Volkswagen Passat / Passat Variant (2011 year). 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
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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