -D 180 KD3 A2- to door apertures

and front and rear window apertures, adhesive bead approx.
3.5 mm ∅.
– Adapt roof side member to fit and fix in position.
– Check fit with bolt-on parts.

Volkswagen AG
CC
swag2010
en AG.➤ , CC 2012 d➤oes, Passat CC 2009 ➤
lk not
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Body Repairs -guEdition
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a
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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
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
♦ Use a »heat stop« to prevent damage to the paintwork of the roof when welding the roof side member.
♦ Stick zinc foil -D 381 ZN1 A2- over roof rack reinforcement, to prevent damage when welding roof frame.
– Weld roof frame to door apertures and front and rear window
apertures, RP spot weld seam (inverter).
– Weld roof frame and parting cuts on A, B and C-pillars using
a ⇒ MIG-L stepped seam.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
RO: 51 07 55 50
4 Renewing front cross member for

roof - vehicles with no panorama tilt‐
ing sunroof yV
olkswage es n
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WARNING th or
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nl
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erm
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ility
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wit
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hole
• Roof with no panorama tilting sunroof already removed
spec
⇒ page 99 .
es, in part or in w
t to the co
1 - Left and right roof frames
rrectness of i
2 - Front roof cross member
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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
4.1 Tools
Note

Volkswagen AG can be found in ⇒ ServiceNet, Workshop agen
AG. Volkswagen AG d
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equipment, EH catalogue, Workshop equipment, olksw and
Body not
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paintwork . ris
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4.2 Removing ss
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un
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cial p
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mer
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n
c
i
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te
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pr
cum
r
fo
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t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Separate original joint from inside.
4. Renewing front cross member for roof - vehicles with no panorama tilting sunroof 143
CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
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nl
pt
du
an
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erm
ab
ility
ot p
wit
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– Remove residues at transition to left and right roof frame.
hole
spec
4.3 Installing
es, in part or in w
t to the co
Note
rrectness of i
l purpos

nform
mercia
at
4.3.1 Welding in
om
ion
c
in t
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Replacement part
his
ate
do
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♦ Front roof cross member

p
cum
for
en
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– Adapt new part to fit and fix in position.

t.
yi Co
Cop py
t. rig
– Check gaps to roof and windscreen. opyri
gh by
Vo
ht
by c lksw
cted agen
Prote AG.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
h
aut ra
ss c
ce
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un
pt
an
d
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ab
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
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te
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pr
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Cop py
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Vo
o
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cted
Note
agen
Prote AG.
Use the elongated holes to weld the new part to the left and right roof frames.
– Weld in front roof cross member, RP spot weld seam and SG

continuous weld seam.
– Install roof ⇒ page 104 .
4. Renewing front cross member for roof - vehicles with no panorama tilting sunroof 145
CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
RO: 51 07 55 53
5 Renewing front cross member for

roof - vehicles with panorama tilting
sunroof
WARNING

• Roof with panorama tilting sunroof already removed
⇒ page 99 .
1 - Cover plate
2 - Front roof cross member
3 - Roof frame
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
tho eo
au ra
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ce
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nl
pt
du
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ab
ility
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wit
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hole
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nf
ercia
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or c
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Cop py
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pyri by
Vo
co lksw
by
cted agen
146
Prote AG.
Rep. gr.51 - Body - centre
CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
5.1 Tools
Note

♦ The welding units (inverters) and bodygetools
n AG. Vauthorised
olkswagen AGby
Volkswagen AG can be found inVo⇒ lkswServiceNet, Workshop es not
a o d
equipment, EH catalogue, Workshop
ed
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ara
paintwork . thoris nte
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5.2 Removing
ce
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nl
pt
du
an
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ab
ility
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wit
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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.
– Roughly cut out cover plate and roof cross member.

– Separate outer and inner original joints.
5. Renewing front cross member for roof - vehicles with panorama tilting sunroof 147
CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
5.3 Installing
Note

olkswagen AG
en AG. V
5.3.1 Preparing
yV
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wag does
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ss for SG plug weld seam. c
ce
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5.3.2 Welding in
du
an
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ab
Replacement part
ility
ot p
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♦ Front roof cross member
, is n
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hole
spec
es, in part or in w
– Check gaps to windscreen and panorama tilting sunroof.
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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Note
– Weld in front roof cross member, RP spot weld seam and SG

plug weld seam.
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
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hole
spec
es, in part or in w
t to the co
– Weld in front cover plate, RP spot weld seam and SG plug

weld seam.
rrectness of i
– Check gaps again.

l purpos
– Install roof with panorama tilting sunroof ⇒ page 121 .

nf
ercia
orm
m
atio
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n in
or c
thi
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sd
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rp
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o
m
f
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 front cross member for roof - vehicles with panorama tilting sunroof 149
CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
RO: 51 08 55 53
6 Renewing roofagreinforcement,
en AG. V
olkswagen AG vehi‐
does
cles withd bpanorama
yV
olksw
tilting sunroof not
gu
ara
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ris
tho eo
au ra
WARNING
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
⇒ page 99 .
t to the co
rrectness of i
2 - Roof reinforcement
l purpos
3 - Bonded area
nf
ercia
orm
m
atio
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n in
or c
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f
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t.
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Cop py
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
6.1 Tools
Note

paintwork .
6.2 Removing
⇒ page 116
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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aut ra
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ce
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un
pt
an
d
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ab
pe
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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
o
by c lksw
cted agen
Prote AG.
6. Renewing roof reinforcement, vehicles with panorama tilting sunroof 151

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
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p
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or

f
en
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t.
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op
6.3 Installing C py
t. rig
gh ht
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cted agen
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Note
AG.

6.3.1 Welding in
Replacement part
♦ Roof reinforcement

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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.
Note
New part must be welded in within 90 minutes or adhesion of adhesive will be impaired.
– Apply 2K body adhesive -D 180 KD3 A2- to areas bonded in

the factory.
– Check fit to roof and panorama tilting sunroof.
6. Renewing roof reinforcement, vehicles with panorama tilting sunroof 153

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
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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.
yi Co
op py
– Weld in roof reinforcement, SG continuous weld seam, RP
t. C rig
gh ht
yri
spot weld seam and SG plug weld seam. p by
co Vo
by lksw
cted agen
Prote AG.
Note

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
RO: 51 09 55 50
7 Renewing rear roof cross member
WARNING

• Roof with no panorama tilting sunroof already removed
⇒ page 99 or
⇒ page 116

2 - Rear roof cross member
lkswage es n
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ir se tee
tho
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a ac
ss
ce
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nl
pt
du
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ab
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wit
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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.
7. Renewing rear roof cross member 155

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
7.1 Tools
Note

paintwork .
AG. Volkswagen AG d
agen oes
ksw
7.2 Removing ol not
byV gu
ara
ed
ris nte
ho eo
aut ra
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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
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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
7.3 Installing
nform
mercia
at
om
ion
c
Note
in t
or
his
ate
do
riv

p
cum
or
f
en
ng

t.
yi Co
Cop py
t. rig
gh ht
yri
7.3.1 Welding in
p by
co Vo
by lksw
cted agen
Prote AG.
Replacement part
♦ Rear roof cross member
– Check fit to roof and rear window.
7. Renewing rear roof cross member 157

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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.
Note
Use the elongated holes to weld the new part to the left and right
roof frames.
– Weld in new part, SG plug weld seam and RP spot weld seam.
– Install roof with no panorama tilting sunroof ⇒ page 104 .

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
AG. Volkswagen AG d
agen oes
RO: 51 37 55 00 olksw not
yV gu
8 Renewing A-pillar d b ara
ise nte
or eo
h
aut ra
ss c
WARNING
ce
e
nl
pt
du
an
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erm
ab
ility
Welding, parting using spark generating machines/tools or tin‐ ot p
wit
, is n
h re
to health and environment. Therefore, refrain from using these
hole
spec
processes.
es, in part or in w
t to the co
rrectness of i
l purpos
1 - Upper parting cut
nf
ercia
orm
m
atio
2 - Moulded foam element
om
n in
or c
2K foam filler -D 506 KD1 A2-
thi
te
must be used on item 2 - A-
sd
iva
o
r
pillar to upper longitudinal

rp
cu
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member.
f
en
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t.
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3 - Partial replacement parting
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cut also possible
rig by
copy Vo
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cted
4 - Parting cut for side member
agen
Prote AG.
Note
5 - Bonded area
8. Renewing A-pillar 159

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
8.1 Tools
Note
n AG. Volkswagen A
♦ The use of different types and
olks
wdifferent
age thicknesses of
G do
es steel
no
requires that only the welding
db
yV units (inverters) authorisedt gby
ua
r
Volkswagen AG may orisebe used to carry out repairs properly. ante
e h
ut or
♦ The welding units
ss (inverters) and body tools authorised by
a ac
ce
e
nl
pt
du
an
itte
paintwork .
y li
erm
ab
ility
ot p
8.2 Removing
wit
, is n
h re
hole
spec
es, in part or in w
Note
t to the co
♦ Make parting cuts with pneumatic jig-saw -V.A.G 1523- only.
rrectness of i
♦ Do not damage A-pillar reinforcement when opening weld
joints (laser seams).
l purpos
♦ If the A-pillar reinforcement is damaged, it must always be re‐

newed.
nf
ercia
orm
♦ Rewelding A-pillar reinforcement is not permitted due to safety
m
atio
m
reasons »crash safety«.

o
n in
or c
thi
♦ Remove as much of the foam residue as possible before start‐

te
sd
a
ing grinding work.

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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
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– Upper outer longitudinal member for wheel housing already cop Vo
by lksw
removed ⇒ page 51 . cted agen
Prote AG.
– According to damage, position parting cut -2- above or below

moulded foam element -1- 550 mm or 620 mm from upper
edge of windscreen aperture and separate
⇒ Item 1 (page 159) .
– Position parting cut -3- according to degree of damage and
cut.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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.

8.3 Installing
Note


CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
Note
cial p
f inform
mer
MIG brazed seams are permitted at the parting cuts shown in the illustration.
atio
om
n
c
i
or

thi
te
sd
iva
o
r
Replacement part
p
cum
r
fo
en
ng
♦ Front side panel sub-part (replacement part designation: A/B-

t.
yi Co
op
pillar sub-part with side member) C py
t. rig
gh ht
yri by
op Vo
by c lksw
cted agen
Prote
♦ Butyl sealing cord -AKD 497 010 04 R10-
AG.
♦ Moulded foam element

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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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.
– Transfer parting cut to new part and cut out.
yi Co
Cop py
t. rig
– Make holes in new part at windscreen aperture, at transition
gh ht
pyri by
to front wheel housing and side member reinforcement.
co Vo
by lksw
cted agen
Prote AG.
Moulded foam elements ⇒ General Information; Body Repairs,
General Body Repairs ; General Notes; Moulded foam elements

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
CC 2010 ➤ , CC 2012 ➤ , tPassat
ho
r CC 2009 ➤ eo
u ra
ss a c
ce
le
un
pt
8.3.3 Welding in
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 must be welded in within 90 minutes or adhesion of adhesive will be impaired.
♦ Adhesive must be cleaned from holes for fastening hinges after bonding in.
– Apply butyl sealing cord -AKD 497 010 04 R10- in area -1-.
– Apply 2K body adhesive -D 180 KD3 A2- to areas of door
aperture, the door hinge and upper longitudinal member, ad‐
hesive bead approx. 3.5 mm ∅.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Note
♦ New part must be welded in within 90 minutes or adhesion of

adhesive will be impaired.
♦ To ensure sufficient sturdiness, the RP weld points must be
set as far as possible from the outer edge of the welding flange.

– Weld A-pillar to windscreen aperture, SG plug weld seam.

– Weld A-pillar to A-pillar reinforcement, SG plug weld seam.
– Weld A-pillar to transition to wheel housing upper longitudinal
member, RP spot weld seam.
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
– Weld in parting cuts, ⇒ MIG-L stepped weld seam.

r
rp
cum
fo
– Weld door aperture in, RP spot weld seam (inverter).

en
ng
t.
yi Co
op
– Weld A-pillar to side member, SG plug weld seam.
C py
ht. rig
rig ht
py by
co Vo
by lksw
167
cted agen
Prote AG.
8. Renewing A-pillar
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
o eo
CC 2010 aut ➤ , CC 2012 ➤ , Passat CC 2009 ➤
h
ra
s c
Body Repairs
s - Edition 11.2011
ce
e
nl
pt
du
an
itte
y li
erm
ab
RO: 51 38 55 50
ility
ot p
9 Renewing A-pillar reinforcement
wit
, is n
h re
hole
spec
WARNING
es, in part or in w
t to the co
Welding, parting using spark generating machines/tools or tin‐
rrectness of i
l purpos

processes.
nform
mercia
at
om
io
n
c
in t
or
his
ate
do
riv

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

lkswage es n
o ot g
byV ua
d ran
ir se
tho CC 2010 ➤ , CC 2012 ➤ , Passat teCC e o 2009 ➤
au r
ss Body Repairs - Edition a11.2011
c
ce
le
un
pt
9.1 Tools
an
d
itte
y li
rm
ab
pe
ility
ot
wit
Note
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
paintwork .
nform
ercia
9.2 Removing
m
a
com
ti
• Upper outer longitudinal member for wheel housing already
on in
removed ⇒ page 51 .
r
te o
thi
s
iva
do
• A-pillar already removed ⇒ page 160 .
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 A-pillar reinforcement original joint.
9. Renewing A-pillar reinforcement 169

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
– Separate original joints to upper and lower hinge mountings.
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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
yri by
– Remove remaining material. cop Vo
by lksw
cted agen
Prote
9.3 Installing
AG.
Note


Replacement part
♦ A-pillar reinforcement

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
– Drill 7 mm ∅ holes in A-pillar reinforcement for SG plug weld

rrectness of i
seam.
l purpos

nf
ercia

orm
m
atio

om
n in

or c
thi
te
9.3.3 Welding in
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op
Note C py
ht. rig
rig ht
py by
Vo
To ensure sufficient sturdiness, the RP weld points must be set
co lksw
by
cted agen
as far as possible from the outer edge of the welding flange. Prote AG.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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.
– Apply 2K body adhesive -D 180 KD3 A2- in areas of door

aperture, the side member, the wheel housing and the wind‐
screen
Note
New part must be welded-in within 90 minutes or adhesion prop‐

erties of adhesive will be impaired.

and fix in place.
– Check fit to A-pillar.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Body Repairs - Edition 11.2011 . Volkswage
AG n AG d
agen oes
olksw not
yV gu
db ara
rise nte
tho eo
s au ra
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
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Weld in A-pillar reinforcement, SG plug weld seam (inverter)

and RP spot weld seam.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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.
– Weld A-pillar reinforcement to windscreen aperture, SG con‐

tinuous weld seam and RP spot weld seam.
– Weld A-pillar reinforcement to wheel housing upper longitudi‐
nal member, RP spot weld seam.
– Weld A-pillar reinforcement to upper and lower hinge mount‐
ings from the interior, SG continuous weld seam.
– Install upper longitudinal member for wheel housing
⇒ page 53 .
– Install A-pillar ⇒ page 162 .

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
CC 2010
autho
➤ , CC 2012 ➤ , Passat CC 2009 ➤ eo
ra
Body
s Repairs - Edition 11.2011
s c
ce
le
un
pt
an
d
itte
y li
erm
ab
RO: 51 41 55 10
ility
ot p
10 Renewing B-pillar
wit
is n
h re
ole,
spec
WARNING
t to the co
rrectne
s
processes.
s o
cial p
f inform
mer
atio
m

o
n
c
i
or
n thi
10.1 Tools
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi
Note
Co
Cop py
t. rig
gh ht
yri
p by
co Vo
by lksw
requires that only the welding units (inverters) authorised by Prote
cted AG.
agen
paintwork .

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
10.2 Removing
1 - B-pillar
2 - Bonded section
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
Note
rrectne
♦ If the B-pillar reinforcement also has to be replaced, the area

s
-1- must also be cut out when cutting out the outer B-pillar.
s o
cial p
f i
♦ Do not damage original joint to roof.

nform
mer
♦ Do not damage internal reinforcements. If the reinforcing at

atio
m
parting cut is damaged, then it must be renewed complete. A

o
n
c
part replacement is not permitted due to a reduction in strength

i
or
n thi
e
»crash safety«.
t
sd
iva
o
pr

um
r
fo
en
ng
ing grinding work.

t.
yi Co
op py
t. C rig
gh ht
pyri by
Vo
♦ Keep the cutting of the replacement part in mind.
co lksw
by
cted agen
Prote AG.
10. Renewing B-pillar 177

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
– Make parting cuts -1- as shown; do not damage the inner re‐
en
ng
t.
yi
inforcements.
Co
Cop py
ht. rig
ht
rig by
copy Vo
by lksw
cted
Partial renewal
agen
Prote AG.
A part replacement of the B-pillar without damage to the side

member is possible with the parting cut -2-.
– Place parting cut -3- according to degree of damage.
– Make parting cut -4- as shown.
– Separate original joint to B-pillar reinforcement.
Note
♦ Do not damage B-pillar reinforcing when opening weld joints (laser seams).
♦ If the B-pillar reinforcing is damaged, then it must be renewed complete.
♦ Rewelding the B-pillar reinforcement is not permitted due to safety »crash safety«.
– Separate original joint to B-pillar reinforcement.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
– Separate original joint to the side member reinforcement.

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.

CC 2010 ➤ , CCwa2012
gen AG➤ , Passatn A
. Volkswage CC
G do2009 ➤
es n
ks
Body Repairs
by V - Edition 11.2011
ol ot g
u ara
ed nte
oris e
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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.

10.3 Installing
Note


CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
Note
When outer side panel is renewed, MIG brazed seams are permitted along the parting cuts indicated in the
rrectne
figure.
ss

o
cial p
f inform
Replacement part
mer
atio
m
♦ Subpart side panel

o
n
c
i
or
n thi

te
sd
iva
o
r

p
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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤

– Make 7 mm ∅ holes in new part.
10.3.2 Marking theagarea

en AG. V
where
olkswagenno
AG dwelding
oes
work
may be
by
V carried out
olksw not
gu
a
d ran
ise
– Mark areasuthon
or outer B-pillar where welding for safety reasons
tee
or
»crash safety«
ss
a is prohibited. ac
ce
le
un
pt
an
d
itte
Note
y li
rm
ab
pe
ility
The measurements given must be adhered to.

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.

lkswage CC 2010 ➤ es n, CC 2012 ➤ , Passat CC 2009 ➤
o ot g
yV Body
ran Repairs - Edition 11.2011
d b ua
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.
♦ Dimension -a- = 50 mm
♦ Dimension -b- = 160 mm


CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
10.3.4 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
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.
– Apply butyl sealing cord -AKD 497 010 04 R10- to area -1-.
– Apply 2K body adhesive -D 180 KD3 A2- to areas -2- and
-3-.
Note

– Check fit with add-on parts.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Note

as far as possible from the outer edge of the welding flange.
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.
– Weld in B-pillar, SG stepped weld seam and RP spot weld

seam (inverter).
Note
The parting cuts can be welded with a ⇒ MIG-L stepped seam.
The weld procedures in area -1- (SG stepped weld seam) apply
only in the case of renewing the B-pillar reinforcing as well.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Note that no welding work may be carried out in areas -2-.
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.
– Reinstate remaining joints to side member reinforcement, SG

stepped weld seam and SG plug weld seam.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
RO: 51 41 55 52
11 Renewing inner B-pillar
WARNING

1 - Inner B-pillar
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.
11. Renewing inner B-pillar 187

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
11.1 Tools
Note
♦ The use of different types and different thicknesses of steel AG. Volkswagen AG d
agen oes
ksw
requires that only the welding units (inverters) authorised byby V ol not
gu
Volkswagen AG may be used to carry out repairs properly. rise
d ara
nte
tho eo
♦ The welding units (inverters) and body tools authoriseds a by
u ra
c
Volkswagen AG can be found in ⇒ ServiceNet, Workshop s
ce
le
un
pt
an
d
paintwork .
itte
y li
rm
ab
pe
ility
11.2 Removing ot
wit
, is n
h re
hole
• B-pillar reinforcement already removed
spec
es, in part or in w
• B-pillar reinforcement already removed
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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
11.3 Installing
spec
es, in part or in w
t to the co
Note
rrectness of i

l purpos
nform
ercia
11.3.1 Welding in
m
a
com
tio
Replacement part
n in
r
te o
thi
♦ Inner B-pillar
s
iva
do
r
rp
cum
♦ 2K body adhesive -D180 KD3 A2-

fo
en
ng
t.
yi
Co
Cop py
ment bracket set using B-pillar reinforcement and outer B-
t. rig
gh ht
yri
pillar to align and fix in position.
p by
o Vo
by c lksw
cted agen
– Check fit with add-on parts.
Prote AG.
11. Renewing inner B-pillar 189

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
– Weld in new part, SG continuous weld seam and RP spot weld

seam.
ss o
cial p
– Install B-pillar reinforcement ⇒ „12.3 Installing“, page 196 .

f inform
mer
– Install B-pillar ⇒ „10.3 Installing“, page 180 .

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.

lkswage es n
o ot g
byV ua
d ran
ir se tee
o
auth CC or2010
ac ➤ , CC 2012 ➤ , Passat CC 2009 ➤
ss Body Repairs - Edition 11.2011
ce
e
nl
pt
du
an
itte
y li
erm
ab
RO: 51 42 55 50
ility
ot p
12 Renewing B-pillar reinforcement
wit
, is n
h re
hole
Includes: front side member reinforcement (part section) and rear
spec
side member reinforcement (part section)
es, in part or in w
t to the co
WARNING
rrectness of i
l purpos

nf
ercia
or
processes.
m
m
atio
om
n in
or c
thi
te
sd
a

iv
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
1 - Roof joint parting cut t. Cop py
rig
gh ht
2 - Bonded section pyri by
Vo
co lksw
by
cted agen
3 - Rear side member rein‐ Prote AG.
forcement parting cut
4 - Front side member rein‐
forcement parting cut
12. Renewing B-pillar reinforcement 191

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Note
♦ Parting cuts for B-pillar reinforcement, front side member re‐

inforcement and rear side member reinforcement may only be
made at positions -1, 3 and 4- as shown.
♦ Cutting or welding at points other than the ones shown is im‐
permissible due to safety reasons »crash safety«.
Note
♦ Parting cuts for B-pillar reinforcement, front side member re‐

AG. Volkswagen
inforcement and rear side member
wage
n
reinforcement
AG do
may
es n only be
olks
made at positions -1,
d by3 and 4- as shown.
V ot g
ua
r e an
ris t
♦ Cutting or welding
ut
ho at points other than the ones shown is im‐e o
e
r
permissible sdue
s a to safety reasons »crash safety«. ac
ce
le
un
pt
12.1 Tools
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
Note
h re
hole
spec
es, in part or in w

Volkswagen AG may be used to carry out repairs properly. t to the co

rrectness of i

l purpos
paintwork .
nform
ercia
12.2 Removing
m
a
com
tio
• Outer B-pillar already cut out.

n in
r
te o
thi
• Side member already removed

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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
– Make parting cut -1- in roof joint as shown.

t to the co
– To do this, part of the outer roof frame must also be cut out
and replaced as shown when the outer B-pillar is cut out
rrectness of i
– Do not damage internal reinforcement -2- of roof frame.

l purpos
Note
nform
mercia
at
If roof frame internal reinforcement is damaged, it must be replaced as well.

om
ion
c
in t
or
his
e
– Drill out weld points on roof joint as shown.

at
do
priv
– Make parting cuts -3 and 4- on front and rear side member

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

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
m
– Separate remaining joint.

o
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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
io
Note
n
c
in t
or
his
te
♦ In areas -1 and 3- separate original joint from outside vehicle.

a
do
priv
cum
or
♦ In area -2- separate original joint from vehicle interior.

f
en
ng
t.
yi Co
♦ Inner B-pillar -4- must be renewed ⇒ „11 Renewing inner B-pillar“, page 187 . Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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.

12.3 Installing
Note


Replacement part
♦ B-pillar reinforcement
♦ Inner B-pillar
♦ Front side member reinforcement
♦ Sealing plate for front side member reinforcement
♦ Rear side member reinforcement

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤

♦ 2K body adhesive -D180 KD3 A2-
Note
AG. Volkswagen AG d
agen oes
ksw
♦ B-pillar reinforcement is identicalby V for Saloon and Variant.
o l not
gu
ara
ed
is nte
♦ The versions for vehiclesthofor North America „NAR“ and "Rest
r eo
of the World" „RoW“ differ.
ss au ra
c
ce
le
un
pt
– Transfer separating cut to B-pillar reinforcement and remove
an
d
itte
y li
-shaded area-.
rm
ab
pe
ility
ot
wit
, is n
h re
– Transfer separating cut to B-pillar reinforcement and remove
hole
-shaded area-.
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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
m
– Transfer separating cut to front and rear side member rein‐

o
n
c
i
forcements and remove -shaded areas-.
or
n thi
te
sd
iva
o
pr
cum
r
fo
Note
en
ng
t.
yi Co
Cop py
♦ Mark the areas on the B-pillar reinforcement in which, for safe‐ ht. rig
rig ht
ty reasons »crash safety«, no welding work may be carried
py by
co Vo
lksw
out.
by
cted agen
Prote AG.
♦ Measure areas and mark

⇒ „12.3.2 Marking the areas where no welding work may be
carried out“, page 199 .

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
12.3.2 Marking the 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
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.
– Mark areas where no welding work may be carried out.

♦ Dimension -a- = 50 mm
♦ Dimension -b- = 160 mm
– Adapt B-pillar reinforcement to front and rear side member re‐
inforcements with vehicle standing on its wheels or on align‐
ment bracket set.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
– Tack weld front and rear side member reinforcements

nform
-1 and 2- centrally at top and bottom -shaded areas- to B-pillar

ercia
reinforcement -3- using one small SG weld at each point and

m
remove B-pillar reinforcement again along with front and rear

com
tio
side member reinforcements.

n 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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
– Adapt side member reinforcement sealing plate -2- to front
h re
side member reinforcement -1- and weld in on inside, SG con‐
ole,
spec
tinuous weld seam
t to the co
When welding use the elongated holes in the replacement part.
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.

AG. Volkswagen AG d
agen oes
olksw not
CC 2010 ➤ , CC 2012 ➤ d by,VPassat CC 2009 ➤ gu
ara
e
Body Repairs - Edition
horis 11.2011 nte
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.
Note
♦ Adapt side member reinforcement sealing plate -2- to rear side member reinforcement -1-.
♦ The holes -3- must align.
– Weld front side member reinforcement -1- and side member

reinforcement sealing plate -2- to B-pillar reinforcement -4-,
RP spot weld seam.


CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
12.3.4 Welding in
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
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
– Apply 2K body adhesive -D180 KD3 A2- to marked area

-shaded area-.
ss
– Adapt B-pillar reinforcement to front and rear side member re‐

o
cial p
f i
inforcements with vehicle standing on alignment bracket set

nform
with the aid of outer B-pillar and outer side member and fix in
mer
position.
atio
om
n
c

i
or
n thi
te
sd
iva
o
pr
cum
r
Note
fo
en
ng
t.
yi Co
op py
. C rig
ht ht
rig
erties of adhesive will be impaired. py by
co Vo
by lksw
cted agen
Prote AG.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
– Weld in parting cut -1- for B-pillar reinforcement, SG continu‐
Co
Cop py
ous weld seam.
t. rig
gh ht
pyri by
Vo
o
– Weld in B-pillar reinforcement, SG plug weld seam.
c by lksw
cted agen
Prote AG.
– Weld in parting cut for B-pillar reinforcement, SG continuous
weld seam.
– Recreate original joint to inner side member, RP spot weld
seam.
Note


CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
Note that no welding work may be carried out in areas -1-.
– Recreate remaining joints, RP spot weld seam (inverter).

– Install outer B-pillar ⇒ „10.3 Installing“, page 180 .
– Install side member ⇒ „13.3 Installing“, page 208 .

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
RO: 51 45 55 10
13 Renewing side member
WARNING

processes.

1 - Moulded foam elements

2 - Bonded section
3 - Parting cuts
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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
13.1 Tools
Note

paintwork .
AG. Volkswagen AG d
agen oes
13.2 Removing d by Volksw not
gu
ara
rise nte
tho eo
au ra
Note ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
ing grinding work.
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.
13. Renewing side member 207

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
– When making parting cut -1- keep cutting/overlap of replace‐

AG. Volkswagen AG d
ment part in mind. agen oes
olksw not
V gu
by ara
ed nte
oris eo
th
Note au ra
c
ss
ce
e
nl
pt
Do not make parting cut in area of 170 - 230 mm from lower securing point for hinge mounting
du
an
itte
y li
erm
ab
– Make parting cuts -3- and -4- as shown.
ility
ot p
wit
, is n
Dimension -a- - 25 mm
h re
hole
spec
Dimension -b- - 20 mm
es, in part or in w
t to the co
– Release original joint to side member reinforcement.
rrectness of i
Note
l purpos
Dimensions -a- and -b- must be strictly adhered to.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
– Clean any dust and grease off adhesive area on wheel arch.
o
m
f
en
ng
t.
yi Co
13.3 Installing Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote
Note
AG.


CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
Note
rp
cu
o
m
f
en
ng
t.
yi
Co
Cop py
figure.
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
agen
Prote AG.
Replacement part
♦ Side member (subpart)

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
13.3.2 Marking the areas where no welding work may be carried out
Note
♦ Mark locations on side member where welding for safety reasons »crash safety« is prohibited.
♦ The measurements given must be adhered to.
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.
– Marking the areas where no welding work may be carried out

⇒ page 182 .


CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
AG. Volkswagen AG d
agen
13.3.4 Welding in by
Volksw
oes
not
gu
d 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.
– Apply butyl sealing cord -AKD 497 010 04 R10- to area -1-.
– Apply 2K body adhesive -D 180 KD3 A2- to marked area. 2
beads each of 3.5 mm ∅.
Note


CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Note

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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.
– Wipe away excess adhesive and seal wheel arch.

– Weld in A and B-pillar parting cuts, SG stepped weld seam.
– Weld side member parting cut to side panel, SG stepped weld
seam.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Note
– Reinstate original joints, RP spot weld seam (inverter).

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.
– Reinstate remaining joints to side member reinforcement, SG

plug weld seam.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
RO: 51 49 55 62
14 Renewing front side member rein‐

forcement
WARNING
n AG. Volkswagen AG
Safety notes ⇒ General age
ksw Information; Body Repairs,
does
not General Body
Repairs ; Safety Vol
notes
y gu
db e
ara
ris nte
utho eo
ra
a
1- Front
ss side member rein‐ c
ce
e
forcement
nl
pt
du
an
itte
2 - B-pillar reinforcement
y li
erm
ab
ility
3 - Residual material of front
ot p
wit
side member reinforcement
, is n
h re
(remains)
hole
spec
4 - Cutting point
es, in part or in w
t to the co
5 - Bonded section
6 - A-pillar reinforcement
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.
14. Renewing front side member reinforcement 215

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
14.1 Tools
Note

paintwork .
14.2 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
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 joints to A-pillar reinforcement -3- and to in‐
ner side member. Ensure reinforcing -2- is not damaged in
process.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
14.3 Installing
Note

must be used for proper spot welding
agen
A⇒
G. page
Volksw216 . Gd
agen A
w oes
olks not
byV gu
ara
14.3.1 Preparing new part ho
ris
ed nte
eo
t
au ra
Replacement partss c
ce
e
nl
♦ Front side member reinforcement pt

du
an
itte
y li
– Transfer parting cut to new part and remove -shaded area-.
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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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.
– Drill 8 mm ∅ holes as shown for SG plug weld seam.
Note
The measurements given must be adhered to.
Dimension -c- = 100 mm
Dimension -d- = 32 mm
Dimension -e- = 18 mm
Dimension -f- = 15 mm
Dimension -g- = 18 mm
Dimension -h- = 32 mm
Dimension -i- = 30 mm
Dimension -k- = 15 mm
Dimension -l- = 20 mm
Dimension -m- = 16 mm
Dimension -n- = 22 mm

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Dimension -o- = 22 mm
Dimension -p- = 32 mm
14.3.2 Welding in
– Apply 2K adhesive -D 180 KD3 A2- to areas indicated.
Note


ment bracket set and fix in position.
– Check fit to side member.
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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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.
Note
Length of seam -1- 20 mm, distance between seams 20 mm.
– SG continuous weld seam (Qty. 3) in areas -1-.

– Weld in front side member reinforcement, SG plug weld seam
and RP spot weld seam.
– Weld in parting cut, SG continuous weld seam.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Note
To ensure sufficient sturdiness, the RP weld points must be set as far as possible from the outer edge of the
welding flange.
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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
RO: 51 49 55 64
15 Renewing rear side member rein‐

forcement
WARNING

1 - Residual material of rear

side member reinforcement
(remains)
2 - Cutting point
3 - Wheel housing liner
4 - Rear longitudinal member
reinforcement
5 - Bonded section
6 - Reinforcement
❑ Shown for greater clarity
only. Must not be dam‐
aged.
7 - 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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
15.1 Tools
Note

♦ The welding units (inverters) and body tools authorised
gen AG
. Voby
lkswagen AG
Volkswagen AG can be found in ⇒ ServiceNet,olks Workshop
wa d oes
not
equipment, EH catalogue, Workshop equipment,
ed
byV Body and gu
ara
paintwork . thoris nte
eo
au ra
c
ss
15.2 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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Separate original joint to inner side member and to outer wheel

housing liner.
15. Renewing rear side member reinforcement 223

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
15.3 Installing
atio
om
n in
or c
thi
te
sd
a
Note
iv
o
r
rp
cu
o
m
f
en
ng

t.
yi Co
op
quires that one of the welding units (inverter) listed under Tools C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
15.3.1 Welding in
AG.
Replacement part
♦ Rear side member reinforcement
♦ 2K adhesive -D 180 KD3 A2-

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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.
– Apply adhesive to area indicated.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
Note
by lksw
cted agen
Prote AG.


15. Renewing rear side member reinforcement 225

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
– Weld in rear side member reinforcement, SG continuous weld

m
atio
m
seam and RP spot weld seam.

o
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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
53 – Body - rear
RO: 53 05 55 50
1 Renewing cross panel

Comprises: inner cross member, left and right retainers for ex‐
haust system and connecting panel for left and right tail light
clusters.
WARNING

Note
The cross panel can be renewed without removing the lock car‐
rier. en AG. V
olkswagen AG
wag does
olks not
byV gu
ara
ed nte
ris
1 - Tail light cluster mounting tho eo
au ra
c
ss
2 - Cross panel
ce
le
un
pt
an
3 - Reinforcing for sealing
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.
1. Renewing cross panel 227

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
channel
lkswage es n
o ot g
byV ua
d ran
ir se
1.1 Tools autho tee
or
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
paintwork .
rrectness of i
1.2 Removing
l purpos
Partial renewal
nform
ercia
A partial replacement of the rear cross panel is also possible

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
co lksw
by
cted agen
Prote AG.
228 Rep. gr.53 - Body - rear

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
– Make parting cut -1-.

Dimension -a- approx. 110 mm
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
– Then slightly bend open panel for sealing channel reinforcing.

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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
– Release original joint to inner cross member and left and right Cop py
. rig
exhaust system retainers.
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
Note
Longitudinal member panel must be drilled through completely in area -1-.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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

thi
te
sd
iva
o
r
1.3 Installing
p
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
Note gh ht
pyri by
Vo
co lksw
by
cted agen
The use of different types and different thicknesses of steel re‐ Prote AG.

Replacement part
♦ Cross panel
♦ Cross member for cross panel
♦ Left exhaust system retainer
♦ Right exhaust system retainer
♦ Connecting plate for left tail light cluster mounting
♦ Connecting plate for right tail light cluster mounting

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
1 - Tail light cluster mounting

– Drill holes for SG plug
weld seam (7 mm ∅).
2 - Cross panel
3 - Exhaust system retainer
– Drill holes for SG plug
weld seam (7 mm ∅).
4 - Cross member for cross

panel
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
1.3.2 Welding in
rm
m
atio
om
– Adapt new parts with vehicle standing on its wheels or on

n in
or c
alignment bracket set and hold in position.

thi
te
sd
iva

r
rp
cu
o
m
f
en
ng
– Check rear lid closes correctly.

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

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
h o eo
ut ra
– Weld in new
ss a parts, RP spot weld seam and SG plug weld c
seam.
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
233
cted agen
Prote AG.
1. Renewing cross panel
CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
– Weld in exhaust system retainers -1- and cross member for ce
le
un
cross panel -2-, SG plug weld seam and RP spot weld seam.
pt
an
d
itte
y li
– For joint from longitudinal member -3- to bracket for exhaust
rm
ab
pe
system -1-, an SG plug weld must be welded through both

ility
ot
panels.
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
Spare wheel well may only be installed after reinstating paintwork

finish.
rrectness of i
l purpos
– Install spare wheel well ⇒ „7.2 Installing“, page 270 .

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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
RO: 53 09 55 50
2 Renewing lock carrier
WARNING

2.1 Tools
Note

. Volkswagen AG
gen AG d
♦ The welding units (inverters)
Vol and body tools authorisedoby
ksw
a oes
n t
Volkswagen AG can ebe d b found in ⇒ ServiceNet, Workshopuara
y g
equipment, EH catalogue,
ho
ris
Workshop equipment, Body and ntee o
paintwork . aut ra
s c 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
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.
2. Renewing lock carrier 235

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
2.2 Removing
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
a
2.3 Installing
iv
o
pr
cum
r
fo
en
ng
t.
yi Co
op
Note
C py
t. rig
gh ht
pyri by
Vo
o
c by lksw
cted agen
Prote AG.
2.3.1 Welding in
Replacement part
♦ Lock carrier
– Check rear lid closes correctly.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a a
– Weld inslock
s carrier, SG plug weld seam and RP spot weld c
seam.
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
237
Prote AG.
2. Renewing lock carrier
CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
RO: 53 10 55 50
3 Renewing tail light mounting

Comprises: connecting plate for tail light cluster mounting
WARNING

3.1 Tools
Note

paintwork .
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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
3.2 Removing
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.

– Roughly cut-out mounting along points as marked, as con‐
necting piece to side panel need only be replaced if side panel
is damaged.
3. Renewing tail light mounting 239

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
– Drill out remains upper inner of tail light cluster -1-.

thi
te
sd
iva

o
r
rp
cu
o
m
f
en

ng
t.
yi Co
surface back to bare metal. t. Cop py
rig
gh ht
yri
3.3 Installing
p by
co Vo
by lksw
cted agen
Prote AG.
Note


Replacement part
♦ Tail light mounting
♦ Connecting plate for tail light cluster mounting

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
3.3.2 Welding in
– Apply 2K body adhesive -D 180 KD3 A2- to factory applied
rrectness of i
adhesive.
l purpos
Note
nf
ercia
or

m
m
atio

om
n in
or c
thi
e

t
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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
– Weld in new parts, SG plug weld seam, SG continuous weld

seam and RP spot weld seam.
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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
– SG stepped weld seam may also be used. Upper inner con‐

wit
, is n
h re
necting piece is welded using SG plug welds.

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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
lkswage es n
RO: 53 48 55 50 yV
o ot g
ua
b
4 Renewing rear longitudinal member -
d ran
ir se tee
tho
or
part section au ac
ss
ce
e
nl
pt
Includes: floor panel, longitudinal member sealing plate and
du
an
itte
bumper mounting
y li
erm
ab
ility
ot p
wit
WARNING
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
1 - Connecting plate
nform
ercia
2 - Floor panel
m
at
om
Note
ion
c
in t
or
his
ate
3 - Cutting point
do
priv
cum
or
Partial renewal
f
en
ng
t.
Position parting cut according op
yi Co
to damage.
C py
t. rig
gh ht
pyri by
Vo
o
4 - Rear longitudinal member
c by lksw
cted agen
Prote AG.
Partial renewal
Position parting cut according
to damage.
5 - Bumper mounting

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
4.1 Tools
Note

paintwork .
4.2 Removing
• Cross panel already cut out.
• Lock carrier already cut out
• Inner cross member already cut out
• Spare wheel well (plastic part) already removed
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.
4. Renewing rear longitudinal member - part section 245

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
– Separate original joint to floor panel -2- and to connecting plate

-1- and remove panels.
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
– Position offset parting cuts on longitudinal member -2- and on

erm
ab
longitudinal member sealing plate -1- and cut out.

ility
ot p
wit
, is n
Dimension -a- approx. 50 mm

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
246
by lksw
cted agen
Rep. gr.53 - Body - rear Prote AG.
CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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.
4.3 Installing
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
Note
cted agen
Prote AG.


Replacement part
♦ Rear longitudinal member
♦ Cover plate for longitudinal member
♦ Bumper mounting (not illustrated)
♦ Floor panel (not illustrated)
♦ Connecting plate (not illustrated)

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
op py
– Transfer parting cuts to new parts and cut out. t. C rig
gh ht
pyri by
– Drill 10 mm ∅ holes in new part for weld seam to bumper
o Vo
by c lksw
cted
mounting.
agen
Prote AG.
4.3.2 Welding in
ment bracket set using rear cross panel to align and hold in
position.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
– Weld in longitudinal member and cover plate, SG continuous

weld seam all round.
nform
ercia
– Weld longitudinal member and cover plate to one another, RP

m
a
com
spot weld seam.

ion 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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
yri
– Weld in bumper mounting, SG plug weld seam.
p by
co Vo
by lksw
cted agen
Prote AG.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
– Weld in connecting plate and floor panel, RP spot weld seam

le
un
pt
and SG plug weld seam.

an
d
itte
y li
erm
ab
– Recreate original joints to floor panel -2- and connecting plate

ility
ot p
-1- joints to side panel.

wit
is n
h re
– Install rear cross panel ⇒ page 231 .

ole,
spec
t to the co
Note
Spare wheel well may only be installed after reinstating paintwork

rrectne
finish
ss
– Install spare wheel well ⇒ „7.2 Installing“, page 270 .

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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
RO: 53 55 55 00
5 Renewing side panel - part section
WARNING

processes.

Note
AG. Volkswagen AG d
2 - Parting cuts agen oes
olksw not
y V gu
d b ara
ise nte
Note thor eo
au ra
ss c
ce
le
3 - Bonded section
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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
5.1 Tools
Note

paintwork .
5.2 Removing
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
– Make parting cuts -1 and 3- only on outer panel; do not dam‐

ng
t.
yi Co
age internal reinforcements. t. Cop py
rig
gh ht
Dimension for parting cut -1- = 50 mm pyri by
Vo
o
by c lksw
cted agen
Dimension for parting cut -3- = 90 mm Prote AG.
– When making parting cut -5- keep cutting/overlap of replace‐

ment part in mind.
5. Renewing side panel - part section 253

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
– Grind open a weld point in area of lock reinforcement.

Note

♦ Keep the cutting of the replacement part in mind.
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
– Grind open MIG-L braze seam in area of tail light cluster.

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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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

5.3 Installing
rrectness of i
l purpos
Note
nf
ercia
or

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
co lksw
by
cted agen
Prote AG.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
Note
l purpos
nf
ercia
figure.
orm
m
atio
m

o
n in
or c
thi
te
Replacement part
sd
iva
o
r
rp
cu
♦ Side panel subpart

o
m
f
en
ng
t.
yi Co
♦ Moulded foam element ht. Cop py
rig
rig ht
♦ 2K body adhesive -D 180 KD3 A2- py by
co Vo
by lksw
cted agen
– Transfer parting cuts to new parts and cut out. Prote AG.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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.
– Drill 7 mm ∅ holes in side panel for SG plug weld seam.

Moulded foam element ⇒ General Information; Body Repairs,
5.3.3 Welding in
– Apply 2K body adhesive -D 180 KD3 A2- to bonding area of
wheel arch. 2 beads each of 3.5 mm ∅.
Note
♦ New part must be welded-in within 90 minutes or adhesion

properties of adhesive will be impaired.
♦ Before starting welding on right-hand side panel, apply butyl
sealing cord in area of fuel filler neck.

and fix in place.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
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.
– Weld in side panel, RP spot weld seam and SG plug weld

seam.
– Weld in parting cuts, SG stepped weld seam.
Note

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
– Weld in original joint of rear window aperture, RP spot weld

seam.
rrectness of i
– Weld in remaining joint, SG plug weld seam.

l purpos
– Reform wheel housing flange.

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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
RO: 53 68 55 50
6 Renewing outer wheel housing liner
WARNING

AG. Volkswagen AG d
agen oes
olksw not
yV gu
1 - Bonded section ed b ara
nte
ris
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.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
6.1 Tools
Note

paintwork .
6.2 Removing
• Side panel already cut out.
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.
– Separate original joint between outer wheel housing liner -1-

and inner wheel housing liner -2-.
6. Renewing outer wheel housing liner 261

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
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
– Separate original joint to C-pillar reinforcement -1- and bonded

h re
hole
joint to lock reinforcement -2-.

spec
es, in part or in w
t to the co
Note
rrectness of i
The bonded joint for the lock reinforcement -2- is reinstated again before adapting the side panel.
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
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CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
6.3.1 Welding in
Replacement part
♦ Outer wheel housing liner -1-
♦ Reinforcement -2-
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– Apply 2K body adhesive -D 180 KD3 A2- to bonding area. 2

beads each of 3.5 mm diameter.

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Note


– Check fit with side panel.
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– Weld outer wheel housing liner -1- and reinforcement -2- to

or
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inner wheel housing liner -3- and rear connecting plate, RP

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spot weld seam.

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– Weld outer wheel housing liner -2- to C-pillar reinforcement
-1-, SG plug weld seam.
– Weld outer wheel housing liner -2- to connecting plate -3- and
side member reinforcement -4-, SG plug weld seam.
Note
The bonded joint for the lock reinforcement -5- is reinstated again before installing the side panel.
– Install side panel ⇒ page 255 .

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
RO: 53 80 55 00
7 Renewing spare wheel well
WARNING

1 - Spare wheel well (bonded)

2 - Rear left/right longitudinal
member
3 - Floor panel
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CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
7.1 Removing
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– Roughly cut out spare wheel well at edge -parting line- using
hole
spec
pneumatic sabre saw -V.A.G 1523/A- .

es, in part or in w
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– Leave bonding flange -1-.

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7. Renewing spare wheel well 269

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Body Repairs - Edition 11.2011 ise
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– 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- .
7.2 Installing

Replacement 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-
♦ Applicator -D 009 500 25-

CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Note
♦ The circumferential adhesive bead -1- on the replacement part

must be cut back to approx. 1 mm.
♦ For bonding reasons, the adhesive bead on the replacement
part should be cut back only just before it is to be fitted.
7.2.2 Bonding in
Note
Reinstate paintwork finish according to guidelines in workshop

manual "Paint" before bonding spare wheel well in vehicle.
Prime bonding surface of spare wheel well -shaded area- on body

with glass and paint primer -D 009 200 02- . Observe "flash-off"
period of approx. 10 minutes. AG. Volkswagen A n G do
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7. Renewing spare wheel well 271

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– Then apply 2K window adhesive -DA 004 600 A2- -A- to

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– Fit new part, align and then place spare wheel in well for weight
wit
is n
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Note
Curing period for 2K window adhesive -DA 004 600 A2- is 4 hours.
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Service

Service Department. Technical Information

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Copyright © 2011 Volkswagen AG, Wolfsburg K0059040920

8 Alignment bracket set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

1 Renewing right console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

2 Renewing left console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

3 Renewing retaining bracket (for subframe) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

2.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

2.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

5.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

6 Renewing roof reinforcement, vehicles with panorama tilting sunroof . . . . . . . . . . . . . . . . 150 n

6.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

6.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

6.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

10.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

15.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

53 - Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

1.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

2.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

2.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

3 Renewing tail light mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

3.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

1.1 Vehicle identification number

If the wing mounting (upper longitudinal member for wheel hous‐

1.2 Identification plate

1. Vehicle identification data 1

1.3 Vehicle data sticker

2 Rep. gr.00 - Technical data

Before beginning any cutting, alignment or dent removal, refer

3 Moulded foam elements

4 Rep. gr.00 - Technical data

4 Galvanized body parts

4. Galvanized body parts 5

4.2 High- and higher-strength body panels

♦ High- and higher-strength body panels are primarily fitted on

Fundamentally when working with high strength body panels

4.3 Hot-formed body panels

Higher-strength body panels are primarily fitted on this vehicle

4. Galvanized body parts 7

8 Rep. gr.00 - Technical data

6 Body panel gaps/shut lines

Use setting gauge -VAS 3371- for checking or adjusting.

Dimension -c- - 3.5 mm ± 1 mm

Dimension -d- - 3.5 mm ± 1 mm

6.2 Body - centre

Dimension -a- - 3.5 mm ± 1 mm

Dimension -b- - 4.5 mm ± 1 mm

6. Body panel gaps/shut lines 9

6.3 Body - rear

10 Rep. gr.00 - Technical data

♦ Dimensions only given for checking purposes. The alignment

7.1 Body - front

Dimension -a- = 990 mm ± 1 mm

Dimension -a- = 543 mm ± 1 mm

12 Rep. gr.00 - Technical data

Dimension -a- = 1,510 mm ± 1 mm

14 Rep. gr.00 - Technical data

Dimension -a- = 1,232 mm ± 1 mm

7.2 Body - centre

Dimension -a- = 1,496 mm ± 1 mm