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Side panel, replacing -partial section- wagon Volkswagen Passat B6

Body Collision Repair 8 illustrations ~455 words

Side panel, replacing -partial section- wagon

CAUTIONObserve safety precautions! If welding or cutting with spark-producing devices tools or when plating in foamed areas where gases are produced that are harmful to humans and the environment, these procedures are to be omitted in each case.

Cautions

Note. The following spot welders (inverter) are recommended to carry out spot welding procedures properly.

Special tools, testers and auxiliary items required

  1. Spot welder (Inverter) VAS 6237
  2. Spot welder (Inverter) VAS 6237 L
  3. Spot welder (Inverter) VAS 6238
  4. Accessory kit for spot welder VAS 6238/1
  1. Spot welder (Inverter) VAS 6239
  2. Spot welder (Inverter) VAS 6249

Scheme 293

Scheme 293
Scheme 293

1 - Molded foam part

2 - Separating cut (partial replacement)

A partial side panel replacement is possible with separating cut - 2 - , depending on extent of damage.

3 - Bonded area

Scheme 294

Scheme 294: Removing
Scheme 294: Removing
  1. Perform separating cuts - 1 - and - 3 - as shown, do not damage internal reinforcements.

Dimension - a - = 25 mm

Dimension - b - = 60 mm

  1. Observe replacement panel separating cut at separating cut - 2 -.
  2. At the wheel well, sand through the outer edge
  3. Separate the original connection.

Note. Only use body repair saw V.A.G 1523 to perform separating cuts. Observe replacement panel separating cut.

Scheme 295

Scheme 295
Scheme 295
  1. Grind out laser brazed seams - 1 - in rear lid cut-out.
  1. Separate original joint to tail lamp mount.

Scheme 296

Scheme 296
Scheme 296
  1. Remove residual material.

Note. Completely remove remainder of laser brazed seam and sand weld area down to bare metal.

  1. Completely remove adhesive remains and grind bonding surfaces down to bare metal.
  2. Clean flanged area on wheelhousing (it must be free of dust and grease).

Replacement part

  1. Side panel sub-part, wagon
  2. Molded foam parts
  3. 2K-body adhesive D 180 KD3 A2

Scheme 297

Scheme 297
Scheme 297
  1. Transfer separating cuts onto new part and cut to shape.
  1. Drill holes in side panel for gas-shielded arc plug weld seam, 7 mm.

Observe repair notes.

Molded foam part Elementary Notes, molded foam parts

  1. Place backing plate behind separating cuts on wheel well and D-pillar.

Scheme 298

Scheme 298
Scheme 298
  1. Apply 2K body adhesive D 180 KD3 A2 to adhesive areas. 2 beads each of 3.5 mm.

Note. New part must be installed within 20 minutes, otherwise bonding properties of adhesive will be impaired. For the right side panel, butyl sealing cord must be applied in area of fuel filler neck before welding on.

  1. Align and secure new part with vehicle standing on wheels or alignment bracket set.
  2. Check fit with attachments.

Scheme 299

Scheme 299
Scheme 299
  1. Weld separating cuts, SG stepped seam.
  1. Weld in side panel, Straight-line spot weld seam and gas-shielded arc plug weld seam.

Scheme 300

Scheme 300
Scheme 300
  1. Re-create remaining joint in rear lid cut-out and tail lamp mount.
  1. Flange wheelhousing.
  2. Wipe off escaping adhesive and seal wheelhousing.

Note. The optical characteristics of laser brazed seams in rear lid cut-out which no longer exists due to repairs must be reproduced using adhesive sealant AKD 476 KD5 05 .