Body Repairs

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety precautions when working with moulded foam inserts
  1
• 2 Key vehicle data
  2
• 2.1 Vehicle identification number
  2
• 2.2 Type plate
  2
• 2.3 Vehicle data sticker
  2
• 3 Moulded foam inserts
  3
• 4 Galvanized body parts, high strength and hot-formed body panels
  5
• 5 Laser welding
  6
• 6 Tools
  7
• 7 Body - gaps
  8
• 7.1 Body - front gaps
  8
• 7.2 Body - centre gaps
  14
• 7.3 Body - rear gaps
  16
• 8 Body dimensions
  20
• 8.1 Preliminary work for determining body dimensions
  20
• 8.2 Body, front
  20
• 8.3 Body, centre
  22
• 8.4 Body, rear
  28
• 8.5 Floor panel, front
  29
• 8.6 Floor panel, centre
  30
• 8.7 Floor panel, rear
  32
• 9 Alignment bracket systems
  34
• 9.1 Alignment set VW Caddy 2020> VAS 801 113
  34
• 10 Portal gauge
  35
• 10.1 Portal gauge VW Caddy 2020> VAS 802 113
  35
• Body - front
  36
• 1 Renewing front bumper carrier
  36
• 1.1 Removing front bumper carrier
  36
• 1.2 Installing front bumper carrier
  37
• 2 Renewing battery carrier
  40
• 2.1 Removing battery tray
  40
• 2.2 Installing battery tray
  41
• 3 Renewing right-hand bracket
  44
• 3.1 Removing right-hand bracket
  44
• 3.2 Installing right-hand bracket
  45
• 4 Renewing hinge reinforcement
  48
• 4.1 Removing hinge reinforcement
  48
• 4.2 Installing hinge reinforcement
  49
• 5 Renewing upper inner wheel housing longitudinal member, part section
  52
• 5.1 Assembly overview – upper inner wheel housing longitudinal member, part section
  52
• 5.2 Removing – upper inner wheel housing longitudinal member, part section
  53
• 5.3 Installing – upper inner wheel housing longitudinal member, part section
  54
• 6 Renewing upper outer wheel housing longitudinal member
  58
• 6.1 Assembly overview – upper outer wheel housing longitudinal member
  58
• 6.2 Removing upper outer wheel housing longitudinal member
  58
• 6.3 Installing upper outer wheel housing longitudinal member
  60
• 7 Renewing upper outer wheel housing longitudinal member, part section
  64
• 7.2 Removing – upper outer wheel housing longitudinal member, part section
  65
• 7.3 Installing – upper outer wheel housing longitudinal member, part section
  66
• 8 Renewing front left longitudinal member, part section 1
  70
• 8.1 Removing – front left longitudinal member, part section 1
  70
• 8.2 Installing – front left longitudinal member, part section 1
  72
• 9 Renewing front right longitudinal member, part section 1
  76
• 9.1 Removing – front right longitudinal member, part section 1
  76
• 9.2 Installing – front right longitudinal member, part section 1
  78
• 10 Renewing retaining bracket for subframe
  82
• Body - centre
  83
• 1 Renewing roof
  83
• 2 Renewing roof side member, part section (vehicles with sliding door)
  84
• 2.1 Assembly overview – roof side member, part section (vehicles with sliding door)
  84
• 2.2 Removing – roof side member, part section (vehicles with sliding door)
  86
• 2.3 Installing – roof side member, part section
  89
• 3 Renewing front cross member for roof
  94
• 3.1 Removing front roof cross member
  94
• 3.2 Installing front roof cross member
  95
• 4 A-pillar, part section
  98
• 4.1 Assembly overview – A-pillar, part section
  98
• 4.2 Removing – A-pillar, part section
  100
• 4.3 Installing – A-pillar, part section
  101
• 5 B-pillar, part section (vehicles with sliding door)
  107
• 5.1 Assembly overview – B-pillar, part section
  107
• 5.2 Type plate
  109
• 5.3 Safety certificate
  110
• 5.4 Removing – B-pillar, part section
  111
• 5.5 Installing – B-pillar, part section
  113
• 6 Renewing B-pillar reinforcement
  119
• 6.1 Assembly overview – B-pillar Reinforcement
  119
• 6.2 Type plate
  120
• 6.3 Safety certificate
  121
• 6.4 Removing – B-pillar Reinforcement
  122
• 6.5 Installing – B-pillar Reinforcement
  124
• 7 Renewing outer side member (vehicles with sliding door)
  129
• 7.1 Assembly overview – outer side member
  129
• 7.2 Type plate
  131
• 7.3 Safety certificate
  131
• 7.4 Removing – outer side member
  132
• 7.5 Installing – outer side member
  134
• Body - rear
  140
• 1 Renewing rear cross panel
  140
• 1.1 Removing rear cross panel
  140
• 1.2 Installing rear cross panel
  141
• 2 Renewing spare wheel holder
  145
• 2.1 Removing spare wheel holder
  145
• 2.2 Installing spare wheel holder
  146
• 3 Renewing upper outer D-pillar
  149
• 4 Renewing lock carrier
  150
• 4.1 Removing lock carrier
  150
• 4.2 Installing lock carrier
  151
• 5 Renewing rear side panel (vehicles with sliding door)
  154
• 5.1 Assembly overview – rear side panel
  154
• 5.2 Removing – side panel, part section
  156
• 5.3 Installing – side panel, part section
  158
• 6 Renewing lower outer D-pillar
  164
• 7 Renewing lower gusset plate
  165
• 7.1 Assembly overview - lower gusset plate
  165
• 7.2 Removing lower gusset plate
  165
• 7.3 Installing lower gusset plate
  167
• 8 Renewing rear cross member
  172
• 8.1 Removing rear cross member
  172
• 8.2 Installing rear cross member
  173
• 9 Renewing floor panel, part section 1
  176
• 9.1 Assembly overview - floor panel, part section 1
  176
• 9.2 Removing floor panel, part section 1
  176
• 9.3 Installing floor panel, part section 1
  178
• 10 Renewing rear bumper bracket
  183
• 10.1 Removing rear bumper bracket
  183
• 10.2 Installing rear bumper bracket
  184
• 11 Renewing rear longitudinal member support piece
  187
• 11.1 Removing rear longitudinal member support piece
  187
• 11.2 Installing rear longitudinal member support piece
  188
• 12 Renewing rear longitudinal member, part section
  191
• 12.1 Assembly overview – rear longitudinal member
  191
• 12.2 Removing rear longitudinal member
  191
• 12.3 Installing rear longitudinal member
  193
• 13 Renewing inner left wheel housing (short wheelbase)
  197
• 13.1 Assembly overview - inner left wheel housing
  197
• 13.2 Removing inner left wheel housing
  197
• 13.3 Installing inner left wheel housing
  199
• 14 Renewing inner right wheel housing (short wheelbase)
  202
• 14.1 Assembly overview - inner right wheel housing
  202
• 14.2 Removing inner right wheel housing
  202
• 14.3 Installing inner right wheel housing
  204