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 Vehicle Identification number - corrosion protection
  2
• 2.3 Destructive labels (Brazil only) - VIS
  3
• 2.4 Destructive labels (Brazil only) - VIS - replacement
  3
• 3 Foam part/support
  4
• 5 Laser welding
  7
• 6 Body clearance dimensions
  8
• 6.1 Front body section
  8
• 6.2 Body - centre section (Polo)
  10
• 6.3 Body - centre section (Virtus)
  12
• 6.4 Rear body section
  14
• 7 Body dimensions
  17
• 7.1 Front body section
  17
• 7.2 Body - centre section (Polo)
  19
• 7.3 Body - centre section (Virtus)
  23
• 7.4 Body - rear section (Polo)
  27
• 7.5 Body - rear section (Virtus)
  29
• 7.6 Body - lower front section
  31
• 7.7 Body - lower centre section
  32
• 7.8 Body - lower rear section (Polo)
  33
• 7.9 Body - lower rear section (Virtus)
  34
• Body - front
  36
• 1 Engine bracket (right side) - replace
  36
• 1.1 Tools
  36
• 1.2 Remove
  37
• 1.3 Install
  37
• 2 Auxiliary frame support thread - repair
  39
• 2.1 M12x1.5 Heli-coil thread repair set VAS 6058
  40
• 2.2 Thread repair
  41
• 3 Front bumper support - replace
  45
• 3.1 Tools
  45
• 3.2 Remove
  46
• 3.3 Install
  46
• 4 Bonnet hinge support - replace
  49
• 4.1 Tools
  49
• 4.2 Remove
  50
• 4.3 Install
  50
• 5 Studs - replace
  53
• Body - centre
  55
• 1 Roof - replace
  55
• 1.1 Roof (Polo) - replace
  55
• 1.2 Roof (Virtus) - replace
  68
• 2 Front roof cross member - replace
  81
• 2.1 Tools
  82
• 2.2 Remove
  82
• 2.3 Install
  83
• 3 Rear roof cross member - replace
  86
• 3.1 Tools
  87
• 3.2 Remove
  87
• 3.3 Install
  88
• 4 Side cuts that are permitted
  92
• 4.1 Side cuts that are permitted (Polo)
  92
• 4.2 Side cuts that are permitted (Virtus)
  92
• 5 External side panel - upper section - replace
  94
• 5.1 External side panel - upper section (Polo) - replace
  94
• 5.2 Outer side panel (upper section) (Virtus) - replace
  104
• 6 Pillar A - replace
  111
• 6.1 Tools
  113
• 6.2 Remove
  113
• 6.3 Install
  115
• 7 A-pillar reinforcement (internal) - replace
  119
• 7.1 Tools
  120
• 7.2 Remove
  120
• 7.3 Install
  121
• 8 B-pillar - replace
  125
• 8.1 Tools
  127
• 8.2 Foam part/support
  127
• 8.3 Remove
  127
• 8.4 Install
  129
• 9 B-pillar reinforcement - replace
  133
• 9.1 Tools
  134
• 9.2 Foam part/support
  134
• 9.3 Remove
  134
• 9.4 Install
  136
• 10 Lower longitudinal member (external section) - replace
  140
• 10.1 Tools
  141
• 10.2 Foam part/support
  142
• 10.3 Remove
  142
• 10.4 Install
  144
• Body - rear
  147
• 1 Back panel - replace
  147
• 1.1 Back panel (Polo) - replace
  147
• 1.2 Back panel (Virtus) - replace
  155
• 2 Rear cross member - replace
  161
• 2.1 Rear cross member (Polo) - replace
  161
• 2.2 Rear cross member (Virtus) - replace
  167
• 3 Tail light cluster housing - replace
  173
• 3.1 Tail light cluster housing (Polo) - replace
  173
• 3.2 Tail light cluster housing (Virtus) - replace
  179
• 4 Luggage compartment floor - replace
  184
• 4.1 Luggage compartment floor (Polo) - replace
  184
• 4.2 Luggage compartment floor (Virtus) - replace
  190
• 5 Rear bumper support - replace
  197
• 5.1 Tools
  198
• 5.2 Remove
  198
• 5.3 Install
  199
• 6 Front longitudinal member (partial part) - replace
  202
• 6.1 Rear longitudinal member (partial part) (Polo) - replace
  202
• 6.2 Rear longitudinal member (Virtus) - replace
  208
• 7 Rear longitudinal member (second cut partial part) - replace
  213
• 7.1 Tools
  214
• 7.2 Foam part/support
  214
• 7.3 Remove
  214
• 7.4 Install
  217
• 8 Rear side panel (partial part) - replace
  226
• 8.1 Rear side panel (partial part) (Polo) - replace
  226
• 8.2 Rear side panel (partial part) (Virtus) - replace
  235
• 9 Wheel housing - replace
  244
• 9.1 Wheel housing (Polo) - replace
  244
• 9.2 Wheel housing (Virtus) - replace
  252
• 10 Wheel housing reinforcement - replace
  260
• 10.1 Tools
  261
• 10.2 Remove
  261
• 10.3 Install
  263