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General body repairs, exterior

For Passat/Passat Variant

Original Volkswagen repair manual


34,44 €7% VAT incl.

Immediately available for download

Language: English

Digital PDF file

19.297 KB

475 Sites

Detailed technical data

Immediately readable

This repair manual contains: Lock carrier, Wings, Bulkhead, Bonnet (hood), Rear lid (estate), Tank flap unit, Door components, Central locking, Sliding/tilting sunroof with glass panel (Meritor), Front bumper cover, Flush bonded windows, Exterior mirror, Mouldings and trims, Tunnel cross-piece, Fuel tank covers (natural gas vehicles), Add-on parts, Passat Alltrack and Scuff protection film. Show more
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Repair manual Passat/Passat Variant General body repairs, exterior PDF download has the following content:

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
Manufacturer's designation General body repairs, exterior
Manufacturer Volkswagen
Suitable for Passat/Passat Variant (2011 >)
Suitable car types 362, 365
Category Reparaturanleitung

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