o1.3 Installing

Protected by copyriht . Copying for pivate r commerci al p r 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. 1.3 Installing Note Only welding units authorised by Volkswagen AG may be used ⇒ page 92 . 1.3.1 Preparing new part New part ♦ Roof u ♦ 1K assembly adhesive -D 190 MKD A3- (3 cartridges) ♦ 2K body adhesive -D 180 KD3 A2- (2 cartridge sets) ♦ Adhesive sealant -AKD 476 KD5 05o ♦ Cavity sealant -AKR 321 M15 4♦ Felt -533 867 910 BNote g♦ Following working sequence must be adhered to in order to ensure correct and long-lasting roof repairs. ♦ For this repair, it is absolutely necessary to work with great Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 care to prevent faults during processing.

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– Lightly sand down bonding areas on left and right of roof. This ensures that the 2K body adhesive -D 180 KD3 A2- bonds well with bonding areas. – 4 suction lifters -V.A.G 1344- are positioned on outer sides of roof.

– Position roof on roof frame.

– Check roof fit with windscreen and rear window. Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011

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. 1.3.2 Adjusting roof depth Note ♦ The securing belts -1- prevent the roof lifting off the roof frame or shifting during the adhesion process. ♦ Securing belts must not be tightened too tightly in order to avoid damage. ♦ Dimension -a- can be set by tightening and loosening tensioning belts, adjusts position roof relative to side parts/panels. ♦ Use setting gauge -3371- to check dimension -a-. Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011

– In areas shown, tension securing belts -T10038- transversely over roof to vary height of roof. – Secure roof in front and rear window apertures using vice-grip pliers. – Check line of roof versus roof side members.

♦ Dimension -a- = 4.0 ± 0.5 mm

– If necessary for compensation purposes, place pieces of felt -533 867 910 B- on roof frame.

Protectd by copyright . Copying fo pivate or co merci 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. 1.3.3 Bonding roof – Remove roof. – Apply corrosion protection measures according to guidelines in ⇒ Paint workshop manual: Corrosion and corrosion pro‐tection, attached and welded parts, materials . – Lightly sand down bonding areas on left and right roof side members. – Clean adhesive surfaces on roof and vehicle with silicone re‐mover -LSE 020 100 A3- . Note m ♦ The adhesive must be applied very quickly. ♦ Always observe the application time (pot life). ♦ Use pneumatic or electric cartridge guns to apply adhesive. r – Cut approx. 2 mm off nozzle -B- to provide appropriate bead geometry. Note e For this repair, it is absolutely necessary to work with great care to prevent faults during processing.

Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011

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– Apply 1K assembly adhesive -D 190 MKD A3- to roof cross member in area of the factory-fitted bonds using compressed air gun -V.A.G 1761/1- .

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– In area of roof side member, apply 1K assembly adhesive -D 190 MKD A3- -1- using pneumatic cartridge gun -

V.A.G 1761/1- .

♦ Dimension -a- = approx. 12 mm ♦ Dimension -b- = approx. 9 mm Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011

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– Apply 1K assembly adhesive -D 190 MKD A3- on inner side of roof parallel to left and right roof flange with pneumatic car‐tridge gun -V.A.G 1761/1- . ♦ Dimension -a- = approx. 4 mm ♦ Dimension -b- = approx. 9 mm

Note

♦ The application time (pot life) of the 2K body adhesive -D 180

KD3 A2- is approx. 90 min. ♦ Remove excessive 2K body adhesive -D 180 KD3 A2- from bonding areas immediately. Once cured 2K body adhesive -D 180 KD3 A2- can only be removed using mechanical means. ♦ An assistant is required for the following work.

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. – Cut first step of static mixer -D- off to achieve corresponding bead cross-section. – Carefully operate double cartridge gun -VAS 5237- without static mixer until adhesive is discharged uniformly from both chambers of cartridge connector. – Screw static mixer onto cartridge connector. – Apply the first 100 mm of adhesive to a piece of cardboard and only then begin to apply the adhesive to the vehicle.

Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011

– Fill area -1- with 2K body adhesive -D 180 KD3 A2- using double cartridge gun -VAS 5237- .

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– Coat roof flanges with 2K body adhesive -D 180 KD3 A2- . – Immediately position and align roof. – Secure roof at front and rear window apertures using vice-grip pliers and also secure centre of roof using securing belts ⇒ page 98 . – Check roof depth dimension and adjust if necessary. – Remove excessive 2K body adhesive -D 180 KD3 A2- along edge of roof immediately using a cloth soaked in silicone re‐mover -LSE 020 100 A3- .

Note

♦ After bonding, vehicle must remain stationary on a level sur‐face for 8-10 hours at room temperature (min. 15 °C) so that adhesive can harden. ♦ No further work should be performed on the vehicle until the „minimum curing time“ has expired.

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Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011

– Weld roof in front and rear window apertures, RP spot weld seam.

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– Apply adhesive sealant -AKD 476 KD5 05- to seam between roof and roof side member to fully seal bonded seam -1-. – After painting, preserve roof cavities -arrow- with corrosionpreventive wax -AKR 321 M15 4- .