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Passat Variant 2011
Volkswagen Passat Variant 2011 User Manual
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Workshop Manual
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General body repairs, exterior
Edition 06.2019
Service
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Table of Contents
Default Chapter
3
Table of Contents
3
Technical Data
11
Safety Information
11
Safety Measures When Working on Vehicles with a Start/Stop System
11
Body - Front
12
Lock Carrier
12
Assembly Overview - Lock Carrier
12
Service Position
13
Removing and Installing Lock Carrier
18
Wings
21
Assembly Overview - Front Wing
21
Removing and Installing Front Wing
22
Bulkhead
25
Assembly Overview - Plenum Chamber Bulkhead
25
Assembly Overview - Plenum Chamber Cover
27
Removing and Installing Plenum Chamber Cover
27
Bonnet, Rear Lid
31
Bonnet (Hood)
31
Assembly Overview - Bonnet
31
Removing and Installing Bonnet
31
Removing Gas Strut
35
Releasing Gas from Gas Strut
35
Assembly Overview - Bonnet Hinge
35
Removing and Installing Bonnet Hinge
36
Removing and Installing Insulation
39
Assembly Overview - Bonnet Lock and Release Components
41
Removing and Installing Bonnet Lock
41
Detaching Bowden Cable
43
Adjusting Bonnet
43
Removing and Installing Release Lever
46
Rear Lid (Saloon)
47
Tools
47
Assembly Overview - Rear Lid
47
Removing and Installing Rear Lid
48
Removing Gas Strut
50
Installing Gas Strut
51
Releasing Gas from Gas Strut
52
Assembly Overview - Rear Lid Hinge
52
Removing and Installing Rear Lid Hinge
53
Assembly Overview - Hinge Seal
56
Removing and Installing Hinge Seal
57
Removing and Installing Striker Pin
59
Adjusting Rear Lid
59
Assembly Overview - Release Element
62
Removing and Installing Release Element
63
Removing and Installing Bonnet Lock
65
Rear Lid Seal
66
Removing and Installing Rear Lid Seal
67
Rear Lid (Estate)
69
Tools
69
Assembly Overview - Rear Lid
69
Removing and Installing Rear Lid
70
Removing and Installing Rear Lid Hinge
72
Removing and Installing Bonnet Lock
74
Removing and Installing Striker Pin
76
Removing and Installing Release Button (Vehicle Identification Number > 3C-8E108000 / 3C-8P064070)
77
Removing and Installing Release Button (Vehicle Identification Number 3C-8E108001 / 3C-8P064071 >)
79
Adjusting Rear Lid
81
Removing and Installing Gas Strut
85
Releasing Gas from Gas Strut
85
Removing and Installing Motor in Control Unit for Electrically Operated Rear Lid
85
Rear Lid Seal
89
Removing and Installing Rear Lid Seal
89
Assembly Overview - Cover
92
Tank Flap Unit
93
Tools
93
Assembly Overview - Tank Flap Unit and Actuator
93
Assembly Overview - Tank Flap Unit for Natural Gas Vehicles
95
Removing and Installing Tank Flap Unit
96
Removing and Installing Actuator
98
Front Doors, Door Components, Central Locking
99
Rear Door
99
Tools
99
Assembly Overview - Front Door
100
Assembly Overview - Door Hinges
102
Removing and Installing Door
103
Adjusting Door
105
Door Components
107
Tools
107
Assembly Overview - Assembly Carrier
108
Removing and Installing Subframe
108
Assembly Overview - Door Handle and Door Lock
114
Removing and Installing Lock Cylinder Housing Cover Cap
115
Removing and Installing Lock Cylinder Housing
116
Removing and Installing Door Handle
117
Removing and Installing Door Handle with Access and Start Authorisation
118
Removing and Installing Door Lock
120
Removing and Installing Mounting Bracket
124
Removing and Installing Retaining Bracket
127
Inner Door Seal
128
Removing and Installing Inner Door Seal
129
Removing and Installing Outer Door Seal
130
Assembly Overview - Insulation
134
Central Locking
135
Fitting Location Overview - Central Locking Components
135
Adapting Remote Control Keys to Remote Control
137
System)
137
Adapting Remote Control Keys to Immobilizer (Vehicles with or Without Entry and Start Authorisation System)
137
Removing and Installing Remote Control Key Battery
137
Rear Doors, Door Components
140
Rear Door (Saloon)
140
Tools
140
Assembly Overview - Rear Door
141
Assembly Overview - Door Hinges
143
Removing and Installing Door
144
Adjusting Door
146
Rear Door (Estate)
148
Tools
148
Assembly Overview - Rear Door
149
Assembly Overview - Door Hinges
150
Removing and Installing Door
152
Adjusting Door
155
Door Components
157
Tools
157
Assembly Overview - Assembly Carrier
158
Removing and Installing Subframe
158
Assembly Overview - Door Handle and Door Lock
165
Removing and Installing Lock Cylinder Housing Cover Cap
166
Removing and Installing Lock Cylinder Housing
167
Removing and Installing Door Handle
168
Removing and Installing Door Handle with Access and Start Authorisation
169
Removing and Installing Door Lock
171
Removing and Installing Mounting Bracket
174
Removing and Installing Retaining Bracket
177
Door Inner Seals
178
Removing and Installing Inner Door Seal
179
Removing and Installing Outer Door Seal
180
Assembly Overview - Insulation
184
Sunroof
185
Sliding/Tilting Sunroof with Glass Panel (Meritor)
185
Tools
185
Function
185
Assembly Overview - Sliding/Tilting Sunroof with Glass Panel
186
Removing and Installing Bellows
189
Removing Sliding/Tilting Sunroof Glass Panel
190
Installing Sliding/Tilting Sunroof Glass Panel
191
Adjusting Height of Sliding/Tilting Sunroof Glass Panel
191
Adjusting Panel Seal
192
Removing and Installing Panel Seal
193
Removing and Installing Wind Deflector
193
Removing and Installing Sliding Headliner
194
Removing and Installing Sliding/Tilting Sunroof Glass Panel Drive
195
Adjusting Drive for Sliding/Tilting Sunroof Glass Panel ("0" Position)
196
Removing and Installing Sliding/Tilting Sunroof Glass Panel Automatic Preselection Switch
197
Checking Parallel Running
197
Adjusting Parallel Running
197
Assembly Overview - Carrier Unit
198
Removing and Installing Carrier Unit
199
Operating Without Current
202
Removing and Installing Guide Plate
202
Removing and Installing Guide Plate
203
Cleaning Water Drainage Hoses
204
Sliding/Tilting Sunroof with Solar Panel (Webasto)
207
Tools
207
Function
207
Assembly Overview - Sliding/Tilting Sunroof with Solar Panel
208
Removing Sliding/Tilting Sunroof Solar Panel
209
Installing Sliding/Tilting Sunroof Solar Panel
210
Adjusting Sliding/Tilting Sunroof Solar Panel Height
210
Checking Parallel Running of Solar Panel
211
Adjusting Parallel Running of Solar Panel
212
Renewing Panel Seal
212
Removing Wind Deflector
212
Removing Solar Panel Trim
213
Removing Sliding/Tilting Sunroof Drive
213
Adjusting Drive for Sliding/Tilting Sunroof (Zero Position)
214
Removing Pre-Selector Control for Sliding/Tilting Sunroof
215
Removing Electrical Contact in Solar Roof
215
Removing Electrical Contact for Sliding/Tilting Sunroof Solar Panel in Carrier Unit
215
Removing and Installing Carrier Unit
216
Operating Without Current
219
Cleaning Water Drainage Hoses
219
Panorama Sliding Sunroof (Arvin-Meritor)
222
Tools
222
Function
222
Basic Setting, Panoramic Sliding Sunroof
223
Assembly Overview - Panoramic Sliding Roof
223
Removing and Installing Front Glass Panel
225
Removing and Installing Rear Glass Panel
229
Adjusting Height of Front and Rear Glass Panel
231
Renewing Seals for Rear Glass Panel
233
Removing and Installing the Exterior Seal
237
Removing and Installing Interior Seal
239
Removing and Installing Wind Deflector
241
Removing and Installing Preselector for Glass Panel and Sunroof Sun Blind
244
Removing and Installing Sliding Sunroof Motor
245
Removing and Installing Sun Blind Motor
248
Removing and Installing Sun Blind
251
Removing and Installing Sunroof Sun Blind Cross Strut
259
Assembly Overview - Assembly Frame
260
Removing and Installing Sun Blind Bowden Cable
261
Removing and Installing Assembly Frame
265
Removing and Installing Rear Part
268
Removing and Installing Front Motor Plate
272
Removing and Installing Tilting Mechanism and Front Glass Panel Cable
275
Maintenance and Care
279
Operating Without Current
280
Cleaning Water Drainage Hoses
281
Bumpers
284
Front Bumper Cover
284
Tools
284
Repairing Front Bumper Cover
284
Installing Brackets for Parking Aid System
284
Assembly Overview - Front Bumper Cover
289
Removing and Installing Front Bumper Cover
290
Front Bumper Cover Add-On Parts
292
Front Bumper Cover Add-On Parts, Passat Alltrack
294
Front Bumper Cover Substructure Parts
295
Assembly Overview - Front Bumper Carrier
296
Assembly Overview - Front Bumper Carrier (USA)
297
Number Plate Carrier
298
Rear Bumper Cover (Saloon)
301
Tools
301
Repairing Rear Bumper Cover
301
Installing Brackets for Parking Aid System
301
Bumper, Rear
306
Rear Bumper Cover Add-On Parts 11.2010
311
Assembly Overview - Rear Bumper Carrier
312
Assembly Overview - Towing Bracket
312
Removing and Installing Drive for Swivelling Ball Head
314
Rear Bumper Cover (Estate)
315
Tools
315
Repairing Rear Bumper Cover
315
Installing Brackets for Parking Aid System
315
Bumper, Rear
320
Rear Bumper Cover Add-On Parts
325
Rear Bumper Cover Add-On Parts, Passat Alltrack
326
Assembly Overview - Rear Bumper Carrier
327
Assembly Overview - Towing Bracket
327
Removing and Installing Drive for Swivelling Ball Head
329
Glazing
330
Flush Bonded Windows
330
Tools
330
Materials
331
Repairing Windscreen
332
Assembly Overview - Windscreen
332
Removing Windscreen
333
Installing Windscreen
335
Assemble Overview - Rear Window (Saloon)
336
Removing Undamaged Rear Window (Saloon)
337
Removing Broken Rear Window (Saloon)
338
Installing Rear Window (Saloon)
338
Assembly Overview - Rear Window (Estate)
338
Removing Undamaged Rear Window (Estate)
339
Removing Broken Rear Window (Estate)
340
Installing Rear Window (Estate)
341
Assembly Overview - Side Window (Estate)
341
Removing Undamaged Side Window (Estate)
343
Removing Broken Side Window (Estate)
344
Installing Side Window (Estate)
344
Preparing Old Undamaged Window for Glazing
345
Preparing New Window Without Precoating for Glazing
345
Preparing Body Flange for Glazing
346
Fitting Instructions
348
Minimum Curing Period
351
Touching up Paint Damage
351
Cleaning in the Event of Dirt Caused by Adhesive Sealant
351
Front Door Window
352
Tools
352
Assembly Overview
353
Removing and Installing Door Window
354
Removing and Installing Window Regulator Motor
358
Removing and Installing Window Channel
359
Removing and Installing Window Channel Trim Strip
362
Rear Door Window (Saloon)
364
Tools
364
Assembly Overview
365
Removing and Installing Door Window
366
Removing and Installing Window Regulator Motor
370
Removing and Installing Window Channel
371
Removing and Installing Window Channel Trim Strip
373
Rear Door Window (Estate)
375
Tools
375
Assembly Overview
376
Removing and Installing Door Window
377
Removing and Installing Window Regulator Motor
382
Removing and Installing Window Channel
383
Removing and Installing Guide Rails
384
Removing and Installing Window Channel Trim Strip
385
Exterior Equipment
387
Wheel Housing Liner
387
Tools
387
Assembly Overview - Front Wheel Housing Liner
387
Assembly Overview - Rear Wheel Housing Liner
389
Removing and Installing Front Wheel Housing Liner
390
Removing and Installing Rear Wheel Housing Liner
392
Exterior Mirror
394
Tools
394
Assembly Overview - Exterior Mirror
394
Removing and Installing Mirror Glass
395
Removing and Installing Mirror Housing
397
Removing and Installing Trim
398
Removing and Installing Side Turn Signal and Entry Light in Exterior Mirror
399
Removing and Installing Exterior Mirror
401
Radiator Grille
402
Tools
402
Removing and Installing Emblem
405
Removing and Installing Emblem in Vehicles with Adaptive Cruise Control
407
Assembly Overview - Number Plate Carrier
408
Removing and Installing Number Plate Carrier
409
Roof Railing
411
Tools
411
Assembly Overview - Roof Railing
411
Removing and Installing Roof Railing
412
Assembly Overview - Roof Railing Retaining Bracket
415
Removing and Installing Roof Railing Retaining Bracket
416
Mouldings and Trims
419
Tools
419
Assembly Overview - Water Deflector
420
Removing and Installing Water Deflector
420
Front and Rear Door Covers
423
Assembly Overview - Side Member Extension
426
Assembly Overview - Rear Lid Trim Strip, Saloon
427
Removing and Installing Rear Side Window Trim Strip
428
Wheel Arch Trim
429
R-Line" and "Exclusive" Cover Strip
430
Noise Insulation
432
Tools
432
Assembly Overview - Noise Insulation
432
Removing and Installing Noise Insulation
435
Skid Plate
436
Assembly Overview - Skid Plate
436
Removing and Installing Skid Plate
437
Removing and Installing Skid Plate Bracket
438
Tunnel Cross-Piece
439
Tools
439
Assembly Overview - Tunnel Cross-Piece
440
Underbody Cladding
441
Tools
441
Assembly Overview - Underbody Cladding
441
Fuel Tank Covers (Natural Gas Vehicles)
443
Assembly Overview - Heat Shield
444
Add-On Parts, Passat Alltrack
445
Safety Requirements
445
Fitting Instructions for Add-On Parts
445
Tools
445
Materials
446
Assembly Overview - Add-On Parts
446
Side Member Extension
447
Front Wheel Housing Trim
449
Rear Wheel Arch Trim
451
Preparing Body Component for Bonding
453
Fitting Instructions
454
Minimum Curing Period
454
Touching up Paint Damage
454
Cleaning Guidelines
454
Special Add-On Parts
455
Safety Requirements
455
Assembly Overview - Add-On Parts
455
Assembly Overview - Side Member Extension
458
Roof Spoiler (Estate)
459
Fitting Instructions
464
Preparing Add-On Parts for Bonding
464
Preparing New Add-On Part for Bonding
465
Preparing Body Component for Bonding
465
Fitting Instructions
465
Minimum Curing Period
466
Touching up Paint Damage
466
Cleaning in the Event of Dirt Caused by Adhesive Sealant
466
Cleaning Guidelines
466
Lettering and Emblems
467
Removing and Installing Emblems at Rear
467
Tools
467
Fitting Instructions
468
Rear Lettering - Dimensions
468
Lettering on Wing
471
Scuff Protection Film
473
Scuff Protection Film at Front and Rear
473
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Volkswagen Passat Variant 2011 Specifications
General
Brand
Volkswagen
Model
Passat Variant 2011
Category
Automobile
Language
English
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