Body Repairs

Chapter overview

• Technical data
  1
• 1 Basic information
  1
• 2 Vehicle identification data
  2
• 2.1 Vehicle identification number (VIN) - localization
  2
• 2.2 Identification number - corrosion protection
  2
• 2.3 Destructive labels (Brazil only) - VIS
  3
• 2.4 Vehicle identification tag
  4
• 3 Safety instructions
  5
• 4 Foam part/support
  6
• 5.1 Body
  7
• 5.2 Overview
  9
• 6 Protection measures against corrosion
  12
• 7 Body clearance dimensions
  13
• 7.1 Front body section
  13
• 7.2 Central section of the body
  14
• 7.3 Rear body section
  16
• 8 Body dimensions
  17
• 8.1 Body - front section
  17
• 8.2 Body - central section
  19
• 8.3 Body - rear section
  27
• 8.4 Body - lower front section
  28
• 8.5 Body - lower central section
  29
• 8.6 Body - lower rear section
  30
• 9 Measurement and alignment system with a set of Celette templates
  31
• 9.1 Overview
  31
• 9.2 Procedures for body structural damages in Volkswagen vehicles
  31
• 10 Alignment platform
  32
• Body - front
  33
• 1 Engine support - right side - replace
  33
• 1.1 Tools
  33
• 1.2 Remove
  33
• 1.3 Install
  35
• 2 Gearbox support - left side - replace
  38
• 2.1 Tools
  38
• 2.2 Remove
  38
• 2.3 Install
  40
• 3 Front bumper support - replace
  43
• 3.1 Tools
  43
• 3.2 Remove
  43
• 3.3 Install
  45
• 4 Front bumper support - replace
  47
• 4.1 Tools
  47
• 4.2 Remove
  47
• 4.3 Install
  49
• 5.1 Tools
  52
• 5.2 Remove
  52
• 5.3 Install
  56
• 6 Front wheel arch - replace
  60
• 6.1 Tools
  61
• 6.2 Remove
  61
• 6.3 Install
  63
• 7 Front longitudinal member - replace
  68
• 7.1 Tools
  69
• 7.2 Remove
  69
• 7.3 Install
  72
• 8 Auxiliary frame support thread - repair
  77
• 8.1 Composition of the Heli-coil M12x1.5 thread set VAS 6058
  79
• 8.2 Thread repair
  79
• Body - centre
  83
• 1 Roof - replace
  83
• 1.1 Tools
  84
• 1.2 Remove
  84
• 1.3 Install
  86
• 2 External side panel - upper region - 2 doors - replace
  97
• 2.1 Tools
  97
• 2.2 Remove
  97
• 2.3 Install
  100
• 3 External side panel - upper region - 4 doors - replace
  106
• 3.1 Tools
  107
• 3.2 Remove
  107
• 3.3 Install
  109
• 4 Front roof cross member - replace
  115
• 4.1 Tools
  115
• 4.2 Remove
  116
• 4.3 Install
  117
• 5 Central roof cross member - replace
  119
• 5.1 Tools
  120
• 5.2 Remove
  120
• 5.3 Install
  121
• 6 Rear roof cross member - replace
  123
• 6.1 Tools
  124
• 6.2 Remove
  124
• 6.3 Install
  125
• 7 A-pillar (external section) - replace
  127
• 7.1 Tools
  128
• 7.2 Remove
  128
• 7.3 Install
  131
• 8 A-pillar reinforcement - replace
  137
• 8.1 Tools
  138
• 8.2 Remove
  138
• 8.3 Install
  141
• 9 B-pillar - replace
  149
• 9.1 Tools
  150
• 9.2 Remove
  150
• 9.3 Install
  153
• 10 B-pillar reinforcement - 2 doors - replace
  161
• 10.1 Tools
  162
• 10.2 Remove
  162
• 10.3 Install
  165
• 11 B-pillar reinforcement - 4 doors - replace
  174
• 11.1 Tools
  175
• 11.2 Remove
  175
• 11.3 Install
  179
• 12 External longitudinal member - 2 doors - replace
  189
• 12.1 Tools
  190
• 12.2 Remove
  190
• 12.3 Install
  192
• 13 Lower longitudinal member reinforcement - partial - replace
  195
• 13.1 Tools
  196
• 13.2 Remove
  196
• 13.3 Install
  198
• 14 Lower longitudinal member rear reinforcement - 2 doors - replace
  201
• 14.1 Tools
  202
• 14.2 Remove
  202
• 14.3 Install
  203
• Body - rear
  207
• 1 Back panel - replace
  207
• 1.1 Tools
  208
• 1.2 Remove
  208
• 1.3 Install
  209
• 2 Back panel side reinforcement - replace
  212
• 2.1 Tools
  213
• 2.2 Remove
  213
• 2.3 Install
  215
• 3 Back panel central reinforcement - replace
  219
• 3.1 Tools
  220
• 3.2 Remove
  220
• 3.3 Install
  221
• 4 Tail light housing - replace
  223
• 4.1 Tools
  224
• 4.2 Remove
  224
• 4.3 Install
  226
• 5 Luggage compartment - replace
  229
• 5.1 Tools
  230
• 5.2 Remove
  230
• 5.3 Install
  231
• 6 C-pillar reinforcement - partial piece - replace
  236
• 6.1 Tools
  237
• 6.2 Remove
  237
• 6.3 Install
  238
• 7 Back longitudinal member - upper section - replace
  241
• 7.1 Tools
  242
• 7.2 Remove
  242
• 7.3 Install
  243
• 8 Rear axle support - replace
  248
• 8.1 Tools
  249
• 8.2 Remove
  249
• 8.3 Install
  250
• 9 Back longitudinal member - partial part - replace
  253
• 9.1 Tools
  254
• 9.2 Remove
  254
• 9.3 Install
  255
• 10 External side panel - 2 doors - replace
  258
• 10.1 Tools
  259
• 10.2 Remove
  259
• 10.3 Install
  262
• 11 External side panel - 4 doors - replace
  269
• 11.1 Tools
  269
• 11.2 Remove
  269
• 11.3 Install
  272