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  • Examplepage for repair manual General body repairs
  • Examplepage for repair manual 2 General body repairs
  • Examplepage for repair manual 3 General body repairs

General body repairs

For Passat / Passat Variant

Original Volkswagen repair manual


19,23 €7% VAT incl.

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Language: English

Digital PDF file

5.752 KB

236 Sites

Detailed technical data

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This repair manual contains: Airbag system self-diagnosis, Body - front, Rear lid, Sliding/tilting sunroof, Front bumper, Flush bonded windows, Windows secured with screws, Roof rails, Wheel housing liner, Exterior mirror, Protective strips, Luggage compartment cover, Airbag, Dash panel and Child bench seat. Show more
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Repair manual Passat / Passat Variant General body repairs PDF download has the following content:

Chapter overview

  • Self-diagnosis
    1
  • 1 Airbag system self-diagnosis
    1
  • 1.1 Function
    1
  • 1.2 Test prerequisites for self-diagnosis
    1
  • 1.3 Connecting fault reader V.A.G 1551 and selecting function
    1
  • 1.4 Interrogating fault memory
    3
  • 1.5 Fault table
    4
  • 1.6 Fault table / rapid data transfer
    4
  • 1.7 Erasing fault memory, ending output
    6
  • 1.8 Disabling front passenger side airbag unit ▸ 09.94
    6
  • 2 Airbag system self-diagnosis 10.94 ▸
    10
  • 2.1 Tools
    10
  • 2.2 Function
    10
  • 2.4 Coding airbag control unit J234 with fault reader V.A.G 1551
    16
  • 2.5 Reading measured value block
    18
  • 2.6 Disabling and activating front passenger side airbag unit (adaption) 10.94 ▸
    21
  • 2.7 Test box VAS 5056
    27
  • Body - front
    30
  • 1 Body - front
    30
  • 1.1 Removing and installing lock carrier
    31
  • 1.2 Removing and installing front wing
    31
  • Bonnet, rear lid
    33
  • 1 Bonnet
    33
  • 1.1 Removing and installing bonnet lock cable
    33
  • 2 Rear lid
    34
  • 2.1 Removing and installing rear lid lock (saloon)
    34
  • 2.2 Removing and installing rear lid lock (estate)
    35
  • 2.3 Removing and installing lock cylinder
    36
  • 2.4 Removing gas strut
    37
  • 2.5 Releasing gas from gas strut
    37
  • 2.6 Removing and installing springs
    37
  • 2.7 Adjusting lid (estate)
    38
  • 2.8 Adjusting lid (saloon)
    39
  • Front doors, door components, central locking
    41
  • 1 Front door
    41
  • 1.1 Repairing door
    41
  • 1.2 Repairing door with electric window regulator
    42
  • 1.3 Removing and installing door
    44
  • 1.4 Removing and installing window regulator
    44
  • 1.5 Removing door window
    44
  • 1.6 Fitting door window to window regulator
    45
  • 1.7 Removing and installing outer window guide
    45
  • 1.8 Fitting rail to door window
    46
  • 1.9 Removing inner door seal
    46
  • 1.10 Removing and installing electrical window regulator
    47
  • 1.11 Repairing electric window regulators
    47
  • 1.12 Repairing door handle for central locking
    47
  • 1.13 Removing and installing door handle
    48
  • 1.14 Removing and installing interior actuation
    49
  • 1.15 Maintaining single-key locking
    49
  • 1.16 Repairing door lock with actuating components
    50
  • 1.17 Removing and installing door lock with tolerance compensation
    51
  • 2 Central locking
    53
  • 2.1 Repairing central locking system (saloon)
    53
  • 2.2 Repairing central locking system (estate)
    54
  • 2.3 Installing dual pressure pump (saloon)
    55
  • 2.4 Removing and installing positioning element for fuel tank flap
    55
  • 2.5 Removing and installing front door positioning elements
    55
  • 2.6 Removing and installing rear door positioning elements
    57
  • 2.7 Functional check of central locking
    58
  • Rear doors, door components
    60
  • 1 Rear door
    60
  • 1.1 Repairing door
    60
  • 1.2 Removing and installing door
    61
  • 1.3 Removing and installing window regulator
    62
  • 1.4 Removing and installing door window
    62
  • 1.5 Fitting door window to window regulator
    63
  • 1.6 Removing and installing outer window guide
    63
  • 1.7 Fitting rail to door window
    64
  • 1.8 Repairing rear electric window regulators
    64
  • 1.9 Removing and installing impact bar
    67
  • 1.10 Repairing door lock with actuating components
    68
  • 1.11 Removing and installing door handle
    68
  • 1.12 Removing and installing door lock
    69
  • 1.13 Removing and installing interior actuation
    70
  • 1.14 Removing inner door seal
    70
  • Sunroof
    71
  • 1 Sliding/tilting sunroof
    71
  • 1.1 Tools
    71
  • 1.2 Assembly overview
    71
  • 1.3 Removing and installing sliding/tilting sunroof panel
    73
  • 1.4 Checking and adjusting parallel running
    74
  • 1.5 Removing sliding headliner for sliding/tilting sunroof
    76
  • 1.6 Adjusting sliding/tilting sunroof panel (height adjustment)
    77
  • 1.7 Checking electric drive (zero position)
    77
  • 1.8 Removing and installing sliding/tilting sunroof carrier unit
    78
  • 1.9 Cleaning water drainage hoses
    82
  • 2 Sliding/tilting sunroof with glass panel
    84
  • 2.1 Assembly overview
    84
  • 2.2 Removing and installing sliding/tilting sunroof glass panel
    85
  • 2.3 Adjusting panel seal
    86
  • 2.4 Removing and installing sliding headliner
    87
  • 2.5 Checking parallel running
    88
  • 2.6 Adjusting parallel running
    88
  • 2.7 Adjusting glass panel for sliding/tilting sunroof (height adjustment)
    89
  • 2.8 Checking electric drive (zero position)
    89
  • 2.9 Removing sliding/tilting sunroof carrier unit
    90
  • 2.10 Cleaning water drainage hoses
    90
  • Bumpers
    91
  • 1 Front bumper
    91
  • 1.1 Removing and installing front bumper
    91
  • 1.2 Removing and installing air intake grille
    92
  • 1.3 Removing and installing front bumper from longitudinal member
    92
  • 2 Rear bumper
    94
  • 2.1 Removing and installing rear bumper
    94
  • Glazing
    95
  • 1 Flush bonded windows
    95
  • 1.1 Tools
    95
  • 1.2 Materials
    96
  • 1.3 Assembly overview - Windscreen
    97
  • 1.4 Removing and installing windscreen
    98
  • 1.5 Removing and installing rear window (saloon)
    100
  • 1.6 Removing and installing rear window (estate)
    102
  • 1.7 Preparing old undamaged rear window for glazing
    104
  • 1.8 Preparing new rear window for glazing
    105
  • 1.9 Preparing body flange for glazing
    106
  • 1.10 Installation instructions
    106
  • 1.11 Curing time
    107
  • 1.12 Touching up paint damage
    107
  • 1.13 Cleaning off excess adhesive sealing material
    107
  • 2 Windows secured with screws
    108
  • 2.1 Removing and installing side window (saloon)
    108
  • 2.2 Removing and installing side window (estate)
    109
  • Exterior equipment
    110
  • 1 Roof mouldings
    110
  • 1.1 Roof moulding (saloon)
    110
  • 1.2 Roof moulding (estate)
    111
  • 2 Roof rails
    113
  • 2.1 Removing and installing roof rails
    113
  • 3 Front trim
    114
  • 3.1 Removing and installing radiator grille
    114
  • 4 Wheel housing liner
    115
  • 5 Exterior mirror
    116
  • 5.1 Tools
    116
  • 5.2 Assembly overview
    116
  • 6 Protective strips
    118
  • Interior equipment
    119
  • 1 Interior mirror
    119
  • 1.1 Removing and installing interior mirror
    119
  • 1.2 Repair method using glass-to-metal adhesive
    119
  • 2 Luggage compartment cover
    121
  • 2.1 Retrofitting luggage compartment cover (PR no. 3U2)
    121
  • 3 Retrofitting net partition
    122
  • 3.1 Installing reinforcement plates and lashing eyes
    122
  • 3.2 Widening openings for cover caps in trim panels
    124
  • 3.3 Removing and installing net partition
    125
  • Passenger protection
    127
  • 1 Seat belts
    127
  • 1.1 Safety regulations for belt tensioners
    127
  • 1.2 Disposal of belt tensioner units
    127
  • 1.3 Removing and installing front seat belts with belt tensioner
    127
  • 1.4 Assembly overview - Belt reel with tensioner unit
    129
  • 1.5 Removing and installing belt reel with tensioner unit
    129
  • 1.6 Removing and installing belt height adjusters
    131
  • 1.7 Removing front fitting
    131
  • 1.8 Removing front belt buckle
    132
  • 1.9 Removing and installing rear belt reel
    132
  • 2 Inspecting seat belts
    133
  • 2.1 Points to check
    133
  • 3 Airbag
    137
  • 3.1 Safety precautions when working on the airbag
    137
  • 3.2 Disposal of airbag units
    138
  • 3.3 Deactivating the airbag
    138
  • 3.4 Renewing airbag units following an accident
    138
  • 3.5 Assembly overview - driver airbag unit
    139
  • 3.6 Removing and installing driver airbag unit
    140
  • 3.7 Removing and installing steering wheel
    142
  • 3.8 Removing and installing return spring with slip ring
    143
  • 3.9 Assembly overview - front passenger airbag unit
    143
  • 3.10 Removing and installing front passenger airbag unit
    144
  • 3.11 Removing mounting frame
    146
  • 3.12 Removing and installing airbag control unit J234
    146
  • Trim, insulation
    148
  • 1 Dash panel
    148
  • 1.1 Removing and installing dash panel
    148
  • 1.2 Removing knee pad
    150
  • 1.3 Removing and installing centre console
    151
  • 1.4 Removing handle and trim of handbrake lever
    153
  • 1.5 Removing and installing centre console extension
    154
  • 1.6 Removing and installing driver stowage compartment
    155
  • 1.7 Removing and installing passenger side storage compartment
    156
  • 1.8 Removing glove box
    156
  • 1.9 Repairing glove box lock
    158
  • 2 Door trims
    159
  • 2.1 Tools
    159
  • 2.2 Assembly overview - Front door trim
    159
  • 2.3 Removing and installing front door trim
    161
  • 2.4 Assembly overview - rear door trim
    162
  • 2.5 Removing and installing rear door trim
    164
  • 2.6 Removing and installing door insulation film
    165
  • 3 Trim
    169
  • 3.1 Removing and installing upper A-pillar trim
    169
  • 3.2 Removing and installing lower A-pillar trim
    170
  • 3.3 Removing and installing B-pillar trim
    170
  • 3.4 Removing and installing upper C-pillar trim
    171
  • 3.5 Removing and installing lower C-pillar trim
    172
  • 3.6 Removing and installing lower C-pillar padding
    174
  • 3.7 Removing and installing D-pillar trim (saloon)
    175
  • 3.8 Removing and installing D-pillar trim (estate)
    176
  • 3.9 Removing and installing rear shelf and belt reel cover (saloon)
    177
  • 3.10 Removing and installing belt guide
    178
  • 3.12 Removing and installing rear luggage compartment trim (estate)
    180
  • 3.13 Removing and installing side trim of luggage compartment (saloon)
    181
  • 3.14 Removing rear bumper carrier cover (saloon)
    182
  • 3.15 Removing rear bumper carrier cover (estate)
    183
  • 3.16 Removing and installing rear lid trim (estate)
    184
  • 3.17 Removing and installing cap for rear lid hinges (estate)
    184
  • 3.18 Removing and installing sill panel strip
    185
  • 4 Roof trims
    186
  • 4.1 Removing and installing moulded headliner (saloon)
    186
  • 4.2 Removing and installing moulded headliner with sliding/tilting roof (saloon)
    188
  • 4.3 Removing and installing moulded headliner (estate)
    191
  • 4.4 Removing and installing moulded headliner with sliding/tilting roof (estate)
    192
  • 4.5 Removing, installing, cutting section in roof insulation/reinforcement (RIR)
    196
  • Seat frames
    198
  • 1 Front seats
    198
  • 1.1 Removing and installing seat
    198
  • 1.2 Separating seat frame and backrest frame
    198
  • 1.3 Repairing seat frame (normal and sport seat)
    199
  • 1.4 Repairing seat frame with mechanical height adjustment
    201
  • 1.6 Repairing seat frame with electric height adjustment
    205
  • 1.7 Dismantling and assembling seat frame with electric height adjustment
    207
  • 1.8 Repairing backrest frame
    210
  • 1.9 Renewing backrest frame
    211
  • 2 Rear seats
    213
  • 2.1 Removing and installing (split folding) bench seat and backrest
    213
  • 3 Child bench seat
    214
  • 3.1 Retrofitting child bench seat
    214
  • 3.2 Modifying child bench seat
    216
  • Seat - padding, covers
    218
  • 1 Front seat covers and padding
    218
  • 1.1 Assembly overview - Cover and padding for front seat part
    218
  • 1.2 Removing and installing cover and padding for front seat part
    218
  • 1.3 Assembly overview - Cover and padding for front seat part with height adjustment
    220
  • 1.5 Removing and installing backrest cover and padding
    222
  • 2 Rear seat covers and padding
    224
  • 2.1 Removing and installing covers and padding for bench seat
    224
  • 2.2 Removing and installing covers and padding for (split folding) backrest
    225
  • 2.3 Removing and installing lock (backrest)
    227
  • 2.4 Removing centre armrest
    227
  • 2.5 Removing and installing padding clips
    228
Manufacturer's designation General body repairs
Manufacturer Volkswagen
Suitable for Passat / Passat Variant (1994 - 1997)
Suitable car types 3A
Category Reparaturanleitung

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