Volkswagen Passat / Passat Variant (2011 year). Service manual - part 2

shop conditions, proceed as follows:
Remove foam material remains on vehicle.
– 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.
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.
The foam filler hardens within 25 minutes.
Do not do perform shielded arc welding within 15 mm of foam

filler.
Carry out cavity protection to repair area after painting vehicle.

Passat 2011 ➤ , Passat Variant 2011 ➤

3. Moulded foam elements    

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Galvanized body parts, high/higher-

strength and hot-formed body panels

Working on galvanized body panels ⇒ General Information; Body

Repairs, General Body Repairs ; Steel panel repairs; galvanized

body parts .

4.1

Body

Note

Repairs may only be made according to the manufacture instruc‐

tions in the respective repair manual. Higher-strength and hot-

formed body panels may only be repaired using modern inverter

technology, otherwise the optimum passenger protection after

repairs is not possible. Form tempered steel panels are used in

areas under extreme stress. These panels offer a clearly higher

strength than conventional high-strength panels for less weight.

Work on strengthened body panels must comply with guide lines

in Workshop Manual ⇒ General Information; Body Repairs, Gen‐

eral Body Repairs ; Steel panel repairs, strengthened body panels
The body of the vehicle is predominantly manufactured from

galvanized steel panels.
This illustration shows those parts of the body manufactured from

hot-formed body panels.

Passat 2011 ➤ , Passat Variant 2011 ➤

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4. Galvanized body parts, high/higher-strength and hot-formed body panels    

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