Body Repairs

Chapter overview

• Technical data
  1
• 1 Vehicle identification data
  1
• 1.1 Vehicle identification number
  1
• 1.2 Identification plate
  1
• 1.3 Vehicle data plate
  1
• 2 Body foam insulation
  2
• 3 Galvanized body parts
  3
• 4 Strengthened steel body panels
  4
• 5 Laser welding
  5
• 6 Body panel gaps/shut lines
  6
• 6.1 Body - front (Golf)
  6
• 6.2 Body - rear (Golf)
  8
• 6.3 Body - front (Bora)
  10
• 6.4 Body - rear (Bora)
  12
• 6.5 Body - rear (estate)
  14
• 7 Body dimensions
  16
• 7.1 Body - front
  16
• 7.2 Body - centre
  20
• 7.3 Body - rear (Golf)
  27
• 7.4 Body - rear (Bora)
  30
• 7.5 Body - rear (estate)
  33
• 7.6 Floor group - front
  36
• 7.7 Floor group - centre
  37
• 7.8 Floor group - rear
  38
• 8 Alignment jig
  39
• 8.1 Overview, Golf
  39
• 8.2 Overview, Bora, Bora estate, Golf estate
  50
• 8.3 Overview, Golf 4MOTION
  53
• 8.4 Overview, Bora 4MOTION, Bora estate 4MOTION, Golf estate 4MOTION
  58
• 8.5 Portal gauge (2-door)
  63
• 8.6 Portal gauge (4-door)
  64
• Body - front
  65
• 1 Renewing engine bracket
  65
• 1.1 Right engine console
  65
• 2 Renewing intermediate piece
  67
• 2.1 Removing
  67
• 3 Renewing wing connecting plate
  69
• 3.1 Removing
  69
• 4 Renewing upper wheel housing longitudinal member
  71
• 4.1 Removing
  71
• 5 Renewing front wheel housing
  73
• 5.1 Removing
  73
• 6 Renewing front wheel housing - partial renewal
  75
• 6.1 Removing
  75
• 7 Renewing front longitudinal member
  77
• 7.1 Removing
  77
• 8 Renewing front longitudinal member - partial renewal
  79
• 8.1 Removing
  79
• 9 Renewing front section of longitudinal member
  81
• 9.1 Removing
  82
• Body - centre
  85
• 1 Renewing roof (Golf)
  85
• 1.1 Removing
  86
• 2 Renewing roof (Bora)
  89
• 2.1 Removing
  90
• 3 Renewing roof (estate)
  92
• 3.1 Tools
  92
• 3.2 Dimensions for roof railing
  98
• 4 Renewing front roof cross member
  99
• 4.1 Removing
  99
• 5 Renewing roof reinforcement
  101
• 5.1 Removing
  101
• 6 Renewing rear roof cross member (Golf)
  103
• 6.1 Removing
  103
• 7 Renewing rear roof cross member (Bora)
  105
• 7.1 Removing
  105
• 8 Renewing rear roof cross member (estate)
  107
• 8.1 Removing
  107
• 9 Renewing A-pillar
  109
• 9.1 Removing
  109
• 10 Renewing inner A-pillar
  113
• 10.1 Removing
  113
• 11 Renewing B-pillar (4-door), renewing B-pillar (Bora)
  116
• 11.1 Removing
  117
• 12 Renewing inner B-pillar (2-door)
  119
• 12.1 Removing
  119
• 13 Renewing inner B-pillar (Golf 4-door), renewing inner B-pillar (Bora)
  122
• 13.1 Removing
  122
• 14 Renewing outer side member (2-door)
  126
• 14.1 Removing
  126
• 15.1 Removing
  130
• 16 Renewing side member reinforcement
  132
• 16.1 Includes: Web plate part section
  132
• 17 Renewing floor panel - partial renewal
  135
• 17.1 Removing
  135
• Body - rear
  138
• 1 Renewing rear cross panel (Golf)
  138
• 1.1 Removing
  138
• 2 Renewing outer rear cross panel (estate)
  140
• 2.1 Tools
  140
• 2.2 Removing
  141
• 3 Renewing complete rear cross panel (estate)
  144
• 3.1 Tools
  144
• 3.2 Removing
  144
• 3.3 Welding in lock carrier
  146
• 3.4 Welding in inner side panel
  146
• 3.5 Welding in lower D-pillar reinforcing
  147
• 3.6 D-pillar reinforcing
  148
• 3.7 Welding in inner D-pillar reinforcing
  149
• 3.8 Welding in tail light cluster mounting
  150
• 3.9 Welding cross member to inner rear cross panel
  150
• 4 Renewing rear cross panel (4MOTION)
  151
• 4.1 Removing
  151
• 5 Renewing complete rear cross panel (4MOTION)
  153
• 5.1 Removing
  153
• 6 Renewing centre piece of rear cross panel (Bora)
  157
• 6.1 Removing
  157
• 7 Renewing rear roof cross panel (Bora)
  160
• 7.1 Removing
  160
• 8 Renewing tail light mounting (Golf)
  162
• 8.1 Removing
  162
• 9 Renewing cross member carrier (Golf)
  165
• 9.1 Removing
  165
• 10 Renewing cross member carrier (Bora)
  167
• 10.1 Removing
  167
• 11 Renewing towing eye (4MOTION)
  169
• 11.1 Removing
  169
• 12 Renewing C-pillar reinforcement (estate)
  172
• 12.1 Removing
  172
• 13 Renewing cover plate (Bora)
  174
• 13.1 Removing
  174
• 14 Renewing longitudinal member - partial renewal (Golf)
  176
• 14.1 Removing
  176
• 15 Renewing longitudinal member - partial renewal (4MOTION)
  178
• 15.1 Removing
  179
• 16 Renewing rear longitudinal member (Bora)
  181
• 16.1 Removing
  181
• 17 Renewing longitudinal member - partial renewal (Bora)
  183
• 17.1 Removing
  183
• 18 Renewing side panel - partial renewal (2-door)
  185
• 18.1 Removing
  186
• 19 Renewing side panel - partial renewal (Golf 4-door)
  189
• 19.1 Removing
  190
• 20 Renewing side panel - partial renewal (Bora)
  193
• 20.1 Removing
  193
• 21 Renewing side panel - partial renewal (estate)
  197
• 21.1 Removing
  197
• 22 Renewing outer wheel housing liner - partial renewal (Golf)
  202
• 22.1 Removing
  202
• 23 Renewing outer wheel housing liner - partial renewal (Bora)
  204
• 23.1 Removing
  204
• 24 Renewing outer wheel housing liner - partial renewal (estate)
  207
• 24.1 Removing
  207
• 25 Renewing spare wheel well (Golf)
  210
• 25.1 Removing
  210
• 26 Renewing spare wheel well - partial renewal (Golf)
  212
• 26.1 Removing
  212
• 27 Renewing spare wheel well (4MOTION)
  214
• 27.1 Removing
  214
• 28 Renewing spare wheel well (Bora)
  217
• 28.1 Removing
  217