Volkswagen Passat / Passat Variant (2011 year). Manual — part 59

Preparing new part

New part
♦ Side panel
♦ Wing bracket
♦ Moulded foam element
♦ Sealing cord -AKD 497 010 04 R10-
♦ 2K body adhesive -D 180 KD3 A2-

– Transfer parting cuts to side panel and cut out.
– Drill 8 mm ∅ holes in side panel -1- and wing retainer -2- for

SG plug weld seams.

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14. Renewing side member

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Marking areas where no welding work

may be carried out

Note

♦

Mark areas on outer side member where welding is not per‐

mitted due to safety reasons »crash safety«.

♦

The measurements given must be adhered to.

– Mark areas where welding is not permitted.
♦ Dimension -a- = 50 mm
♦ Dimension -b- = 160 mm

14.3.3

Moulded foam elements

Follow repair instructions.
Moulded foam elements ⇒ General Information; Body Repairs,

General Body Repairs ; General Notes; Moulded foam elements

14.3.4

Welding in

Note

♦

The new part must be welded in within 90 minutes, or adhesion

of adhesive will be impaired.

♦

Adhesive must be cleaned from holes for fastening hinges af‐

ter bonding in.

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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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tips.

– Adapt new part with vehicle standing on its wheels or on align‐

ment bracket set and hold in position.

– Check fit with bolt-on parts.

Note

Note prohibited weld areas -1- where welding is not allowed.

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