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  • Examplepage for repair manual 3 General body repairs, exterior

General body repairs, exterior

For Passat / Passat Variant

Original Volkswagen repair manual


19,01 €7% VAT incl.

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Language: English

Digital PDF file

6.251 KB

233 Sites

Detailed technical data

Immediately readable

This repair manual contains: Lock carrier, Wing, Noise insulation, Bonnet lid, Tank flap unit, Rear door, Sliding/tilting sunroof with glass panel ▸ 07.98, Flush bonded windows and Protective strips. Show more
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Repair manual Passat / Passat Variant General body repairs, exterior PDF download has the following content:

Chapter overview

  • Body - front
    1
  • 1 Lock carrier
    1
  • 1.1 Tools
    1
  • 1.2 Assembly overview - Lock carrier with add-on parts ▸ 09.00
    2
  • 1.3 Removing and refitting lock carrier with add-on parts ▸ 09.00
    3
  • 1.4 Lock carrier - Service position ▸ 09.00
    4
  • 1.5 Unbolting hydraulic oil cooler
    6
  • 1.6 Assembly overview - Lock carrier add-on parts 10.00 ▸
    6
  • 1.7 Removing and refitting lock carrier with add-on parts 10.00 ▸
    7
  • 1.8 Assembly overview - Lock carrier, service position 10.00 ▸
    8
  • 1.9 Service position 10.00 ▸
    10
  • 2 Wing
    12
  • 2.1 Tools
    12
  • 2.2 Assembly overview - Front wing ▸ 09.00
    12
  • 2.3 Removing and refitting front wing ▸ 09.00
    14
  • 2.4 Removing and refitting closing piece
    15
  • 2.5 Assembly overview - Front wing 10.00 ▸
    15
  • 2.6 Removing and refitting front wing 10.00 ▸
    17
  • 3 Noise insulation
    19
  • 3.1 Tools
    19
  • 3.2 Assembly overview - Noise insulation
    19
  • Bonnet, rear lid
    21
  • 1 Bonnet lid
    21
  • 1.1 Tools
    21
  • 1.2 Assembly overview - Bonnet lid
    21
  • 1.3 Removing and refitting bonnet lid
    23
  • 1.4 Adjusting bonnet
    24
  • 1.5 Removing gas strut
    26
  • 1.6 Releasing gas from gas strut
    26
  • 1.7 Assembly overview- Bowden cable for bonnet lock
    26
  • 1.8 Disconnecting Bowden cable
    27
  • 1.9 Assembly overview- Bonnet lock
    28
  • 1.10 Removing and refitting bonnet lock
    29
  • 1.11 Adjusting bonnet lock
    30
  • 1.12 Assembly overview- Bonnet seal
    31
  • 1.13 Removing and refitting insulation
    31
  • 2 Rear lid, saloon
    34
  • 2.1 Tools
    34
  • 2.2 Assembly overview - Rear lid
    34
  • 2.3 Removing gas strut
    35
  • 2.4 Adjusting rear lid ▸ 09.00
    35
  • 2.5 Adjusting rear lid 10.00 ▸
    37
  • 2.6 Assembly overview- Rear lid lock ▸ 09.00
    37
  • 2.7 Removing and refitting lock cylinder carrier
    39
  • 2.8 Assembly overview - Rear lid lock and lock cylinder carrier 10.00 ▸
    40
  • 2.10 Assembly overview- Lock cylinder housing 10.00 ▸
    42
  • 3 Rear lid, Estate
    43
  • 3.1 Tools
    43
  • 3.2 Assembly overview - Rear lid
    43
  • 3.3 Removing gas strut
    44
  • 3.4 Assembly overview- Rear lid lock, Estate ▸ 09.00
    45
  • 3.5 Removing and refitting lock cylinder carrier, Estate ▸ 09.00
    46
  • 3.6 Removing and refitting lock cylinder, Estate ▸ 09.00
    47
  • 3.7 Assembly overview - Rear lid lock and lock cylinder carrier 10.00 ▸
    48
  • 3.8 Assembly overview- Lock cylinder housing 10.00 ▸
    49
  • 4 Tank flap unit
    50
  • 4.1 Tools
    50
  • 4.2 Assembly overview - Tank flap unit
    50
  • 4.3 Removing and refitting tank flap unit
    51
  • Front doors, door components, central locking
    54
  • 1 Front door
    54
  • 1.1 Tools
    54
  • 1.2 Assembly overview - Front door
    55
  • 1.3 Removing and refitting front door
    57
  • 1.4 Adjusting front door
    58
  • 1.5 Assembly overview - Door handle and door lock
    59
  • 1.6 Removing and refitting lock cylinder housing
    60
  • 1.7 Removing and refitting door handle
    61
  • 1.8 Removing and refitting door lock
    63
  • 1.9 Vehicles with electric windows
    66
  • 1.10 Removing inner release handle
    67
  • 1.11 Door seals
    67
  • 1.12 Removing and refitting door inner seal
    68
  • 1.13 Removing and refitting locking knob for locking rod
    68
  • 2 Central locking
    71
  • 2.1 Location overview - Central locking components
    71
  • 2.2 Removing and refitting batteries for key (non-folding type) with remote-control unit
    73
  • 2.3 Removing and refitting batteries for key (folding type) with remote control ▸ 07.00
    75
  • 2.7 Configuring keys with remote-control
    79
  • Rear doors, door components
    80
  • 1 Rear door
    80
  • 1.1 Tools
    80
  • 1.2 Assembly overview - Rear door
    81
  • 1.3 Removing and refitting rear door
    82
  • 1.4 Adjusting rear door
    82
  • 1.5 Assembly overview - Door handle and door lock
    83
  • 1.6 Removing and refitting door handle
    85
  • 1.7 Removing and refitting door lock
    87
  • 1.8 Fitting door window to window actuator
    92
  • 1.9 Removing inner release handle
    92
  • 1.10 Door seals
    92
  • 1.11 Removing and refitting door inner seal
    93
  • Sunroof
    94
  • 1 Sliding/tilting sunroof with glass panel ▸ 07.98
    94
  • 1.1 Tools
    94
  • 1.2 Assembly overview- Sliding/tilting sunroof with glass panel
    94
  • 1.3 Removing glass panel for sliding/tilting sunroof
    96
  • 1.4 Refitting glass panel for sliding/tilting sunroof
    96
  • 1.5 Adjusting sliding/tilting sunroof glass panel height
    97
  • 1.6 Adjusting panel seal
    98
  • 1.7 Replacing panel seal
    98
  • 1.8 Removing wind deflector
    99
  • 1.9 Removing sun shield
    99
  • 1.10 Removing drive for sliding/tilting sunroof
    100
  • 1.11 Adjusting drive for sliding/tilting sunroof (zeroising)
    100
  • 1.12 Removing pre-selector rotary switch for sliding/tilting sunroof
    100
  • 1.13 Checking parallel running
    101
  • 1.14 Adjusting parallel running
    101
  • 1.15 Removing and refitting sliding/tilting sunroof carrier unit
    102
  • 1.16 Operating without current
    102
  • 1.17 Removing guide rail
    103
  • 1.18 Cleaning water drain hoses
    104
  • 2 Sliding/tilting sunroof with glass panel 08.98 ▸
    107
  • 2.1 Tools
    107
  • 2.2 Function
    107
  • 2.3 Assembly overview- Sliding/tilting sunroof with glass panel
    108
  • 2.4 Removing and refitting bellows
    110
  • 2.5 Removing glass panel for sliding/tilting sunroof
    111
  • 2.6 Refitting glass panel for sliding/tilting sunroof
    112
  • 2.7 Adjusting sliding/tilting sunroof glass panel height
    113
  • 2.8 Adjusting panel height
    114
  • 2.9 Replacing panel seal
    115
  • 2.10 Removing and refitting wind deflector
    115
  • 2.11 Removing sun shield
    116
  • 2.12 Removing and refitting sliding/tilting sunroof drive
    117
  • 2.13 Adjusting drive for sliding/tilting sunroof (zeroising)
    117
  • 2.14 Removing pre-selector rotary switch for sliding/tilting sunroof
    118
  • 2.15 Checking parallel running
    118
  • 2.16 Adjusting parallel running
    119
  • 2.17 Removing and refitting assembly unit
    119
  • 2.18 Operating without current
    122
  • 2.19 Removing guide rail
    122
  • 2.20 Cleaning water drain hoses
    123
  • 3 Sliding/tilting sunroof with solar panel
    127
  • 3.1 Tools
    127
  • 3.2 Function
    127
  • 3.3 Assembly overview- Sliding/tilting sunroof with solar panel
    128
  • 3.4 Removing sliding/tilting sunroof solar panel
    129
  • 3.5 Refitting sliding/tilting sunroof solar panel
    129
  • 3.6 Adjusting sliding/tilting roof solar panel height
    130
  • 3.7 Checking parallel running of solar panel
    131
  • 3.8 Adjusting parallel running of solar panel
    131
  • 3.9 Replacing panel seal
    132
  • 3.10 Removing wind deflector
    132
  • 3.11 Removing solar panel trim
    132
  • 3.12 Removing drive for sliding/tilting sunroof
    132
  • 3.13 Adjusting drive for sliding/tilting sunroof (zeroising)
    133
  • 3.14 Removing pre-selector rotary switch for sliding/tilting sunroof
    134
  • 3.15 Removing DC converter
    134
  • 3.16 Removing solar contact in solar panel
    135
  • 3.17 Removing solar contact from roof carrier unit
    135
  • 3.18 Removing and refitting assembly unit
    135
  • 3.19 Operating without current
    138
  • 3.20 Cleaning water drain hoses
    138
  • Bumpers
    142
  • 1 Front bumper
    142
  • 1.1 Tools
    142
  • 1.2 Assembly overview - Front bumper cover ▸ 09.00
    142
  • 1.3 Removing and refitting front bumper cover ▸ 09.00
    144
  • 1.4 Removing release lever
    145
  • 1.5 Adjusting guide
    145
  • 1.6 Assembly overview - Front bumper cover 10.00 ▸
    145
  • 1.7 Removing and refitting front bumper cover 10.00 ▸
    147
  • 1.8 Assembly overview - Front bumper cover add-on parts 10.00 ▸
    148
  • 1.9 Removing and refitting bumper strip
    149
  • 1.10 Refitting number plate panel (US vehicles only)
    149
  • 1.11 Assembly overview - Front bumper cover, underbody parts 10.00 ▸
    149
  • 2 Rear bumper
    152
  • 2.1 Tools
    152
  • 2.2 Assembly overview - Rear bumper cover ▸ 09.00
    152
  • 2.3 Removing and refitting rear bumper cover ▸ 09.00
    154
  • 2.4 Assembly overview - Rear bumper cover 10.00 ▸
    155
  • 2.5 Removing and refitting rear bumper cover 10.00 ▸
    156
  • 2.6 Assembly overview - Rear bumper cover, add-on parts 10.00 ▸
    157
  • 2.7 Removing and refitting bumper strip
    157
  • 2.8 Assembly overview - Rear bumper cover, underbody parts 10.00 ▸
    158
  • 2.10 Assembly overview - Towing bracket
    160
  • 2.11 Assembly overview - Towing bracket (4 Motion)
    161
  • 3 Rear bumper Estate
    162
  • 3.1 Tools
    162
  • 3.2 Assembly overview - Rear bumper cover ▸ 09.00
    162
  • 3.3 Removing and refitting rear bumper cover ▸ 09.00
    164
  • 3.4 Assembly overview - Rear bumper cover 10.00 ▸
    165
  • 3.5 Removing and refitting rear bumper cover 10.00 ▸
    166
  • 3.6 Assembly overview - Rear bumper cover, add-on parts 10.00 ▸
    167
  • 3.7 Removing and refitting bumper strip
    167
  • 3.8 Attaching transparent film
    168
  • 3.9 Assembly overview - Rear bumper cover, underbody parts 10.00 ▸
    168
  • Glazing
    170
  • 1 Flush bonded windows
    170
  • 1.1 Tools
    170
  • 1.2 Materials
    171
  • 1.3 Assembly overview - Windscreen
    172
  • 1.4 Removing and refitting plenum chamber cover
    173
  • 1.5 Removing windscreen
    174
  • 1.6 Refitting windscreen
    176
  • 1.8 Assembly overview- Side window, Estate ▸ 09.00
    176
  • 1.9 Assembly overview- Side window, Estate 10.00 ▸
    178
  • 1.10 Removing undamaged side window
    178
  • 1.11 Removing broken side window
    180
  • 1.12 Assembly overview- Side window, Saloon ▸ 09.00
    180
  • 1.13 Assembly overview- Side window, Saloon 10.00 ▸
    181
  • 1.14 Removing undamaged side window
    181
  • 1.15 Removing broken side window
    182
  • 1.16 Refitting side window
    182
  • 1.17 Assembly overview- Rear window, Estate
    183
  • 1.18 Removing undamaged rear window (Estate)
    184
  • 1.19 Assembly overview - Rear window
    185
  • 1.20 Removing undamaged rear window
    186
  • 1.21 Removing broken rear window
    187
  • 1.22 Refitting rear window
    187
  • 1.23 Preparing old undamaged window for glazing
    188
  • 1.24 Preparing new window for glazing
    188
  • 1.25 Preparing new window without precoating for glazing
    189
  • 1.26 Preparing body flange for glazing
    190
  • 1.27 Installation instructions
    191
  • 1.28 Curing time
    192
  • 1.29 Touching up paint damage
    192
  • 1.30 Cleaning off excess adhesive sealing material
    192
  • 2 Front door windows
    193
  • 2.1 Assembly overview- Front door window
    193
  • 2.2 Removing front door window
    194
  • 2.3 Adjusting door window
    194
  • 2.4 Removing and refitting assembly carrier
    195
  • 3 Rear door windows
    197
  • 3.1 Assembly overview- Rear door window
    197
  • 3.2 Removing rear door window
    198
  • 3.3 Fitting door window to window lifter
    199
  • 3.4 Removing and refitting assembly carrier
    199
  • 3.5 Removing and refitting window motor or assembly carrier with window actuator
    201
  • Exterior equipment
    204
  • 1 Wheelarch liner
    204
  • 1.1 Tools
    204
  • 1.2 Assembly overview - Front wheelarch liner
    204
  • 1.3 Assembly overview - Rear wheelarch liner
    206
  • 2 Rear-view mirror
    207
  • 2.1 Tools
    207
  • 2.2 Assembly overview - Rear-view mirror
    207
  • 2.3 Removing mirror housing
    208
  • 2.4 Removing and refitting mirror housing with indicator
    209
  • 3 Roof railing
    211
  • 3.1 Assembly overview - Roof railing
    211
  • 4 Roof mouldings
    213
  • 4.1 Assembly overview- Roof moulding
    213
  • 4.2 Assembly overview- Outer roof moulding
    214
  • 4.3 Assembly overview - Water deflector
    215
  • 5 Radiator grille
    216
  • 5.1 Assembly overview- Radiator grille ▸ 09.00
    216
  • 5.2 Assembly overview- Radiator grille 10.00 ▸
    217
  • 5.3 Removing release lever
    217
  • 6 Protective strips
    218
  • 6.1 Tools
    218
  • 6.2 Assembly overview- Protective side strips
    218
  • 6.3 Removing and refitting protective side strips
    219
  • 6.4 Assembly overview- Door sill trim
    222
  • 6.5 Assembly overview - Door strips
    223
  • 6.6 Replacing stone-chip protective film
    224
  • 6.7 Replacing kick plate protective film
    225
Manufacturer's designation General body repairs, exterior
Manufacturer Volkswagen
Suitable for Passat / Passat Variant (1997 - 2005)
Suitable car types 3B
Category Reparaturanleitung

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