Body Repairs

Chapter overview

• Technical data
  1
• 1 Vehicle identification data
  1
• 1.1 Vehicle chassis number (VIN) - location
  1
• 1.2 Destructive labels (only for Brazil) - VIS
  1
• 1.3 Destructible labels (only for Brazil) - VIS - replacement
  2
• 1.4 Labels on front end - location
  2
• 1.5 Body nameplate
  3
• 1.6 Chassis number - anti-corrosion protection
  4
• 2 Zinc-coated body parts
  5
• 3 High-strength body plat
  6
• 3.1 Front section
  6
• 3.2 Central Part (Gol and Voyage)
  7
• 3.3 Central Part (Saveiro)
  8
• 3.4 Rear part (Gol and Voyage)
  9
• 3.5 Rear part (Saveiro)
  10
• 4 Foam parts/support
  11
• 5 Body clearance dimensions
  14
• 5.1 Front body section
  14
• 5.2 Front body section (Saveiro)
  17
• 5.3 Rear body section (Gol)
  19
• 5.4 Rear body section (Voyage)
  21
• 5.5 Rear body section (Saveiro - extended cab)
  24
• 6 Body dimensions
  27
• 6.1 Body - front section
  28
• 6.2 Body - central section (Gol and Voyage)
  36
• 6.3 Body - central section (Saveiro)
  42
• 6.4 Body - rear section (Gol)
  47
• 6.5 Body - rear section (Voyage)
  50
• 6.6 Body - rear section (Saveiro Extended cab)
  55
• 6.7 Body - rear section (Saveiro Single cab)
  57
• 6.8 Body - rear section (Saveiro Extended and single cab)
  60
• 6.9 Body - lower front section
  61
• 6.10 Body - central lower section (Gol and Voyage)
  65
• 6.11 Body - central lower section (Saveiro)
  67
• 6.12 Body - Rear lower section (Gol)
  69
• 6.13 Body - rear lower section (Voyage)
  72
• 6.14 Body - rear lower section (Saveiro)
  74
• Body - Front section
  76
• 1 Engine support (engine support, right side) - replace
  76
• 1.1 Tools
  76
• 1.2 Remove
  77
• 1.3 Install
  77
• 2 Suspension wedges (Saveiro ▶ BP055162) - replace
  79
• 2.1 Tools
  79
• 2.2 Remove
  80
• 2.3 Install
  80
• 3 Hinge support - replace
  82
• 3.1 Tools
  82
• 3.2 Remove
  83
• 3.3 Install
  83
• 4 Wheel case (upper part) - replace
  86
• 4.1 Tools
  86
• 4.2 Remove
  86
• 4.3 Install
  87
• 5 Wheel housing reinforcement - replace
  90
• 5.1 Tools
  90
• 5.2 Remove
  91
• 5.3 Install
  92
• 6 Front wheel arch - replace
  94
• 6.1 Tools
  94
• 6.2 Remove
  94
• 6.3 Install
  95
• 7 Front wheel housing - partial part - replace
  98
• 7.1 Tools
  98
• 7.2 Remove
  98
• 7.3 Install
  99
• 8 Front longitudinal member - replace
  102
• 8.1 Tools
  102
• 8.2 Remove
  103
• 8.3 Install
  103
• 9 Front longitudinal member - partial part - replace
  105
• 9.1 Tools
  105
• 9.2 Remove
  106
• 9.3 Install
  106
• 10 Fastening support for the front panel - replace
  108
• 10.1 Tools
  108
• 10.2 Remove
  109
• 10.3 Install
  109
• 11 Threads of the assembly mounting fastening points - repair
  111
• 11.1 Thread - repair by inserting new thread
  113
• Body - central section
  115
• 1 Roof (Gol) - replace
  115
• 1.1 Remove
  115
• 1.2 Install
  116
• 2 Roof (Voyage) - replace
  119
• 2.1 Remove
  119
• 2.2 Install
  120
• 3 Roof (Saveiro - extended cab) - replace
  123
• 3.1 Remove
  123
• 3.2 Install
  124
• 4 Roof (Saveiro - single cab) - replace
  128
• 4.1 Remove
  128
• 4.2 Install
  129
• 5 Front roof cross member - replace
  133
• 5.1 Tools
  133
• 5.2 Remove
  133
• 5.3 Install
  134
• 6 Roof reinforcement - replace
  136
• 6.1 Tools
  136
• 6.2 Remove
  136
• 6.3 Welding
  137
• 7 Rear roof cross member (Gol) - replace
  139
• 7.1 Tools
  139
• 7.2 Remove
  139
• 7.3 Install
  141
• 8 Rear roof cross member (Voyage) - replace
  142
• 8.1 Tools
  142
• 8.2 Remove
  142
• 8.3 Install
  144
• 9 Rear roof cross member (Saveiro - single cab) - replace
  145
• 9.1 Tools
  145
• 9.2 Remove
  145
• 9.3 Install
  147
• 10 Rear roof cross member (Saveiro - extended cab) - replace
  149
• 10.1 Tools
  149
• 10.2 Remove
  149
• 10.3 Install
  151
• 11 Pillar A - replace
  153
• 11.1 Tools
  153
• 11.2 Remove
  154
• 11.3 Install
  155
• 12 Internal section of A pillar - replace
  158
• 12.1 Tools
  158
• 12.2 Remove
  159
• 12.3 Install
  160
• 13 Pillar B - external section (Gol and Voyage) - replace
  163
• 13.1 Tools
  163
• 13.2 Remove
  164
• 13.3 Install
  165
• 14 Pillar B - internal section (Gol and Voyage) - replace
  167
• 14.1 Tools
  167
• 14.2 Remove
  167
• 14.3 Install
  169
• 15 Pillar B - internal section (Saveiro - extended cab) - replace
  171
• 15.1 Tools
  171
• 15.2 Remove
  171
• 15.3 Install
  173
• 16 Pillar C - internal section (Saveiro - extended cab) - replace
  174
• 16.1 Tools
  174
• 16.2 Remove
  174
• 16.3 Install
  176
• 17 External side panel reinforcement (Saveiro) - replace
  177
• 17.1 Tools
  177
• 17.2 Remove
  177
• 17.3 Install
  178
• 18 Lower Longitudinal member - external section (Gol and Voyage) - replace
  180
• 18.1 Tools
  180
• 18.2 Remove
  181
• 18.3 Install
  182
• 19 Lower longitudinal member reinforcement (Gol and Voyage) - replace
  185
• 19.1 Tools
  185
• 19.2 Remove
  185
• 19.3 Install
  186
• 20 Floor - partial part - replace
  189
• 20.1 Tools
  189
• 20.2 Remove
  190
• 20.3 Install
  192
• Body - Rear section
  196
• 1 Rear panel (with rear cross member - Gol) - replace
  196
• 1.1 Tools
  196
• 1.2 Remove
  197
• 1.3 Install
  198
• 2 Rear panel (with rear cross member - Voyage) - replace
  201
• 2.1 Tools
  201
• 2.2 Remove
  202
• 2.3 Install
  204
• 3 Rear cross member (Gol) - replace
  208
• 3.1 Tools
  208
• 3.2 Remove
  209
• 3.3 Install
  209
• 4 Luggage compartment floor complement reinforcement (Voyage) - replace
  212
• 4.1 Tools
  212
• 4.2 Remove
  212
• 4.3 Install
  213
• 5 Bucket floor reinforcement (Saveiro) - replace
  215
• 5.1 Tools
  215
• 5.2 Remove
  215
• 5.3 Install
  216
• 6 Tail light housing (Gol) - replace
  219
• 6.1 Tools
  219
• 6.2 Remove
  219
• 6.3 Install
  220
• 7 Tail light housing (Voyage) - replace
  223
• 7.1 Tools
  223
• 7.2 Remove
  223
• 7.3 Install
  224
• 8 Tail light housing (Saveiro) - replace
  227
• 8.1 Tools
  227
• 8.2 Remove
  227
• 8.3 Install
  228
• 9 Luggage compartment floor (partial - Gol) - replace
  231
• 9.1 Tools
  231
• 9.2 Remove
  231
• 9.3 Install
  233
• 10 Luggage compartment floor complement (Voyage) - replace
  235
• 10.1 Tools
  235
• 10.2 Remove
  235
• 10.3 Install
  237
• 11 Rear longitudinal member (partial part - Gol) - replace
  239
• 11.1 Tools
  239
• 11.2 Remove
  239
• 11.3 Install
  240
• 12 Rear longitudinal member (partial part - Voyage) - replace
  243
• 12.1 Tools
  243
• 12.2 Remove
  243
• 12.3 Install
  244
• 13 Rear longitudinal member (partial part - Saveiro) - replace
  246
• 13.1 Tools
  246
• 13.2 Remove
  246
• 13.3 Install
  247
• 14 Side panel (partial part - Gol) - replace
  249
• 14.1 Tools
  249
• 14.2 Remove
  250
• 14.3 Install
  251
• 15 Side panel (partial part - Voyage) - replace
  255
• 15.1 Tools
  255
• 15.2 Remove
  256
• 15.3 Install
  258
• 16 Side panel (partial part - Saveiro - Extended cab) - replace
  262
• 16.1 Tools
  262
• 16.2 Remove
  263
• 16.3 Install
  265
• 17 Side panel (partial part - Saveiro - Extended cab) - replace
  270
• 17.1 Tools
  270
• 17.2 Remove
  271
• 17.3 Install
  273
• 18 Spare wheel housing (Gol and Voyage) - replace
  278
• 18.1 Tools
  278
• 18.2 Remove
  279
• 18.3 Install
  280
• 19 Cargo compartment floor (partial - Saveiro) - replace
  282
• 19.1 Tools
  282
• 19.2 Remove
  283
• 19.3 Install
  284