10.3 Installing

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– Remove remaining material. – Remove remaining adhesive completely and grind bonded surface back to bare metal.

Note

Only welding units authorised by Volkswagen AG may be used ⇒ page 193 .

10.3.1 Preparing new part

New part ♦ A-pillar reinforcement ♦ Moulded foam element

♦ 2K body adhesive -D 180 KD3 A2Passat 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. Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011

– Transfer parting cut to new part and cut out. – Drill holes for SG plug weld seam (8 mm ∅). – Clip new moulded foam element -2- into hinge reinforcing -1-.

– Apply 2K body adhesive -D 180 KD3 A2- in the areas indica‐ted.

10.3.2 Moulded foam elements

Follow repair instructions. Moulded foam elements ⇒ General Information; Body Repairs, General Body Repairs ; General Notes; Moulded foam elements Position of the moulded foam elements ⇒ page 4

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. 10.3.3 Welding in Note ♦ In the area of the A, B and C-pillars, high tensile, highest tensile and hot formed steels are used. The weld flanges in these areas are about 13mm wide. ♦ If spot welds are located at the edge of hot formed steel panels, the high temperature will cause the bond between the panels to change, which will subsequently have an effect on crash safety. Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011

Therefore, locate spot welds as close to the centre as possible. • Dimension -a- of 8mm can be achieved using angled welding tips. – Adapt new part with vehicle positioned on alignment bracket set and fix in place. – Check fit with bolt-on parts.

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– Weld in A-pillar reinforcement, SG plug weld seam and RP spot weld seam (inverter). – Recreate original joint to front wheel housing, MIG solder seam.

– Weld in parting cut, SG continuous weld seam. – Install A-pillar ⇒ page 185 .