3 Moulded foam elements

Protected by copyright . Copying for pivate or commerci al pur po s e s , i n p a r t r o r in w ho le, is not permitted unless authorised by Volkswagen AG. Volkswagen AG does notguarantee or accept any liabilit y wi th res pect t o t h e c o r r e c t n e ss o f in format ion in this document. Copyright by Volkswagen AG. 3 Moulded foam elements On this vehicle, various bodywork cavities are fitted with moulded foam elements. The moulded foam elements reduce the amount of driving noise that is transmitted into the interior. The moulded elements are fitted during body shell construction and increase their volume in the paint shop drying oven at approx. 180°C, after priming. Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 The exact location of these moulded foam elements are shown at the beginning of the respective repair description. Caution

The replacement moulded foam elements expand first at ap‐prox. 180° This is why a foam filler is used in some repair cases. The foam filler D 506 KD1 A2 is required for these repair cases.

Protected by copyright . Co ying fo pivate r co merci al pur po e s , i n p a r t r o r in w ho le, is not permitted unless authorised by Volkswagen AG. Volkswagen AG does notguarantee or accept any liabilit y wi th res pect t o t h e c o r r e c t n e ss o f in format ion in this document. Copyright by Volkswagen AG. As these temperatures cannot be achieved under normal work‐shop conditions, proceed as follows: Remove foam material remains on vehicle. s – Apply corrosion protection measures according to guidelines in ⇒ Paint workshop manual: Corrosion and corrosion pro‐tection, attached and welded parts, materials . Prerequisites Before continuing with this procedure, ensure that the part for re‐placement is correctly prepared e.g. cut and adapt to fit, corrosion protection measures. Renewing moulded foam element Fix moulded foam element to vehicle. m Apply foam filler D 506 KD1 A2 to replacement part. Secure new part in position. Gently press new part, in vicinity of moulded foam element, until it makes contact and then weld in. o The foam filler hardens within 25 minutes. r Do not do perform shielded arc welding within 15 mm of foam filler. p Carry out cavity protection to repair area after painting vehicle. Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011