Body Repairs

Chapter overview

• Technical data
  1
• 1 Vehicle identification data
  1
• 1.1 Type plate and vehicle identification number
  1
• 1.2 Vehicle data plate
  1
• 2 Moulded foam elements
  2
• 3 Strengthened steel body panels
  3
• 4 W8 reinforcement
  5
• 4.1 The body on the Passat W8 is reinforced as follows
  5
• 4.2 Body - front
  5
• 4.3 Body - centre
  6
• 5 Laser welding
  7
• 6 Bonded joints
  8
• 6.1 Bonded joints
  8
• 6.2 Spot welded/bonded joints
  8
• 6.3 Checking and repairing spot welded/bonded joints
  8
• 6.4 Repair remedies for partial repairs
  8
• 6.5 Repair remedies for bonded joints
  10
• 7 Galvanized body parts
  15
• 8 Body panel gaps/shut lines
  16
• 8.1 Body - front
  16
• 8.2 Body - rear
  18
• 9 Body dimensions
  22
• 9.1 Floor group - front
  22
• 9.2 Floor group - rear
  23
• 9.3 Body - front
  24
• 9.4 Body - centre
  28
• 9.5 Body - rear
  34
• 10 Alignment jig
  37
• 10.1 Positioning alignment fixtures
  42
• Body - front
  48
• 1 Renewing upper wheel housing longitudinal member
  48
• 1.1 Removing
  48
• 2 Renewing reinforcement for wheel housing
  50
• 2.1 Removing
  51
• 3 Renewing front wheel housing
  52
• 3.2 Removing
  52
• 4 Renewing reinforcement plate for wheel housing, 10.00 ▸
  55
• 4.1 Removing
  55
• 5 Renewing front longitudinal member
  57
• 5.1 Removing
  57
• 6 Renewing front part of longitudinal member - subpart
  60
• 6.1 Removing
  60
• Body - centre
  62
• 1 Renewing roof (saloon)
  62
• 1.1 Removing
  62
• 2 Renewing roof (estate)
  66
• 2.1 Removing
  66
• 3 Renewing front roof cross member
  70
• 3.1 Removing
  70
• 4 Renewing rear roof cross member (saloon)
  72
• 4.1 Removing
  72
• 5 Renewing rear roof cross member (estate)
  74
• 5.1 Removing
  74
• 6 Renewing A-pillar
  76
• 6.1 Includes: Wheel housing reinforcement
  76
• 7 Renewing B-pillar
  81
• 7.1 Outer B-pillar
  82
• 7.2 Inner B-pillar
  85
• 7.3 Removing
  85
• 8 Renewing outer side member
  88
• 8.1 Removing
  90
• 9 Renewing side member reinforcement ▸ 09.00
  94
• 9.1 Removing
  94
• 10 Renewing side member reinforcement 10.00 ▸
  97
• 10.1 Removing
  97
• 11 Renewing inner side member
  100
• 11.1 Removing
  100
• 12 Renewing floor panel - partial renewal
  103
• 12.1 Removing
  103
• Body - rear
  105
• 1 Renewing rear cross panel (saloon)
  105
• 1.1 Removing
  105
• 2 Renewing rear cross panel (estate)
  108
• 2.1 Removing
  108
• 3 Renewing corner reinforceing (estate 4Motion)
  111
• 3.1 Removing
  111
• 4 Renewing rear lock carrier (saloon)
  113
• 4.1 Removing
  113
• 5 Renewing rear lock carrier (estate)
  115
• 5.1 Removing
  115
• 6 Renewing tail light mounting (saloon ▸ 09.00)
  118
• 6.1 Removing
  118
• 7 Renewing tail light mounting (saloon 10.00 ▸)
  120
• 7.1 Removing
  120
• 8 Renewing tail light mounting (estate)
  122
• 8.1 Removing
  122
• 9 Renewing rear longitudinal member
  124
• 9.1 Removing
  124
• 10 Renewing rear longitudinal member (4Motion)
  127
• 10.1 Removing
  127
• 11 Renewing side panel (saloon)
  130
• 11.1 Removing
  131
• 12 Renewing side panel (estate)
  135
• 12.1 Removing
  136
• 13 Renewing outer wheel housing liner - partial renewal
  142
• 13.1 Removing
  142
• 14 Renewing spare wheel well
  144
• 14.1 Removing
  144
• 15 Renewing spare wheel well ( 4Motion)
  147
• 15.1 Removing
  147
• 16 Renewing spare wheel well - partial renewal
  150
• 16.1 Removing
  150