Volkswagen Passat / Passat Variant (2011 year). Manual — part 33
Installing
Note
Only welding units authorised by Volkswagen AG may be used
3.3.1
Preparing new part
New part
♦ Roof
♦ 1K assembly adhesive -D 190 MKD A3- (3 cartridges)
♦ 2K body adhesive -D 180 KD3 A2- (2 cartridge sets)
♦ Adhesive sealant -AKD 476 KD5 05-
♦ Cavity sealant -AKR 321 M15 4-
♦ Felt -533 867 910 B-
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.
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3. Renewing roof (Variant)
129
gate aperture.
– Lightly sand down bonding areas -1- on left and right of roof.
This ensures that the 2K body adhesive -D 180 KD3 A2- bonds
well with bonding areas.
– 4 suction lifters -V.A.G 1344- are positioned on outer sides of
roof.
– Position roof on roof frame.
– Check roof fit with windscreen and tailgate.
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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.
– Check line of roof versus roof side members.
♦ Dimension -a- = 4.0 ± 0.5 mm
– If necessary for compensation purposes, place pieces of felt
-533 867 910 B- on roof frame.
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3. Renewing roof (Variant)
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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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