Volkswagen Passat / Passat Variant (2011 year). Service manual - part 37

roof cross members.

– Remove all adhesive residues from left and right roof side

members.

– Touch up paint damage in accordance with Paint Workshop

Manual.

4.3

Installing

Note

Only welding units authorised by Volkswagen AG may be used

⇒ page 141

 .

4.3.1

Preparing new part

New part
♦ Roof
♦ 1K assembly adhesive -D 190 MKD A3- (3 cartridges)

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Note

♦

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

care to prevent faults during processing.

– Drill 8 mm ∅ holes for SG plug weld seam at transition to tail‐

gate aperture.

– Lightly sand down bonding areas on left and right of roof and

on reinforcing frame.

This ensures that the 2K body adhesive -D 180 KD3 A2- bonds

well with bonding areas.

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roof.

– Position roof on roof frame.
– Check roof fit with windscreen and tailgate.

4.3.2

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-.

– In areas shown, tension securing belts -T10038- transversely

over roof to vary height of roof.

– Secure roof in windscreen aperture and tailgate aperture using

vice-grip pliers.

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-533 867 910 B- on roof frame.

4.3.3

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

♦

The adhesive must be applied very quickly.

♦

Always observe the application time (pot life).

♦

Use pneumatic or electric cartridge guns to apply adhesive.

– Cut approx. 2 mm off nozzle -B- to provide appropriate bead

geometry.

Note

For this repair, it is absolutely necessary to work with great care

to prevent faults during processing.

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