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General body repairs, exterior

For Passat Var. / Passat Variant

Original Volkswagen repair manual


36,71 €7% VAT incl.

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Language: English

Digital PDF file

42.342 KB

518 Sites

Detailed technical data

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This repair manual contains: Lock carrier, Wings, Bulkhead, Bonnet, Tank flap unit, Door, Central locking, Repair instructions, Side window, Radiator grille and front trim, Exterior mirror, Lettering and emblems and Decorative film / protective film. Show more
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Repair manual Passat Var. / Passat Variant General body repairs, exterior PDF download has the following content:

Chapter overview

  • Body - front
    1
  • 1 Lock carrier
    1
  • 1.1 Assembly overview – lock carrier
    1
  • 1.2 Removing and installing lock carrier
    3
  • 1.3 Moving to and back from service position
    5
  • 2 Wings
    10
  • 2.1 Assembly overview - wing
    10
  • 2.2 Removing and installing wing
    10
  • 3 Bulkhead
    15
  • 3.1 Assembly overview - plenum chamber bulkhead
    15
  • 3.2 Assembly overview - plenum chamber cover
    15
  • 3.3 Removing and installing plenum chamber bulkhead
    16
  • 3.4 Removing and installing plenum chamber cover
    17
  • Bonnet, rear lid
    21
  • 1 Bonnet
    21
  • 1.1 Assembly overview - bonnet
    21
  • 1.2 Assembly overview - Bowden cable
    23
  • 1.3 Assembly overview - gas strut
    23
  • 1.4 Removing and installing bonnet
    24
  • 1.5 Adjusting bonnet
    26
  • 1.6 Removing and installing rear lid lock
    32
  • 1.7 Removing and installing bonnet release lever
    37
  • 1.8 Removing and installing striker pin
    39
  • 1.9 Removing and installing hinges
    41
  • 1.10 Removing and installing insulation
    43
  • 1.11 Removing and installing gas strut
    45
  • 1.12 Releasing gas from gas strut
    47
  • 1.13 Removing and installing Bowden cable
    47
  • 2 Rear lid
    51
  • 2.1 Assembly overview - rear lid
    51
  • 2.2 Assembly overview - gas strut
    54
  • 2.3 Removing and installing rear lid
    55
  • 2.4 Adjusting rear lid
    57
  • 2.5 Removing and installing rear lid lock
    64
  • 2.6 Removing and installing operating mechanism
    76
  • 2.7 Removing and installing hinges
    81
  • 2.8 Removing and installing striker pin
    84
  • 2.9 Removing and installing rear lid seal
    85
  • 2.10 Removing and installing gas strut
    87
  • 2.11 Releasing gas from gas strut
    89
  • 2.12 Removing and installing drive unit for rear lid VX69
    91
  • 2.13 Removing and installing rear lid control unit J605
    96
  • 3 Tank flap unit
    98
  • 3.1 Assembly overview - tank flap unit
    98
  • 3.2 Removing and installing tank flap unit
    98
  • 3.3 Removing and installing fuel tank flap
    101
  • 4 Charging flap unit
    104
  • 4.1 Assembly overview - Charging flap unit
    104
  • 4.2 Removing and installing charging flap unit
    104
  • Front doors, door components, central locking
    107
  • 1 Door
    107
  • 1.1 Assembly overview - door
    107
  • 1.2 Removing and installing inner door seal
    110
  • 1.3 Removing and installing outer door seal
    113
  • 1.4 Removing and installing door
    115
  • 1.5 Adjusting door
    118
  • 1.6 Adjusting striker pin
    121
  • 1.7 Removing and installing door arrester
    123
  • 2 Door components
    126
  • 2.1 Assembly overview - door components
    126
  • 2.2 Assembly overview - window regulator
    128
  • 2.3 Assembly overview - door handle and door lock
    129
  • 2.4 Removing and installing window regulator motor
    130
  • 2.5 Removing and installing window regulator
    133
  • 2.6 Removing and installing inner door cover
    136
  • 2.7 Removing and installing striker pin
    138
  • 2.8 Removing and installing cap on door handle
    140
  • 2.9 Removing and installing lock cylinder
    146
  • 2.10 Removing and installing door handle
    150
  • 2.11 Removing and installing mounting bracket
    154
  • 2.12 Removing and installing door lock
    156
  • 2.13 Removing and installing window channel
    161
  • 2.14 Removing and installing window slot inner seal
    164
  • 2.15 Removing and installing window slot outer seal
    165
  • 3 Central locking
    167
  • 3.1 Overview of fitting locations - central locking
    167
  • 3.2 Assembly overview - ignition key
    169
  • 3.3 Removing and installing bonnet contact switch F266
    170
  • 3.6 Removing and installing tank filler flap locking motor V155
    174
  • 3.7 Removing and installing actuator for high-voltage charging flap lock 1 F496
    175
  • 3.8 Removing and installing ignition key battery
    176
  • 3.9 Removing and installing cap on ignition key
    178
  • Rear doors, door components
    179
  • 1 Door
    179
  • 1.1 Assembly overview - door
    179
  • 1.2 Removing and installing door
    182
  • 1.3 Adjusting door
    184
  • 1.4 Adjusting striker pin
    187
  • 1.5 Removing and installing door arrester
    189
  • 1.6 Removing and installing inner door seal
    191
  • 1.7 Removing and installing outer door seal
    194
  • 2 Door components
    197
  • 2.1 Assembly overview - door components
    197
  • 2.2 Assembly overview - window regulator
    199
  • 2.3 Assembly overview - door handle and door lock
    199
  • 2.4 Removing and installing window regulator motor
    200
  • 2.5 Removing and installing window regulator
    203
  • 2.6 Removing and installing inner door cover
    206
  • 2.7 Removing and installing striker pin
    208
  • 2.8 Removing and installing cap on door handle
    210
  • 2.9 Removing and installing door handle
    215
  • 2.10 Removing and installing mounting bracket
    219
  • 2.11 Removing and installing door lock
    222
  • 2.12 Removing and installing window channel
    226
  • 2.13 Removing and installing window slot outer seal
    229
  • 2.14 Removing and installing window slot inner seal
    231
  • Sunroof
    232
  • 1 Sliding sunroof
    232
  • 1.1 Assembly overview - sliding sunroof
    232
  • 1.2 Assembly overview - sunroof roller blind
    234
  • 1.3 Removing and installing sunroof panel
    235
  • 1.4 Removing and installing rear sunroof panel
    239
  • 1.5 Adjusting sunroof panel
    243
  • 1.6 Removing and installing sliding sunroof frame
    247
  • 1.7 Removing and installing wind deflector
    249
  • 1.8 Removing and installing sunroof motor V1
    251
  • 1.9 Removing and installing sunroof roller blind motor V260
    253
  • 1.10 Removing and installing sunroof roller blind control unit J394
    255
  • 1.11 Removing and installing sliding sunroof adjustment control unit J245
    256
  • 1.12 Removing and installing sliding sunroof seals
    258
  • 1.13 Removing and installing sunroof roller blind
    263
  • 1.14 Programming sliding sunroof adjustment control unit J245
    266
  • 1.15 Adapting sunroof roller blind control unit J394
    266
  • 1.16 Removing and installing rear part
    266
  • 1.17 Removing and installing tilt mechanism for sliding sunroof
    271
  • 1.18 Removing and installing sunroof roller blind cable
    273
  • 1.19 Operating without current
    275
  • 2 Water drain hoses
    276
  • 2.1 Assembly overview - water drainage hoses
    276
  • 2.2 Cleaning water drain hoses
    276
  • 2.3 Removing and installing water drain hoses
    278
  • Bumpers
    280
  • 1 Bumper, front
    280
  • 1.1 Assembly overview - bumper cover
    280
  • 1.2 Assembly overview - add-on parts
    284
  • 1.3 Assembly overview - impact bar
    292
  • 1.4 Removing and installing bumper cover
    293
  • 1.5 Removing and installing add-on parts
    297
  • 1.6 Repairing bumper cover
    314
  • 1.7 Installing brackets for parking aid system
    314
  • 1.8 Installing brackets for park assist steering
    319
  • 2 Bumper, rear
    323
  • 2.1 Assembly overview - bumper cover
    323
  • 2.2 Assembly overview - guides for bumper cover
    325
  • 2.3 Assembly overview - add-on parts
    326
  • 2.4 Assembly overview - impact bar
    329
  • 2.5 Removing and installing bumper cover
    330
  • 2.6 Removing and installing add-on parts
    334
  • 2.7 Removing and installing impact bar
    342
  • 2.8 Repairing bumper cover
    344
  • 2.9 Installing brackets for parking aid system
    345
  • 2.10 Installing brackets for park assist steering
    350
  • Glazing
    354
  • 1 Repair instructions
    354
  • 1.1 Minimum curing periods for bonded windows
    354
  • 1.2 Window repair
    354
  • 1.3 Installation instructions for bonded windows
    355
  • 1.4 Preparing old undamaged windows for fitting
    356
  • 1.5 Preparing new windows for installing
    357
  • 1.6 Preparing body flange for fitting
    357
  • 1.7 Cleaning off excess adhesive
    359
  • 2 Windscreen
    360
  • 2.1 Assembly overview - windscreen
    360
  • 2.2 Removing and installing windscreen
    361
  • 3 Rear windscreen
    369
  • 3.1 Assembly overview - rear window
    369
  • 3.2 Removing and installing rear window
    370
  • 4 Side window
    374
  • 4.1 Assembly overview - rear side windows
    374
  • 4.2 Removing and installing rear side window
    375
  • 5 Door windows
    378
  • 5.1 Assembly overview - front door window
    378
  • 5.2 Assembly overview - rear door window
    378
  • 5.3 Removing and installing front door window
    379
  • 5.4 Removing and installing rear door window
    382
  • 5.5 Removing and installing fixed front door window
    384
  • 5.6 Removing and installing fixed rear door window
    386
  • Exterior equipment
    389
  • 1 Radiator grille and front trim
    389
  • 1.1 Assembly overview - radiator grille
    389
  • 1.2 Removing and installing radiator grille
    392
  • 1.3 Removing and installing radiator grille seal, R-Line models as of 07.2019
    394
  • 2 Spoiler
    396
  • 2.1 Assembly overview - spoiler
    396
  • 2.2 Removing and installing spoiler
    398
  • 3 Mouldings, trims, extensions
    408
  • 3.1 Assembly overview - trim strip and covers
    408
  • 3.2 Assembly overview - side member trim
    410
  • 3.3 Assembly overview - water deflector
    412
  • 3.4 Assembly overview - heat shield
    413
  • 3.5 Removing and installing cover
    415
  • 3.6 Removing and installing wheel arch covers
    420
  • 3.7 Removing and installing side member trim
    428
  • 3.8 Removing and installing water deflector
    433
  • 3.9 Removing and installing B-pillar trim on door
    434
  • 3.10 Removing and installing trim strip
    436
  • 3.11 Removing and installing entry moulding
    442
  • 3.12 Removing and installing underbody heat shield
    445
  • 4 Noise insulation
    450
  • 4.1 Assembly overview - noise insulation
    450
  • 5 Underbody cladding
    453
  • 5.1 Overview of fitting locations - trim
    453
  • 5.2 Assembly overview - bracing on underbody
    458
  • 5.3 Removing and installing underbody cladding
    459
  • 5.4 Removing and installing tunnel cross-piece
    464
  • 6 Roof moulding and roof railing
    467
  • 6.1 Assembly overview - roof railing
    467
  • 6.2 Removing and installing roof railing
    467
  • 7 Exterior mirror
    472
  • 7.1 Assembly overview - exterior mirror
    472
  • 7.2 Removing and installing exterior mirror
    474
  • 7.3 Removing and installing mirror glass
    476
  • 7.4 Removing and installing mirror adjustment unit
    478
  • 7.5 Removing and installing mirror cover
    480
  • 7.6 Removing and installing mirror frame
    481
  • 8 Wheel housing liner
    483
  • 8.1 Assembly overview - front wheel housing liner
    483
  • 8.2 Assembly overview - rear wheel housing liner
    484
  • 8.3 Removing and installing front wheel housing liner
    484
  • 8.4 Removing and installing rear wheel housing liner
    486
  • 9 Lettering and emblems
    490
  • 9.1 Dimensions - lettering and emblems on rear
    490
  • 9.2 Dimensions - lettering and emblems on sides
    494
  • 9.3 Removing and installing badges at front
    494
  • 9.4 Removing and installing lettering
    499
  • 10 Decorative film / protective film
    501
  • 10.1 Removing and installing protective film
    501
  • 11 Special add-on parts
    504
  • 11.1 Assembly overview – special add-on parts
    504
  • 12 Towing bracket
    506
  • 12.1 Assembly overview - towing bracket
    506
  • 12.2 Removing and installing towing bracket
    507
  • 12.3 Removing and installing trigger unit
    509
Manufacturer's designation General body repairs, exterior
Manufacturer Volkswagen
Suitable for Passat Var. (2015 >) / Passat Variant (2019 >)
Suitable car types 3G5, CB5
Category Reparaturanleitung

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