15.3 Installing

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. Dimension -a- = 100 mm Note Web plate -2- must not be damaged. – Separate original joint to A-pillar reinforcement -1- and to inner side member. Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011 – 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 239 .

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. 15.3.1 Preparing new part New part ♦ Front side member reinforcement ♦ 2K body adhesive -D 180 KD3 A2– Transfer parting cut to new part and cut out. – Drill holes for SG plug weld seam (8 mm ∅) in area of factoryfitted weld points. Passat 2011 ➤ , Passat Variant 2011 ➤ Body Repairs - Edition 04.2011

15.3.2 Welding in

Note

The new part must be welded in within 90 minutes, or adhesion of adhesive will be impaired.

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

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.

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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 to side member.

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

– Weld in side member front reinforcement, SG plug weld seam and RP spot weld seam (inverter). – Weld in parting cut, SG continuous weld seam. – Weld in transition to A-pillar reinforcement, SG continuous weld seam (qty 3). Length of seam 20 mm, distance between seams 20 mm. – Install side member ⇒ page 232 .