General body repairs, exterior

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety measures when working on vehicles with a start/stop system
  1
• Body - front
  2
• 1 Lock carrier
  2
• 1.1 Assembly overview – lock carrier
  2
• 1.2 Service position
  3
• 1.3 Removing and installing lock carrier
  8
• 2 Wings
  11
• 2.1 Assembly overview - front wing
  11
• 2.2 Removing and installing front wing
  12
• 3 Bulkhead
  15
• 3.1 Assembly overview - plenum chamber bulkhead
  15
• 3.2 Assembly overview - plenum chamber cover
  17
• 3.3 Removing and installing plenum chamber cover
  17
• Bonnet, rear lid
  21
• 1 Bonnet (hood)
  21
• 1.1 Assembly overview - bonnet
  21
• 1.2 Removing and installing bonnet
  21
• 1.3 Removing gas strut
  25
• 1.4 Releasing gas from gas strut
  25
• 1.5 Assembly overview - bonnet hinge
  25
• 1.6 Removing and installing bonnet hinge
  26
• 1.7 Removing and installing insulation
  29
• 1.8 Assembly overview - bonnet lock and release components
  31
• 1.9 Removing and installing bonnet lock
  31
• 1.10 Detaching Bowden cable
  33
• 1.11 Adjusting bonnet
  33
• 1.12 Removing and installing release lever
  36
• 2 Rear lid (saloon)
  37
• 2.1 Tools
  37
• 2.2 Assembly overview - rear lid
  37
• 2.3 Removing and installing rear lid
  38
• 2.4 Removing gas strut
  40
• 2.5 Installing gas strut
  41
• 2.6 Releasing gas from gas strut
  42
• 2.7 Assembly overview - rear lid hinge
  42
• 2.8 Removing and installing rear lid hinge
  43
• 2.9 Assembly overview - hinge seal
  46
• 2.10 Removing and installing hinge seal
  47
• 2.11 Removing and installing striker pin
  49
• 2.12 Adjusting rear lid
  49
• 2.13 Assembly overview - release element
  52
• 2.14 Removing and installing release element
  53
• 2.15 Removing and installing bonnet lock
  55
• 2.16 Rear lid seal
  56
• 2.17 Removing and installing rear lid seal
  57
• 3 Rear lid (estate)
  59
• 3.1 Tools
  59
• 3.2 Assembly overview - rear lid
  59
• 3.3 Removing and installing rear lid
  60
• 3.4 Removing and installing rear lid hinge
  62
• 3.5 Removing and installing bonnet lock
  64
• 3.6 Removing and installing striker pin
  66
• 3.9 Adjusting rear lid
  71
• 3.10 Removing and installing gas strut
  75
• 3.11 Releasing gas from gas strut
  75
• 3.12 Removing and installing motor in control unit for electrically operated rear lid
  75
• 3.13 Rear lid seal
  79
• 3.14 Removing and installing rear lid seal
  79
• 3.15 Assembly overview - cover
  82
• 4 Tank flap unit
  83
• 4.1 Tools
  83
• 4.2 Assembly overview - tank flap unit and actuator
  83
• 4.3 Assembly overview - tank flap unit for natural gas vehicles
  85
• 4.4 Removing and installing tank flap unit
  86
• 4.5 Removing and installing actuator
  88
• Front doors, door components, central locking
  89
• 1 Rear door
  89
• 1.1 Tools
  89
• 1.2 Assembly overview - front door
  90
• 1.3 Assembly overview - door hinges
  92
• 1.4 Removing and installing door
  93
• 1.5 Adjusting door
  95
• 2 Door components
  97
• 2.1 Tools
  97
• 2.2 Assembly overview - assembly carrier
  98
• 2.3 Removing and installing subframe
  98
• 2.4 Assembly overview - door handle and door lock
  104
• 2.5 Removing and installing lock cylinder housing cover cap
  105
• 2.6 Removing and installing lock cylinder housing
  106
• 2.7 Removing and installing door handle
  107
• 2.8 Removing and installing door handle with access and start authorisation
  108
• 2.9 Removing and installing door lock
  110
• 2.10 Removing and installing mounting bracket
  114
• 2.11 Removing and installing retaining bracket
  117
• 2.12 Inner door seal
  118
• 2.13 Removing and installing inner door seal
  119
• 2.14 Removing and installing outer door seal
  120
• 2.15 Assembly overview - insulation
  124
• 3 Central locking
  125
• 3.1 Fitting location overview - central locking components
  125
• 3.4 Removing and installing remote control key battery
  127
• Rear doors, door components
  130
• 1 Rear door (saloon)
  130
• 1.1 Tools
  130
• 1.2 Assembly overview - rear door
  131
• 1.3 Assembly overview - door hinges
  133
• 1.4 Removing and installing door
  134
• 1.5 Adjusting door
  136
• 2 Rear door (estate)
  138
• 2.1 Tools
  138
• 2.2 Assembly overview - rear door
  139
• 2.3 Assembly overview - door hinges
  140
• 2.4 Removing and installing door
  142
• 2.5 Adjusting door
  145
• 3 Door components
  147
• 3.1 Tools
  147
• 3.2 Assembly overview - assembly carrier
  148
• 3.3 Removing and installing subframe
  148
• 3.4 Assembly overview - door handle and door lock
  155
• 3.5 Removing and installing lock cylinder housing cover cap
  156
• 3.6 Removing and installing lock cylinder housing
  157
• 3.7 Removing and installing door handle
  158
• 3.8 Removing and installing door handle with access and start authorisation
  159
• 3.9 Removing and installing door lock
  161
• 3.10 Removing and installing mounting bracket
  164
• 3.11 Removing and installing retaining bracket
  167
• 3.12 Door inner seals
  168
• 3.13 Removing and installing inner door seal
  169
• 3.14 Removing and installing outer door seal
  170
• 3.15 Assembly overview - insulation
  174
• Sunroof
  175
• 1 Sliding/tilting sunroof with glass panel (Meritor)
  175
• 1.1 Tools
  175
• 1.2 Function
  175
• 1.3 Assembly overview - sliding/tilting sunroof with glass panel
  176
• 1.4 Removing and installing bellows
  179
• 1.5 Removing sliding/tilting sunroof glass panel
  180
• 1.6 Installing sliding/tilting sunroof glass panel
  181
• 1.7 Adjusting height of sliding/tilting sunroof glass panel
  181
• 1.8 Adjusting panel seal
  182
• 1.9 Removing and installing panel seal
  183
• 1.10 Removing and installing wind deflector
  183
• 1.11 Removing and installing sliding headliner
  184
• 1.12 Removing and installing sliding/tilting sunroof glass panel drive
  185
• 1.13 Adjusting drive for sliding/tilting sunroof glass panel ("0" position)
  186
• 1.14 Removing and installing sliding/tilting sunroof glass panel automatic preselection switch
  187
• 1.15 Checking parallel running
  187
• 1.16 Adjusting parallel running
  187
• 1.17 Assembly overview - carrier unit
  188
• 1.18 Removing and installing carrier unit
  189
• 1.19 Operating without current
  192
• 1.20 Removing and installing guide plate
  192
• 1.21 Removing and installing guide plate
  193
• 1.22 Cleaning water drainage hoses
  194
• 2 Sliding/tilting sunroof with solar panel (Webasto)
  197
• 2.1 Tools
  197
• 2.2 Function
  197
• 2.3 Assembly overview - sliding/tilting sunroof with solar panel
  198
• 2.4 Removing sliding/tilting sunroof solar panel
  199
• 2.5 Installing sliding/tilting sunroof solar panel
  200
• 2.6 Adjusting sliding/tilting sunroof solar panel height
  200
• 2.7 Checking parallel running of solar panel
  201
• 2.8 Adjusting parallel running of solar panel
  202
• 2.9 Renewing panel seal
  202
• 2.10 Removing wind deflector
  202
• 2.11 Removing solar panel trim
  203
• 2.12 Removing sliding/tilting sunroof drive
  203
• 2.13 Adjusting drive for sliding/tilting sunroof (zero position)
  204
• 2.14 Removing pre-selector control for sliding/tilting sunroof
  205
• 2.15 Removing electrical contact in solar roof
  205
• 2.17 Removing and installing carrier unit
  206
• 2.18 Operating without current
  209
• 2.19 Cleaning water drainage hoses
  209
• 3 Panorama sliding sunroof (Arvin-Meritor)
  212
• 3.1 Tools
  212
• 3.2 Function
  212
• 3.3 Basic setting, panoramic sliding sunroof
  213
• 3.4 Assembly overview - panoramic sliding roof
  213
• 3.5 Removing and installing front glass panel
  215
• 3.6 Removing and installing rear glass panel
  219
• 3.7 Adjusting height of front and rear glass panel
  221
• 3.8 Renewing seals for rear glass panel
  223
• 3.9 Removing and installing the exterior seal
  227
• 3.10 Removing and installing interior seal
  229
• 3.11 Removing and installing wind deflector
  231
• 3.12 Removing and installing preselector for glass panel and sunroof sun blind
  234
• 3.13 Removing and installing sliding sunroof motor
  235
• 3.14 Removing and installing sun blind motor
  238
• 3.15 Removing and installing sun blind
  241
• 3.16 Removing and installing sunroof sun blind cross strut
  249
• 3.17 Assembly overview - assembly frame
  250
• 3.18 Removing and installing sun blind Bowden cable
  251
• 3.19 Removing and installing assembly frame
  255
• 3.20 Removing and installing rear part
  258
• 3.21 Removing and installing front motor plate
  262
• 3.22 Removing and installing tilting mechanism and front glass panel cable
  265
• 3.23 Maintenance and care
  269
• 3.24 Operating without current
  270
• 3.25 Cleaning water drainage hoses
  271
• Bumpers
  274
• 1 Front bumper cover
  274
• 1.1 Tools
  274
• 1.2 Repairing front bumper cover
  274
• 1.3 Installing brackets for parking aid system
  274
• 1.4 Assembly overview - front bumper cover
  279
• 1.5 Removing and installing front bumper cover
  280
• 1.6 Front bumper cover add-on parts
  282
• 1.7 Front bumper cover add-on parts, Passat Alltrack
  284
• 1.8 Front bumper cover substructure parts
  285
• 1.9 Assembly overview - front bumper carrier
  286
• 1.10 Assembly overview - front bumper carrier (USA)
  287
• 1.11 Number plate carrier
  288
• 2 Rear bumper cover (saloon)
  291
• 2.1 Tools
  291
• 2.2 Repairing rear bumper cover
  291
• 2.3 Installing brackets for parking aid system
  291
• 2.4 Bumper, rear
  296
• 2.5 Rear bumper cover add-on parts 11.2010 ►
  301
• 2.6 Assembly overview - rear bumper carrier
  302
• 2.7 Assembly overview - towing bracket
  302
• 2.8 Removing and installing drive for swivelling ball head
  304
• 3 Rear bumper cover (estate)
  305
• 3.1 Tools
  305
• 3.2 Repairing rear bumper cover
  305
• 3.3 Installing brackets for parking aid system
  305
• 3.4 Bumper, rear
  310
• 3.5 Rear bumper cover add-on parts
  315
• 3.6 Rear bumper cover add-on parts, Passat Alltrack
  316
• 3.7 Assembly overview - rear bumper carrier
  317
• 3.8 Assembly overview - towing bracket
  317
• 3.9 Removing and installing drive for swivelling ball head
  319
• Glazing
  320
• 1 Flush bonded windows
  320
• 1.1 Tools
  320
• 1.2 Materials
  321
• 1.3 Repairing windscreen
  322
• 1.4 Assembly overview - windscreen
  322
• 1.5 Removing windscreen
  323
• 1.6 Installing windscreen
  325
• 1.7 Assemble overview - rear window (saloon)
  326
• 1.8 Removing undamaged rear window (saloon)
  327
• 1.9 Removing broken rear window (saloon)
  328
• 1.10 Installing rear window (saloon)
  328
• 1.11 Assembly overview - rear window (estate)
  328
• 1.12 Removing undamaged rear window (estate)
  329
• 1.13 Removing broken rear window (estate)
  330
• 1.14 Installing rear window (estate)
  331
• 1.15 Assembly overview - side window (estate)
  331
• 1.16 Removing undamaged side window (estate)
  333
• 1.17 Removing broken side window (estate)
  334
• 1.18 Installing side window (estate)
  334
• 1.19 Preparing old undamaged window for glazing
  335
• 1.20 Preparing new window without precoating for glazing
  335
• 1.21 Preparing body flange for glazing
  336
• 1.22 Fitting instructions
  338
• 1.23 Minimum curing period
  341
• 1.24 Touching up paint damage
  341
• 1.25 Cleaning in the event of dirt caused by adhesive sealant
  341
• 2 Front door window
  342
• 2.1 Tools
  342
• 2.2 Assembly overview
  343
• 2.3 Removing and installing door window
  344
• 2.4 Removing and installing window regulator motor
  348
• 2.5 Removing and installing window channel
  349
• 2.6 Removing and installing window channel trim strip
  352
• 3 Rear door window (saloon)
  354
• 3.1 Tools
  354
• 3.2 Assembly overview
  355
• 3.3 Removing and installing door window
  356
• 3.4 Removing and installing window regulator motor
  360
• 3.5 Removing and installing window channel
  361
• 3.6 Removing and installing window channel trim strip
  363
• 4 Rear door window (estate)
  365
• 4.1 Tools
  365
• 4.2 Assembly overview
  366
• 4.3 Removing and installing door window
  367
• 4.4 Removing and installing window regulator motor
  372
• 4.5 Removing and installing window channel
  373
• 4.6 Removing and installing guide rails
  374
• 4.7 Removing and installing window channel trim strip
  375
• Exterior equipment
  377
• 1 Wheel housing liner
  377
• 1.1 Tools
  377
• 1.2 Assembly overview - front wheel housing liner
  377
• 1.3 Assembly overview - rear wheel housing liner
  379
• 1.4 Removing and installing front wheel housing liner
  380
• 1.5 Removing and installing rear wheel housing liner
  382
• 2 Exterior mirror
  384
• 2.1 Tools
  384
• 2.2 Assembly overview - exterior mirror
  384
• 2.3 Removing and installing mirror glass
  385
• 2.4 Removing and installing mirror housing
  387
• 2.5 Removing and installing trim
  388
• 2.6 Removing and installing side turn signal and entry light in exterior mirror
  389
• 2.7 Removing and installing exterior mirror
  391
• 3 Radiator grille
  392
• 3.1 Tools
  392
• 3.2 Radiator grille
  392
• 3.3 Removing and installing emblem
  395
• 3.4 Removing and installing emblem in vehicles with adaptive cruise control
  397
• 3.5 Assembly overview - number plate carrier
  398
• 3.6 Removing and installing number plate carrier
  399
• 4 Roof railing
  401
• 4.1 Tools
  401
• 4.2 Assembly overview - roof railing
  401
• 4.3 Removing and installing roof railing
  402
• 4.4 Assembly overview - roof railing retaining bracket
  405
• 4.5 Removing and installing roof railing retaining bracket
  406
• 5 Mouldings and trims
  409
• 5.1 Tools
  409
• 5.2 Assembly overview - water deflector
  410
• 5.3 Removing and installing water deflector
  410
• 5.4 Front and rear door covers
  413
• 5.5 Assembly overview - side member extension
  416
• 5.6 Assembly overview - rear lid trim strip, saloon
  417
• 5.7 Removing and installing rear side window trim strip
  418
• 5.8 Wheel arch trim
  419
• 5.9 »R-Line« and »Exclusive« cover strip
  420
• 6 Noise insulation
  422
• 6.1 Tools
  422
• 6.2 Assembly overview - noise insulation
  422
• 6.3 Removing and installing noise insulation
  425
• 7 Skid plate
  426
• 7.1 Assembly overview - skid plate
  426
• 7.2 Removing and installing skid plate
  427
• 7.3 Removing and installing skid plate bracket
  428
• 8 Tunnel cross-piece
  429
• 8.1 Tools
  429
• 9 Assembly overview - tunnel cross-piece
  430
• 10 Underbody cladding
  431
• 10.1 Tools
  431
• 10.2 Assembly overview - underbody cladding
  431
• 11 Fuel tank covers (natural gas vehicles)
  433
• 12 Assembly overview - heat shield
  434
• 13 Add-on parts, Passat Alltrack
  435
• 13.1 Safety requirements
  435
• 13.2 Fitting instructions for add-on parts
  435
• 13.3 Tools
  435
• 13.4 Materials
  436
• 13.5 Assembly overview - add-on parts
  436
• 13.6 Side member extension
  437
• 13.7 Front wheel housing trim
  439
• 13.8 Rear wheel arch trim
  441
• 13.9 Preparing body component for bonding
  443
• 13.10 Fitting instructions
  444
• 13.11 Minimum curing period
  444
• 13.12 Touching up paint damage
  444
• 13.13 Cleaning guidelines
  444
• 14 Special add-on parts
  445
• 14.1 Safety requirements
  445
• 14.2 Assembly overview - add-on parts
  445
• 14.3 Assembly overview – side member extension
  448
• 14.4 Roof spoiler (estate)
  449
• 14.5 Fitting instructions
  454
• 14.6 Preparing add-on parts for bonding
  454
• 14.7 Preparing new add-on part for bonding
  455
• 14.8 Preparing body component for bonding
  455
• 14.9 Fitting instructions
  455
• 14.10 Minimum curing period
  456
• 14.11 Touching up paint damage
  456
• 14.12 Cleaning in the event of dirt caused by adhesive sealant
  456
• 14.13 Cleaning guidelines
  456
• 15 Lettering and emblems
  457
• 15.1 Removing and installing emblems at rear
  457
• 15.2 Tools
  457
• 15.3 Fitting instructions
  458
• 15.4 Rear lettering - dimensions
  458
• 15.5 Lettering on wing
  461
• 16 Scuff protection film
  463
• 16.1 Scuff protection film at front and rear
  463