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Body Repairs
Passat 2011 ➤
Passat Variant 2011 ➤
Edition 04.2011
Service
Service Department. Technical Information
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Repair Group overview for Body Repairs
Re pa ir G ro up
00 - Technical data
50 - Body - front
51 - Body - centre
53 - Body - rear
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.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2011 Volkswagen AG, Wolfsburg D3E80312527
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Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Vehicle identification data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Moulded foam elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 Galvanized body parts, high/higher-strength and hot-formed body panels . . . . . . . . . . . . 6
4.1 Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5 Laser welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6 Body panel gaps/shut lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.1 Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.2 Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.3 Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.4 Body - rear (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7 Body dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7.1 Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7.2 Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.3 Body - centre (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.4 Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7.5 Body - rear (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.6 Floor group - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7.7 Floor group - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.8 Floor group - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
8 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9 Alignment bracket set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
9.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
10 Portal gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
50 - Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1 Renewing left console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2 Renewing right console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3 Renewing retaining bracket for subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4 Renewing bumper bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5 Renewing upper wheel housing longitudinal member . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6 Renewing front wheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
Contents i
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6.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7 Repairing threads for securing subframe (suspension subframe) . . . . . . . . . . . . . . . . . . . . 66
7.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
7.2 Contents of thread repair kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
7.3 Repairing threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
8 Renewing front longitudinal member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
9 Renewing front longitudinal member - part section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
9.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
9.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
9.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
51 - Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1 Renewing roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2 Renewing roof - vehicles with sliding/tilting sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
2.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
2.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3 Renewing roof (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
3.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4 Renewing roof - Variant with panorama sliding sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
4.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
5 Renewing roof side member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
5.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
5.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
5.4 Foam treating roof side member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
6 Renewing front roof cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
6.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
6.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
6.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
7 Renewing rear roof cross member (saloon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
7.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
7.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
7.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
8 Renewing rear roof cross member (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
8.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
8.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
8.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
9 Renewing A-pillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
9.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
9.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
9.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
ii Contents
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10 Renewing A-pillar reinforcement - part section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
10.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
10.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
10.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
11 Renewing B-pillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
11.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
11.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
11.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
12 Renewing B-pillar reinforcement - part section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
12.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
12.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
12.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
13 Renewing inner B-pillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
13.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
13.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
13.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
14 Renewing side member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
14.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
14.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
14.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
15 Renewing front side member reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
15.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
15.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
15.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
16 Renewing rear side member reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
16.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
16.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
16.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
17 Renewing seat middle cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
17.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
17.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
17.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
18 Renewing inner mounting for seat cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
18.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
18.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
18.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
19 Renewing outer mounting for seat cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
19.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
19.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
19.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
53 - Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
1 Renewing rear cross panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
1.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
1.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
2 Renewing rear cross panel (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
2.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
2.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
3 Renewing lock carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
3.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
3.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
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Body Repairs - Edition 04.2011
Contents iii
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4 Renewing tail light mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
4.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
4.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
5 Renewing tail light mounting (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
5.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
5.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
6 Renewing C-pillar reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
6.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
6.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
6.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
7 Renewing C-pillar reinforcement (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
7.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
7.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
7.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
8 Renewing D-pillar reinforcement - part section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
8.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
8.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
8.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
9 Renewing inner D-pillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
9.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
9.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
9.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
10 Renewing rear longitudinal member - part section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
10.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
10.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
10.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
11 Renewing side panel - part section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
11.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
11.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
11.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
12 Renewing side panel (Variant) - part section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
12.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
12.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
12.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
13 Renewing outer wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
13.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
13.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
13.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
14 Renewing outer wheel housing liner (Variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
14.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
14.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
14.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
15 Renewing spare wheel well . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
15.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
15.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
15.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
iv Contents
Page 7
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00 – Technical data
1 Vehicle identification data
1.1 Vehicle identification number
The vehicle identification number -1- is located in the area of the
lower left-hand side of the windscreen (driver's perspective).
Note
♦
The vehicle identification number is also stamped at three oth‐
er locations.
♦
If the component has to be renewed in the event of damage,
the repair must be documented according to the market-spe‐
cific legislation.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
1. Vehicle identification data 1
Page 8
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♦ The vehicle identification number -arrow A- is located on the
wing mounting on the right in the luggage compartment (driv‐
er's perspective).
♦ The vehicle identification number -arrow B- is located on the
sill panel seat mounting in the vicinity of the front door on the
right side of the vehicle.
♦ The vehicle identification number -arrow C- is located on the
floor panel of the rear seats.
Note
The numbers are located at the same points on the Variant.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
2 Rep. gr.00 - Technical data
Page 9
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2 Safety instructions
WARNING
Before beginning any cutting, alignment or dent removal, refer
to safety notes in the binder General information, body repairs
and general body repairs.
Safety notes ⇒ General Information; Body Repairs, General Body
Repairs ; Safety notes
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
2. Safety instructions 3
Page 10
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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 moulded elements are fitted during body shell construction
and increase their volume in the paint shop drying oven at approx.
180°C, after priming.
The exact location of these moulded foam elements are shown
at the beginning of the respective repair description.
Caution
The replacement moulded foam elements expand first at ap‐
prox. 180° This is why a foam filler is used in some repair
cases.
The foam filler D 506 KD1 A2 is required for these repair cases.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
4 Rep. gr.00 - Technical data
Page 11
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As these temperatures cannot be achieved under normal work‐
shop conditions, proceed as follows:
Remove foam material remains on vehicle.
– Apply corrosion protection measures according to guidelines
in ⇒ Paint workshop manual: Corrosion and corrosion pro‐
tection, attached and welded parts, materials .
Prerequisites
Before continuing with this procedure, ensure that the part for re‐
placement is correctly prepared e.g. cut and adapt to fit, corrosion
protection measures.
Renewing moulded foam element
Fix moulded foam element to vehicle.
Apply foam filler D 506 KD1 A2 to replacement part.
Secure new part in position. Gently press new part, in vicinity of
moulded foam element, until it makes contact and then weld in.
The foam filler hardens within 25 minutes.
Do not do perform shielded arc welding within 15 mm of foam
filler.
Carry out cavity protection to repair area after painting vehicle.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
3. Moulded foam elements 5
Page 12
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4 Galvanized body parts, high/higher-
strength and hot-formed body panels
Working on galvanized body panels ⇒ General Information; Body
Repairs, General Body Repairs ; Steel panel repairs; galvanized
body parts .
4.1 Body
Note
Repairs may only be made according to the manufacture instruc‐
tions in the respective repair manual. Higher-strength and hotformed body panels may only be repaired using modern inverter
technology, otherwise the optimum passenger protection after
repairs is not possible. Form tempered steel panels are used in
areas under extreme stress. These panels offer a clearly higher
strength than conventional high-strength panels for less weight.
Work on strengthened body panels must comply with guide lines
in Workshop Manual ⇒ General Information; Body Repairs, Gen‐
eral Body Repairs ; Steel panel repairs, strengthened body panels
The body of the vehicle is predominantly manufactured from
galvanized steel panels.
This illustration shows those parts of the body manufactured from
hot-formed body panels.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
6 Rep. gr.00 - Technical data
Page 13
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Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
4. Galvanized body parts, high/higher-strength and hot-formed body panels 7
Page 14
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Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
8 Rep. gr.00 - Technical data
Page 15
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5 Laser welding
On this vehicle, the roof and parts of the body are laser welded.
With laser welding, a high-energy beam of light is directed over
the seam to be welded by optical lenses or optical fibre.
During the welding process, the upper panel is melted onto the
partially molten lower panel, creating a welded joint without the
need of additional material.
For repairs (except for roof repairs), the laser weld seam is re‐
placed by a RP spot weld seam.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
5. Laser welding 9
Page 16
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6 Body panel gaps/shut lines
Note
Use setting gauge -3371- to set or check shut lines.
6.1 Body - front
a - 2.5 mm ± 0.5 mm
b - – 2.6 mm ± 0.8 mm
c - 2.8 mm ± 0.5 mm
d - – 0.1 mm ± 0.5 mm
e - 0.8 mm ± 0.5 mm
f - 2.0 mm ± 0.5 mm
g - 5.0 mm ± 0.5 mm
h - 4.7 mm ± 0.5 mm
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
10 Rep. gr.00 - Technical data
Page 17
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6.2 Body - centre
a - 2.0 mm ± 1.0mm
b - 0.6 mm ± 0.5 mm
c - 0.0 mm + 1.0 mm
d - 4.2 mm ± 1.5 mm
e - 0.0 mm + 1.0 mm
f - 3.2 mm – 0.5 mm + 1.0 mm
g - 12.7 mm ± 0.5 mm
h - 4.2 mm – 0.5 mm + 1.0 mm
i - 0.0 mm + 1.0 mm
j - 12.7 mm ± 0.5 mm
k - 3.5 mm – 0.5 mm + 1.0 mm
l - 0.0 mm – 1.0 mm
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
6. Body panel gaps/shut lines 11
Page 18
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6.3 Body - rear
a - 2.5 mm ± 0.5 mm
b - – 3.2 mm ± 0.5 mm
c - 5.5 mm ± 0.5 mm
d - 3.5 mm ± 0.5 mm
e - – 0.7 mm ± 0.5 mm
f - 2.5 mm ± 1.0 mm
g - – 6.6 mm ± 0.5 mm
h - 3.5 mm ± 0.5 mm
i - – 0.5 mm ± 0.5 mm
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
12 Rep. gr.00 - Technical data
Page 19
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6.4 Body - rear (Variant)
a - 5.0 mm ± 0.5 mm
b - – 0.8 mm – 1.0 mm + 0.5
mm
c - 5.0 mm ± 0.5 mm
d - 3.5 mm ± 0.5 mm
e - – 1.1 mm ± 0.5 mm
f - – 0.6 mm ± 0.5 mm
g - 3.5 mm ± 0.5 mm
h - 5.0 mm ± 0.5 mm
i - – 4.3 mm ± 0.5 mm
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
6. Body panel gaps/shut lines 13
Page 20
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7 Body dimensions
Note
♦
Dimensions only given for checking purposes. The alignment
bracket set is the final authority.
♦
Bolts, screws, plugs, trim and attached components must be
removed before starting the measuring process.
♦
Use Telescopic gauge -VAS 5159- or Telescopic gauge -VAS
5160- to determine body dimensions.
♦
Ensure measuring probes are always of even length to prevent
inaccuracies when measuring.
7.1 Body - front
a - 938 mm ± 2.0 mm
b - 1,438 mm ± 2.0 mm
c - 1,550 mm ± 2.0 mm
d - 1,513 mm ± 2.0 mm
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
14 Rep. gr.00 - Technical data
Page 21
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a - 920 mm ± 2.0 mm
b - 1,479 mm ± 2.0 mm
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
7. Body dimensions 15
Page 22
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7.2 Body - centre
a - 1,445 mm ± 2.0 mm
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
16 Rep. gr.00 - Technical data
Page 23
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a - 1,480 mm ± 2.0 mm
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
7. Body dimensions 17
Page 24
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a - 1,472 mm ± 2.0 mm
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
18 Rep. gr.00 - Technical data
Page 25
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a - 882 mm ± 2.0 mm
b - 896 mm ± 2.0 mm
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
7. Body dimensions 19
Page 26
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a - 970 mm ± 2.0 mm
b - 741 mm ± 2.0 mm
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
20 Rep. gr.00 - Technical data
Page 27
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7.3 Body - centre (Variant)
a - 972 mm ± 2.0 mm
b - 740 mm ± 2.0 mm
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
7. Body dimensions 21
Page 28
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7.4 Body - rear
a - 528 mm ± 2.0 mm
b - 1,125 mm ± 2.0 mm
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
22 Rep. gr.00 - Technical data
Page 29
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7.5 Body - rear (Variant)
a - 857 mm ± 2.0 mm
b - 938 mm ± 2.0 mm
c - 1,198 mm ± 2.0 mm
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
7. Body dimensions 23
Page 30
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7.6 Floor group - front
a - 430 mm ± 2.0 mm
b - 874 mm ± 2.0 mm
c - 678 mm ± 2.0 mm
d - 1,152 mm ± 2.0 mm
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
24 Rep. gr.00 - Technical data
Page 31
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7.7 Floor group - centre
Note
Dimension -a- is measured on floor at the left and right B-pillar.
a - 1,486 mm ± 2.0 mm
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
7. Body dimensions 25
Page 32
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7.8 Floor group - rear
a - 1,000 mm ± 2.0 mm
b - 1,085 mm ± 2.0 mm
c - 987 mm ± 2.0 mm
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
26 Rep. gr.00 - Technical data
Page 33
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8 Tools
Note
♦
The use of different types and different thicknesses of steel
requires that only the welding units (inverters) authorised by
Volkswagen AG may be used to carry out repairs properly.
♦
The welding units (inverters) and body tools authorised by
Volkswagen AG are listed in ⇒ ServiceNet, Workshop Equip‐
ment, EH catalogue, Workshop equipment, Body and paint‐
work .
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
8. Tools 27
Page 34
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9 Alignment bracket set
Note
Alignment tasks may only be performed using Volkswagen AG
approved alignment bracket sets or measurement and alignment
systems .
9.1 Overview
Special tools and workshop equipment required
♦ Alignment bracket set Passat 2011 -VAS6325/3-
♦ Basic alignment bracket set -V.A.G 1610/-
Set up of complete alignment bracket set for Passat 2011 VAS6325/3- .
Detailed information on setting up the alignment bracket set can
be found with the equipment.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
28 Rep. gr.00 - Technical data
Page 35
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10 Portal gauge
Note
Alignment tasks may only be performed using Volkswagen AG
approved alignment bracket sets or measurement and alignment
systems .
10.1 Overview
Special tools and workshop equipment required
♦ Portal gauge -VAS 5007-
♦ Portal gauge supplementary set for Passat 2006 -VAS
5007/22-
♦ Alignment bracket set Passat 2011 -VAS6325/3-
♦ Basic alignment bracket set -V.A.G 1610/-
10.1.1 Front door aperture
Set up for portal gauge -VAS 5007- with portal gauge supplement
for Passat 2006 -VAS 5007/22- , front door aperture.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
10. Portal gauge 29
Page 36
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Detailed information on setting up the portal gauge supplement
for Passat 2006 -VAS 5007/22- set can be found with the equip‐
ment.
10.1.2 Rear door aperture
Set up for portal gauge -VAS 5007- with portal gauge supplement
for Passat 2006 -VAS 5007/22- , rear door aperture.
Detailed information on setting up the portal gauge supplement
for Passat 2006 -VAS 5007/22- set can be found with the equip‐
ment.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
30 Rep. gr.00 - Technical data
Page 37
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.
50 – Body - front
RO: 50 40 55 50
1 Renewing left 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
requires that only the welding units (inverters) authorised by
Volkswagen AG may be used to carry out repairs properly.
♦
The welding units (inverters) and body tools authorised by
Volkswagen AG are listed in ⇒ ServiceNet, Workshop Equip‐
ment, EH catalogue, Workshop equipment, Body and paint‐
work .
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
1. Renewing left console 31
Page 38
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.
1.2 Removing
– Separate original joint.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
32 Rep. gr.50 - Body - front
Page 39
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– Separate original joint.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
1. Renewing left console 33
Page 40
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– Remove remaining material.
1.3 Installing
Note
Only welding units authorised by Volkswagen AG may be used
⇒ page 31 .
1.3.1 Preparing new part
New part
♦ Left engine console
– Drill holes for SG plug weld seam (8 mm ∅).
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
34 Rep. gr.50 - Body - front
Page 41
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1.3.2 Welding in
– Adapt new part with vehicle positioned on alignment bracket
set and fix in place.
– Weld in console, SG plug weld seam and RP spot weld seam.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
1. Renewing left console 35
Page 42
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RO: 50 40 55 53
2 Renewing right console
WARNING
Observe safety notes!
Safety notes ⇒ General Information; Body Repairs, General Body
Repairs ; Safety notes
2.1 Tools
Note
♦
The use of different types and different thicknesses of steel
requires that only the welding units (inverters) authorised by
Volkswagen AG may be used to carry out repairs properly.
♦
The welding units (inverters) and body tools authorised by
Volkswagen AG are listed in ⇒ ServiceNet, Workshop Equip‐
ment, EH catalogue, Workshop equipment, Body and paint‐
work .
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
36 Rep. gr.50 - Body - front
Page 43
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2.2 Removing
– Separate original joint.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
2. Renewing right console 37
Page 44
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– Remove remaining material.
2.3 Installing
Note
Only welding units authorised by Volkswagen AG may be used
⇒ page 36 .
2.3.1 Welding in
New part
♦ Right engine bracket
– Adapt new part with vehicle positioned on alignment bracket
set and fix in place.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
38 Rep. gr.50 - Body - front
Page 45
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– Weld in console, RP spot weld seam.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
2. Renewing right console 39
Page 46
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RO: 50 43 55 00
3 Renewing retaining bracket for sub‐
frame
WARNING
Observe safety notes!
Safety notes ⇒ General Information; Body Repairs, General Body
Repairs ; Safety notes
Note
The description of the procedure for renewing the front left sub‐
frame retaining bracket uses this vehicle as an example. The
procedure, as appropriate, should be used for the other 3 retain‐
ing brackets.
3.1 Tools
Note
♦
The use of different types and different thicknesses of steel
requires that only the welding units (inverters) authorised by
Volkswagen AG may be used to carry out repairs properly.
♦
The welding units (inverters) and body tools authorised by
Volkswagen AG are listed in ⇒ ServiceNet, Workshop Equip‐
ment, EH catalogue, Workshop equipment, Body and paint‐
work .
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
40 Rep. gr.50 - Body - front
Page 47
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3.2 Removing
– Separate original joint.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
3. Renewing retaining bracket for subframe 41
Page 48
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– Remove remaining material.
3.3 Installing
Note
Only welding units authorised by Volkswagen AG may be used
⇒ page 40 .
3.3.1 Preparing new part
New part
♦ Retaining bracket for subframe (parts designation: subframe
retaining bracket)
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
42 Rep. gr.50 - Body - front
Page 49
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– Drill holes for SG plug weld seam (8 mm ∅).
3.3.2 Welding in
– Adapt new part with vehicle positioned on alignment bracket
set and fix in place.
– Weld in new part, SG plug weld seam.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
3. Renewing retaining bracket for subframe 43
Page 50
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RO: 50 65 55 50
4 Renewing bumper bracket
WARNING
Observe safety notes!
Safety notes ⇒ General Information; Body Repairs, General Body
Repairs ; Safety notes
1 - Bumper bracket
2 - Longitudinal member with
cover plate
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
44 Rep. gr.50 - Body - front
Page 51
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.
4.1 Tools
Note
♦
The use of different types and different thicknesses of steel
requires that only the welding units (inverters) authorised by
Volkswagen AG may be used to carry out repairs properly.
♦
The welding units (inverters) and body tools authorised by
Volkswagen AG are listed in ⇒ ServiceNet, Workshop Equip‐
ment, EH catalogue, Workshop equipment, Body and paint‐
work .
4.2 Removing
– Separate original joint.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
4. Renewing bumper bracket 45
Page 52
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– Remove remaining material.
4.3 Installing
Note
Only welding units authorised by Volkswagen AG may be used
⇒ page 45 .
4.3.1 Welding in
New part
♦ Front bumper bracket
– Adapt new part with vehicle positioned on alignment bracket
set and fix in place.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
46 Rep. gr.50 - Body - front
Page 53
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– Weld in bumper bracket, SG continuous weld seam.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
4. Renewing bumper bracket 47
Page 54
P
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RO: 50 72 55 00
5 Renewing upper wheel housing lon‐
gitudinal member
Comprises: upper outer longitudinal member and upper inner
longitudinal member
Note
♦
If the upper longitudinal member for wheel housing is re‐
newed, the repairs must be documented according to the
market-specific legislation.
♦
The vehicle identification number should be installed/em‐
bossed before the new part is welded in.
WARNING
Observe safety notes!
Safety notes ⇒ General Information; Body Repairs, General Body
Repairs ; Safety notes
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
48 Rep. gr.50 - Body - front
Page 55
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.
1 - Front outer longitudinal
member
2 - Front inner longitudinal
member
3 - Bonded area
4 - Aperture to plenum cham‐
ber
Cut out together with
⇒ Item 1 (page 49) .
5 - Parting cut for partial re‐
placement
A partial replacement can also
be made with the specified
parting cut.
Dimension -a- = 270 mm
5.1 Tools
Note
♦
The use of different types and different thicknesses of steel
requires that only the welding units (inverters) authorised by
Volkswagen AG may be used to carry out repairs properly.
♦
The welding units (inverters) and body tools authorised by
Volkswagen AG are listed in ⇒ ServiceNet, Workshop Equip‐
ment, EH catalogue, Workshop equipment, Body and paint‐
work .
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
5. Renewing upper wheel housing longitudinal member 49
Page 56
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.
5.2 Removing
– Separate original joint at upper outer longitudinal member
-1-.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
50 Rep. gr.50 - Body - front
Page 57
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.
– Separate original joint at upper inner longitudinal member
-1-.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
5. Renewing upper wheel housing longitudinal member 51
Page 58
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– Remove remaining material.
5.3 Installing
Note
Only welding units authorised by Volkswagen AG may be used
⇒ page 49 .
5.3.1 Preparing new part
New part
♦ Upper inner longitudinal member
♦ Upper outer longitudinal member
♦ 2K body adhesive -D 180 KD3 A2-
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
52 Rep. gr.50 - Body - front
Page 59
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.
– Drill 8 mm ∅ holes in upper outer longitudinal member for SG
plug weld seam.
5.3.2 Welding in
Note
New part must be welded in within 90 minutes or adhesion of ad‐
hesive will be impaired.
– Adapt new part with vehicle standing on its wheels or align‐
ment bracket set and fix in position.
– Check fit with bolt-on parts.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
5. Renewing upper wheel housing longitudinal member 53
Page 60
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.
– Weld in upper inner longitudinal member -1-, RP spot weld
seam and SG staggered continuous weld seam.
– Apply 2K body adhesive -D 180 KD3 A2- to areas bonded in
the factory.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
54 Rep. gr.50 - Body - front
Page 61
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– Adapt upper outer longitudinal member to fit with upper inner
longitudinal member and check fit with adjacent parts.
– Weld in upper outer longitudinal member, SG plug weld seam
and RP spot weld seam.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
5. Renewing upper wheel housing longitudinal member 55
Page 62
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RO: 50 74 55 50
6 Renewing front wheel housing
Includes: suspension strut mounting
WARNING
Observe safety notes!
Safety notes ⇒ General Information; Body Repairs, General Body
Repairs ; Safety notes
• Longitudinal member for upper wheel housing already re‐
moved ⇒ page 48 .
1 - Wheel housing
2 - Plenum chamber
3 - Suspension strut mounting
With suspension strut mount‐
ing reinforcement
4 - Longitudinal member with
cover plate
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
56 Rep. gr.50 - Body - front
Page 63
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6.1 Tools
Note
♦
The use of different types and different thicknesses of steel
requires that only the welding units (inverters) authorised by
Volkswagen AG may be used to carry out repairs properly.
♦
The welding units (inverters) and body tools authorised by
Volkswagen AG are listed in ⇒ ServiceNet, Workshop Equip‐
ment, EH catalogue, Workshop equipment, Body and paint‐
work .
6.2 Removing
Partial renewal
Depending on damage, a partial renewal is possible using parting
cut -1-.
– Separate original joint to front longitudinal member cover plate
and to plenum chamber from wheel housing side.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
6. Renewing front wheel housing 57
Page 64
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– Separate remainder of joint to plenum chamber -1-.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
58 Rep. gr.50 - Body - front
Page 65
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– Remove remaining material.
6.3 Installing
Note
Only welding units authorised by Volkswagen AG may be used
⇒ page 57 .
6.3.1 Preparing new parts
♦ Wheel housing
♦ Suspension strut mounting
♦ Suspension strut mounting reinforcement
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
6. Renewing front wheel housing 59
Page 66
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– Drill holes for SG plug weld seam (8 mm ∅).
Note
♦
Drill a double row of holes in area -1-.
♦
Distance between holes: approx. 30 mm.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
60 Rep. gr.50 - Body - front
Page 67
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6.3.2 Welding in
– Adapt new part with assistance of alignment bracket fixtures
-item 13-, -item 15-, -item 16- and -item 17- from alignment
bracket set and to adjacent parts and fix in place.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
6. Renewing front wheel housing 61
Page 68
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– Weld suspension strut mounting to suspension strut mounting
reinforcement, SG plug weld seam.
– Drill holes -1- (10 mm ∅) for mounting suspension strut. Ad‐
ditionally secure suspension strut mounting and suspension
strut mounting reinforcement to alignment bracket fixture -2using bolts.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
62 Rep. gr.50 - Body - front
Page 69
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– Weld wheel housing and suspension strut mounting reinforce‐
ment, SG plug weld seam.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
6. Renewing front wheel housing 63
Page 70
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– Recreate joint between suspension strut mounting and ple‐
num chamber; SG plug weld seam.
– Recreate original joint between suspension strut mounting and
suspension strut mounting reinforcement, RP spot weld seam.
– Recreate remaining joints for wheel housing, RP spot weld
seam.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
64 Rep. gr.50 - Body - front
Page 71
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– Enlarge hole in suspension strut mounting reinforcement to
dimension -a-.
Dimension -a- = 34 mm
Note
Item 17 of alignment bracket set can be used to check dimension -a- ⇒ page 27 .
– Install upper longitudinal member for wheel housing
⇒ page 52 .
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
6. Renewing front wheel housing 65
Page 72
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RO: 50 79 49 90
7 Repairing threads for securing sub‐
frame (suspension subframe)
WARNING
Observe safety notes!
Safety notes ⇒ General Information; Body Repairs, General Body
Repairs ; Safety notes
Note
The thread repair is described for the front left retaining bracket
for the subframe on this vehicle and the procedure, as appropri‐
ate, should be used for the other 3 retaining brackets.
1 - Longitudinal member
2 - Threaded plate (welded to
subframe retaining bracket)
Note
3 - Retaining bracket for sub‐
frame
4 - Helicoil thread insert
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
66 Rep. gr.50 - Body - front
Page 73
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7.1 Tools
Special tools and workshop equipment required
♦ M12x1.5 thread repair set -VAS 6058-
♦ Drill -VAS 6267-
7.2 Contents of thread repair kit
1 - Twist drill 12.5 mm ∅
2 - Thread-cutting tap M12 x
1.5
3 - Fitting spindle
4 - Thread insert M12 x 1.5 x
24 -VAS 6058/1-
5 - Pin breaker with magnetic
end
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
7. Repairing threads for securing subframe (suspension subframe) 67
Page 74
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7.3 Repairing threads
7.3.1 Drilling thread
– Drill out thread using twist drill.
Note
♦
The drill must be held by an assistant using an additional hand
support when drilling.
♦
Use drill -VAS 6267- when drilling and shaping.
♦
Do not cant drill.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
68 Rep. gr.50 - Body - front
Page 75
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7.3.2 Cutting thread
– Cut thread with thread-cutting tap
– Clean threaded sleeve (with compressed air).
7.3.3 Inserting thread insert
– Screw thread insert -3- onto fitting spindle until the fitting pin
-2- contacts the fitting lug -1- on the fitting spindle.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
7. Repairing threads for securing subframe (suspension subframe) 69
Page 76
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– Screw thread insert into the threaded plate until the top of the
thread insert is flush with the outer edge of the threaded plate
(visual check).
–
Then screw thread insert inwards a 1/4 turn.
Note
Thread insert must screw in easily.
– Remove fitting spindle.
– Break off drive pin of thread insert using pin breaker.
– Install subframe (suspension subframe) ⇒ Suspension, axles,
steering; Rep. gr. 40 ; Subframe, anti-roll bar, suspension link .
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
70 Rep. gr.50 - Body - front
Page 77
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.
RO: 50 79 55 00
8 Renewing front longitudinal member
Includes: bumper mounting
WARNING
Observe safety notes!
Safety notes ⇒ General Information; Body Repairs, General Body
Repairs ; Safety notes
1 - Parting cut (cover plate)
2 - Parting cut (longitudinal
member)
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
8. Renewing front longitudinal member 71
Page 78
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8.1 Tools
Note
♦
The use of different types and different thicknesses of steel
requires that only the welding units (inverters) authorised by
Volkswagen AG may be used to carry out repairs properly.
♦
The welding units (inverters) and body tools authorised by
Volkswagen AG are listed in ⇒ ServiceNet, Workshop Equip‐
ment, EH catalogue, Workshop equipment, Body and paint‐
work .
8.2 Removing
– Separate original joint.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
72 Rep. gr.50 - Body - front
Page 79
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– Make parting cut on longitudinal member as shown.
Dimension -a- = 55 mm
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
8. Renewing front longitudinal member 73
Page 80
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– Make parting cut on longitudinal member cover plate as
shown.
Dimension -a- = 55 mm
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
74 Rep. gr.50 - Body - front
Page 81
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– Remove remaining material.
8.3 Installing
Note
Only welding units authorised by Volkswagen AG may be used
⇒ page 72 .
8.3.1 Preparing new part
New part
♦ Longitudinal member assembly
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
8. Renewing front longitudinal member 75
Page 82
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– Transfer parting cuts to new part and cut out.
– Drill holes for SG plug weld seam (8 mm ∅).
8.3.2 Welding in
– Adapt new part with vehicle positioned on alignment bracket
set and fix in place.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
76 Rep. gr.50 - Body - front
Page 83
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– Check fit with adjacent parts.
– Butt weld parting cut of longitudinal member all around (SG
continuous weld seam).
– Butt weld cover plate parting cut, SG continuous weld seam.
– Restore remaining joint, SG plug weld seam and RP spot weld
seam.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
8. Renewing front longitudinal member 77
Page 84
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8.3.3 Shortening new longitudinal member with cover plate
Note
The longitudinal member -2- with cover plate -1- (parts designation: longitudinal member) is too long at the front
-shaded area- and must be shortened when adapting and welding in the bumper bracket.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
78 Rep. gr.50 - Body - front
Page 85
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– Assemble alignment bracket mounting for front longitudinal
member -RW 1- with spacer -RW 3- as shown and hold against
longitudinal member from below.
– Transfer dimensions (plus an additional 2mm) -a- to longitu‐
dinal member and cover plate and remove excessive material.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
8. Renewing front longitudinal member 79
Page 86
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– Fix front bumper bracket -1- in position in front of longitudinal
member -2- with aid of -RW 1- and -RW 3-.
Note
There must be a gap of 1-2 mm between longitudinal member -2- with cover plate -3- and bumper bracket
-1-.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
80 Rep. gr.50 - Body - front
Page 87
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– Weld in bumper bracket, SG continuous weld seam.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
8. Renewing front longitudinal member 81
Page 88
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RO: 50 79 55 02
9 Renewing front longitudinal member
- part section
Includes: bumper bracket and longitudinal member reinforcement
WARNING
Observe safety notes!
Safety notes ⇒ General Information; Body Repairs, General Body
Repairs ; Safety notes
1 - Cover plate
2 - Longitudinal member
3 - Laser weld seam
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
82 Rep. gr.50 - Body - front
Page 89
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.
9.1 Tools
Note
♦
The use of different types and different thicknesses of steel
requires that only the welding units (inverters) authorised by
Volkswagen AG may be used to carry out repairs properly.
♦
The welding units (inverters) and body tools authorised by
Volkswagen AG are listed in ⇒ ServiceNet, Workshop Equip‐
ment, EH catalogue, Workshop equipment, Body and paint‐
work .
9.2 Removing
Note
♦
The parting cut for cover plate -1- and the parting cut for longitudinal member -2- must be offset.
♦
Do not cut or weld 50 mm before or after the laser weld seam -3- (shaded area).
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
9. Renewing front longitudinal member - part section 83
Page 90
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.
– Position parting cuts -1 and 3- on longitudinal member ac‐
cording to degree of damage and cut out.
Caution
The parting cut for the longitudinal member is permitted only
in the area shown. If the longitudinal member is damaged be‐
yond this area, it must be renewed entirely.
– Position parting cut -1- for cover plate as shown and cut out.
– Separate original joint.
– Remove cover plate.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
84 Rep. gr.50 - Body - front
Page 91
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.
– Position parting cut -3- on longitudinal member -1- and longi‐
tudinal member -2- congruently and cut out.
– Take note of laser weld seam -4-.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
9. Renewing front longitudinal member - part section 85
Page 92
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.
– Remove residual material and remainder of longitudinal mem‐
ber reinforcement -1-.
9.3 Installing
Note
Only welding units authorised by Volkswagen AG may be used
⇒ page 83 .
9.3.1 Preparing new part
New part
♦ Longitudinal member
♦ Cover plate for longitudinal member
♦ Longitudinal member reinforcement (parts designation: bulk‐
head plate)
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
86 Rep. gr.50 - Body - front
Page 93
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.
– Transfer parting cut to longitudinal member and longitudinal
member cover plate and cut out.
9.3.2 Welding in
– Adapt new part with vehicle positioned on alignment bracket
set and fix in place.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
9. Renewing front longitudinal member - part section 87
Page 94
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.
– Check fit with adjacent parts.
– Weld in longitudinal member parting cut (all round), SG con‐
tinuous weld seam.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
88 Rep. gr.50 - Body - front
Page 95
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.
– Weld in longitudinal member reinforcement, RP spot weld
seam.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
9. Renewing front longitudinal member - part section 89
Page 96
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.
– Weld in cover plate, RP spot weld seam.
Note
Distance between weld points -a- approx. 35-40 mm
– Weld in cover plate parting cut, SG continuous weld seam.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
90 Rep. gr.50 - Body - front
Page 97
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.
51 – Body - centre
RO: 51 03 55 00
1 Renewing roof
WARNING
Observe safety notes!
Safety notes ⇒ General Information; Body Repairs, General Body
Repairs ; Safety notes
1 - Roof
2 - Laser solder seam
3 - Bonded areas
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
1. Renewing roof 91
Page 98
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.
1.1 Tools
Note
♦
The use of different types and different thicknesses of steel
requires that only the welding units (inverters) authorised by
Volkswagen AG may be used to carry out repairs properly.
♦
The welding units (inverters) and body tools authorised by
Volkswagen AG are listed in ⇒ ServiceNet, Workshop Equip‐
ment, EH catalogue, Workshop equipment, Body and paint‐
work .
Special tools and workshop equipment required
♦ Pneumatic cartridge gun -V.A.G 1761/1-
♦ Cartridge heater -V.A.G 1939 A-
♦ Double-cartridge gun -VAS 5237-
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
92 Rep. gr.51 - Body - centre
Page 99
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♦ Setting gauge -3371-
♦ Tensioning strap -T10038-
♦ Suction lifter -V.A.G 1344-
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
1. Renewing roof 93
Page 100
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1.2 Removing
Note
♦
Apply textile adhesive tape on left and right roof members parallel to laser solder seams. This reduces
danger of damage and contamination during repairs.
♦
When separating, ensure sufficient distance of to roof member -2- is kept, to assure it is not damaged during
repairs.
♦
When making parting cuts -1-, ensure that the panels lying behind are not damaged.
– Separate original joint to front and rear roof cross members.
– From interior, separate bonded joints to front and rear roof
cross members.
– Roughly cut roof out parallel to laser solder seams.
Passat 2011 ➤ , Passat Variant 2011 ➤
Body Repairs - Edition 04.2011
94 Rep. gr.51 - Body - centre
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