Volkswagen Passat / Passat Variant (2011 year). 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
5
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 ➤
6
4. Galvanized body parts, high/higher-strength and hot-formed body panels
7
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