Skoda Kodiaq Body Repairs Eng

Service
Body Repairs
Kodiaq 2017 ➤
Kodiaq 2019 ➤
Edition 04.2018
Service Department. Technical Information

Service
Repair Group overview for Body Repairs
Repair Group
00 - Technical data
50 - Body - front
51 - Body - centre
53 - Body - rear
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Kodiaq 2017 ➤ , Kodiaq 2019 ➤
Body Repairs - Edition 04.2018
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Basic instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Fundamentals of bodywork repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Vehicle identification data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Foam moulds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.1 Position of the moulded foam parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.2 Replace the moulded foam part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5 Galvanised body parts, high/ultra high-strength and hot-formed body panels . . . . . . . . . . 5
5.1 Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6 Gap sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.1 Front body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.2 Middle body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.3 Rear body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7 Vehicle body dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
7.1 Front body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
7.2 Middle body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7.3 Rear body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7.4 Body platform at the front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.5 Body platform in the middle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.6 Body platform at the rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.1 List of tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
9 Straightening square set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
9.1 Straightening square set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
10 Portal gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
10.1 Portal gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
50 - Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1 Replace engine mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.2 Preparing the new part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.3 Part welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2 Replacing support block for assembly carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.1 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.4 Part welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3 Replacing the front bumper holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.3 Part welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4 Replacing outer top frame side rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.3 Part welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5 Replacing the inner top frame side rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Contents i
5.3 Part welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

6 Replacing the front wheelhouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.4 Part welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7 Replacing the front wheelhouse -part- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
7.4 Part welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
8 Replacing front frame side rail -part- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
8.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
8.3 Part welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
9 Replacing front frame side rail -part- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
9.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
9.4 Part welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
51 - Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1 Replacing the roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.4 Setting roof countersinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.5 Gluing in the roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.6 Part welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2 Replacing outer A pillar -cutoff part- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2.3 Moulded foam parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.4 Part welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
3 Replacing reinforcement of A-pillar - part- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
3.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
3.4 Part welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4 Replacing outer B-pillar -cutoff part- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.3 Part welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5 Replacing reinforcement of B pillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.4 Part welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
6 Replacing the outside bottom side rail -cutoff part- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
6.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
6.3 Part welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
7 Replace the bottom side rail reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
7.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
ii Contents
7.2 Part welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

8 Replace seat belt holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
8.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
8.2 Part welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
9 Replacing rear bottom side rail reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
9.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
9.3 Part welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
53 - Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

1 Replacing outer rear side part -cutoff part- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
1.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
1.4 Part welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2 Replacing the outer wheelhouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
2.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
2.2 Part welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
3 Replacing the support of the tail light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
3.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
3.2 Part welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4 Replacing sealing channel -part- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
4.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
4.3 Part welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
5 Replacing the separation reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
5.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
5.2 Part welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
6 Replacing the reinforcement of the sealing channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
6.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
6.2 Part welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
7 Replacing the end cover cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
7.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
7.2 Part welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
8 Replacing the end cover plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
8.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
8.2 Part welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
9 Replacing the end luggage compartment floor -part- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
9.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
9.4 Part welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
10 Replacing rear frame side rail -part- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
10.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
10.4 Part welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Contents iii
iv Contents
00 – Technical data
1 Basic instructions
(SKI000054; Edition 04.2018)
⇒ “1.1 Fundamentals of bodywork repair”, page 1
1.1 Fundamentals of bodywork repair
Caution
Follow the general notes! ⇒ General Information; Body Re‐

pairs, General Body Repairs
⇒ General Information; Body Repairs, General Body Repairs ;

Fundamentals of bodywork - repairs; Fundamentals of bodywork
- repair
1. Basic instructions 1
2 Vehicle identification data

⇒ “2.1 Vehicle identification number”, page 2
2.1 Vehicle identification number
Note
If a corresponding body part with vehicle identification number must be replaced in case of damage, the repair
must be documented according to the market-specific, legal regulations.
1 - Vehicle identification num‐

ber at the top right frame side
rail
2 - Vehicle identification num‐
ber on the bottom left wind‐
screen frame
2 Rep. gr.00 - Technical data

3 Safety measures
⇒ “3.1 Safety measures”, page 3
3.1 Safety measures
Caution
Observe the safety instructions in the binder general notes,

body repair and body work before commencing any cutting,
straightening and body panelling work. ⇒ General Information;
Body Repairs, General Body Repairs ; Safety measures
3. Safety measures 3
4 Foam moulds
⇒ “4.1 Position of the moulded foam parts”, page 4
⇒ “4.2 Replace the moulded foam part”, page 4
4.1 Position of the moulded foam parts
Various hollow spaces in this vehicle are filled with moulded foam
parts.
The moulded foam parts reduce the transmission of vehicle
noises into the passenger compartment.
The moulded foam parts are fitted during the manufacturing of the
body structure and expand in volume after the primer is applied
in the drying chamber of the paint shop at approx. 180 °C.
4.2 Replace the moulded foam part

Fundamentals of bodywork repairs; moulded foam parts

5 Galvanised body parts, high/ultra

high-strength and hot-formed body
panels
⇒ “5.1 Body”, page 5
5.1 Body
Note
Repairs may only be carried out in accordance with the instruc‐

tions of the manufacturer in the relevant Workshop Manual. High-
strength hot-formed steels can only be repaired with modern
inverter technology, otherwise optimum occupant protection is
not guaranteed following the repair. Panels made of tempered
steel must be used in areas that are exposed to extreme forces.
These panels offer significantly greater strength than standard
high-strength panels at a lower weight.
The structure of this vehicle is made for the most part out of
galvanised steel sheet.
Follow the basic Instructions⇒ General Information; Body Re‐
pairs, General Body Repairs ; Basic instructions; High-strength/
ultra-strength and warm-formed body panels .
View from above
5. Galvanised body parts, high/ultra high-strength and hot-formed body panels 5

The entire exterior side wall and the roof are not shown for rea‐
sons of clarity. These body parts are made of »normal« body
panels.
View from below

5. Galvanised body parts, high/ultra high-strength and hot-formed body panels 7

6 Gap sizes
⇒ “6.1 Front body”, page 8
⇒ “6.2 Middle body”, page 9
⇒ “6.3 Rear body”, page 10
6.1 Front body

– For example the setting gauge - 3371- can be used to set or
inspect.

-a- = 3.4 mm
-b- = 2.5 mm ± 0.5 mm
-c- = 1.5 mm ± 0.5 mm
-d- = 3.4 mm
-e- = 0.5 + 0.5 mm
-f- = 0 mm ± 0.5 mm
-g- = 3.5 mm ± 0.5 mm
-h- = max. 0.5 mm
6.2 Middle body

inspect.
Volkswagen Technical Site: http://vwts.ru http://vwts.info
6. Gap sizes 9
-a- = 3.5 mm ± 0.5 mm

-b- = 0 mm + 1 mm
-c- = 4.2 mm ± 0.5 mm
-d- = 0 mm + 1 mm
-e- = 3.5 mm ± 0.5 mm
-f- = 0 mm + 1 mm
-g- = 8 mm ± 0.8 mm
6.3 Rear body

inspect.

-a- = 3.5 mm ± 0.5 mm

-b- = 1 mm ± 0.5 mm
-c- = 1 mm ± 0.5 mm
-d- = 2.7 mm ± 0.5 mm
-e- = 0 mm + 0.5 mm
-f- = 0.5 mm ± 0.5 mm
-g- = 4.9 mm ± 0.4 mm
-h- = 1.2 mm + 0.5 mm
-i- = 3.5 mm ± 0.5 mm
-j- = 0.5 mm ± 0.5 mm
-k- = 10 mm ± 0.5 mm
6. Gap sizes 11
7 Vehicle body dimensions

⇒ “7.1 Front body”, page 12
⇒ “7.2 Middle body”, page 13
⇒ “7.3 Rear body”, page 15
⇒ “7.4 Body platform at the front”, page 17
⇒ “7.5 Body platform in the middle”, page 18
⇒ “7.6 Body platform at the rear”, page 19
7.1 Front body
Note
♦ The vehicle body dimensions are only relevant for the inspec‐
tion. The straightening bracket set is used as standard.
♦ Screws, plugs, trim panels and components parts must be re‐
moved before the measurement.
– In order to determine the body dimensions, use for example

the telescopic dipstick - VAS 5159- or the telescopic dipstick
- VAS 5160- .
– Ensure that the measuring tips are always the same length in
order to avoid inaccuracies during the measurement.

-a- = 1153 mm ± 2.0 mm

-b- = 1412 mm ± 2.0 mm
-c- = 1423 mm ± 2.0 mm
-d- = 1072 mm ± 2.0 mm
-e- = 879 mm ± 2.0 mm
7.2 Middle body
Note

- VAS 5160- .
7. Vehicle body dimensions 13

Dimension between the A-, B- and C-pillars
-a- = 1542 mm ± 2.0 mm

-b- = 1582 mm ± 2.0 mm
-c- = 1559 mm ± 2.0 mm
Dimension between the A-, B- and C-pillars

-a- = 1510 mm ± 2.0 mm

-b- = 1510 mm ± 2.0 mm
-c- = 1510 mm ± 2.0 mm
-d- = 1510 mm ± 2.0 mm
7.3 Rear body
Note

- VAS 5160- .

-a- = 1074 mm ± 2.0 mm

-b- = 1322 mm ± 2.0 mm
-c- = 1354 mm ± 2.0 mm
-d- = 1292 mm ± 2.0 mm
-e- = 1062 mm ± 2.0 mm

-a- = 645 mm ± 2.0 mm

-b- = 793 mm ± 2.0 mm
7.4 Body platform at the front
Note

- VAS 5160- .

-a- = 970 mm ± 2.0 mm

-b- = 630 mm ± 2.0 mm
-c- = 1040 mm ± 2.0 mm
-d- = 874 mm ± 2.0 mm
-e- = 730 mm ± 2.0 mm
-f- = 404 mm ± 2.0 mm
7.5 Body platform in the middle
Note

- VAS 5160- .

-a- = 1551 mm ± 2.0 mm

-b- = 1551 mm ± 2.0 mm
-c- = 1447 mm ± 2.0 mm
-d- = 1551 mm ± 2.0 mm
-e- = 1220 mm ± 2.0 mm
7.6 Body platform at the rear
Note


- VAS 5160- .

-a- = 1075 mm ± 2.0 mm
-b- = 1000 mm ± 2.0 mm
-c- = 1085 mm ± 2.0 mm
-d- = 987 mm ± 2.0 mm
-e- = 469 mm ± 2.0 mm

8 Tools
⇒ “8.1 List of tools”, page 21
8.1 List of tools

Tools; List of tools
Special tools and workshop equipment required
♦ Resistance-spot welding unit (Inverter) e.g. -VAS 6530A- or -
VAS 6545A- or -VAS 6755-
♦ Right angle grinder and wire brush
♦ Welding point loosening tool e.g. -V.A.G 1731- and replace‐
ment breaker for high-strength panels e.g. -V.A.G 1731/2- or
-V.A.G 1731/3-
♦ Body saw e.g. -V.A.G 1523 A-
♦ Extraction device
♦ Door tension adjuster, e.g. -V.A.G 1438-
♦ Telescopic dipstick e.g. -VAS 5159- or -VAS 5160-
♦ Underbody sealant gun, e.g. -V.A.G 1379-
♦ Double cartridge gun - VAS 5237-
♦ Compressed air gun e.g. -V.A.G 2005B- for adhesive e.g. -DA
001 730 A2-
♦ Pressure beaker gun for hollow space sealing e.g. -
V.A.G 1538-
♦ Inert gas shielded welding tool
♦ Burring pliers - burr panels e.g. for overlapping seams
♦ Punch pliers, e.g. -V.A.G 1329- - To punch holes in panels e.g.
for GS plug welding
♦ Panel nibbler - To cut out panels without warpage or burring,
e.g. when subsequently fitting a glass sun roof.
♦ Compressed air pistol e.g. -V.A.G 1761/1- - Compressed air
pistol for creating seals and underbody protection with original
factory finish- all 310 ml cartridges can be used with this gun.
♦ Power knife e.g.. -V.A.G. 1561/A- or compressed air cutter e.g.
-VAS 5177- and cutting discs e.g. -V.A.G. 1561/25- or -V.A.G.
1561/26- - For precisely cutting through the panel or the weld‐
ing seam e. g when removing the roof.
♦ Milling machine for cutting the laser welding seam e.g. -VAS
6319- - for accurate grinding of the weld seam e.g. when re‐
moving the roof
8. Tools 21
9 Straightening square set

⇒ “9.1 Straightening square set”, page 22
9.1 Straightening square set

⇒ “9.1.1 Measuring and guidance system, version 1”, page 22
⇒ “9.1.2 Straightening square set, version 2”, page 22
9.1.1 Measuring and guidance system, ver‐

sion 1
♦ Measurement and straightening system, Basic - VAS 6526- or
♦ Measurement and straightening system, Profi - VAS 6527- or
♦ Measurement and straightening system, Profi Plus - VAS
6528- or
9.1.2 Straightening square set, version 2

♦ Straightening bracket set - VAS 6789 (2579.500)- +
♦ Supplement to straightening bracket set, Kodiaq - VAS 801
047 (2579.518)-
– The detailed information for removal can be found in the de‐
sign plan enclosed with the straightening square set.

10 Portal gauge
⇒ “10.1 Portal gauge”, page 23
10.1 Portal gauge

♦ Portal gauge - VAS 802 001 (9113.063)- +
♦ Straightening bracket set - VAS 6789 (2579.500)- +
♦ Supplement to straightening bracket set, Kodiaq - VAS 801
047 (2579.518)- +
♦ Supplement to portal gauge, Kodiaq - VAS 802 047
(2579.80M)-
– The detailed information for removal can be found in the de‐
sign plan enclosed with the straightening square set.
10. Portal gauge 23

50 – Body - front
1 Replace engine mount
⇒ “1.1 Removing”, page 24
⇒ “1.2 Preparing the new part”, page 25
⇒ “1.3 Part welding”, page 26
1.1 Removing
Caution

– Loosen the original welding.

– Remove the mount from the body.
24 Rep. gr.50 - Body - front

– Remove any residues.
1.2 Preparing the new part
Caution

New part
♦ Engine mount
1. Replace engine mount 25

– Drill holes for the GS plug weld seam, 8 mm ∅.

– Slightly grind out the welding surfaces.
1.3 Part welding
Caution

– Adjust the new part and fix. For this purpose, the vehicle is
standing on the straightening bracket set .

– Check the fit with adjoining components.
– Weld in the new part, GS plug weld seam.
1. Replace engine mount 27

2 Replacing support block for assem‐

bly carrier
⇒ “2.1 Summary of components”, page 28
2.1 Summary of components
Caution

1 - Corner reinforcement top

2 - Corner reinforcement bot‐
tom
3 - Support block for assembly
carrier
4 - End part

2.2 Removing
Caution

2. Replacing support block for assembly carrier 29

Caution

New part
♦ Corner reinforcement top
♦ Corner reinforcement bottom
♦ Support block for assembly carrier
♦ End part

– Grind through and drill holes for the GS plug weld seam, 8 mm
∅.
2.4 Part welding
Caution

2. Replacing support block for assembly carrier 31

– Weld in the new part, RP spot weld seam, GS plug weld seam
and GS continuous seam.

3 Replacing the front bumper holder

Caution

1 - Bumper mount
3. Replacing the front bumper holder 33

3.2 Removing
Caution


3.3 Part welding
Caution

New part
♦ Front bumper holder
3. Replacing the front bumper holder 35

– Weld in the bumper holder, GS plug weld seam.

4 Replacing outer top frame side rail

4.1 Removing
Caution

– Loosen the original welding or cut the part according to the

damage.
4. Replacing outer top frame side rail 37

Caution

New part
♦ Outer top frame side rail
– Drill holes for the SG plug weld seam or cut the part depending
on the damage.
4.3 Part welding
Caution


– Fit the outer top frame side rail to the wheelhouse and fix. For
this purpose, the vehicle is standing on its wheels or on the
straightening bracket set .
– Weld in outside top frame side rail, RP spot weld seam and
GS plug weld seam. Or weld the separation line, SG continu‐
ous seam.
4. Replacing outer top frame side rail 39

5 Replacing the inner top frame side

rail
5.1 Removing
Caution

Outer top frame side rail already separated.
– Loosen the original welding or cut the part, depending on the

damage.

Caution

New part
♦ Inner top wheelhouse frame side rail
– Cut the part, depending on the damage.
5.3 Part welding
Caution

5. Replacing the inner top frame side rail 41

standing on its wheels or on the straightening bracket set .
– Weld in rear frame side rail, RP spot seam.
– Weld the separation line, an inert gas shielded full weld.

6 Replacing the front wheelhouse

Caution

Inner upper frame side rail already separated.
1 - Wheelhouse
❑ Complete front wheel‐
house
2 - Plenum chamber
❑ Connect wheelhouse to
plenum chamber
3 - Adhesive area
❑ Cannot be restored
when installing
4 - Reinforcement, wheel‐
house
❑ Not included under
spare parts for front
wheelhouse, use if nec‐
essary
6. Replacing the front wheelhouse 43

6.2 Removing
Caution


– Loosen original welding from inside and outside.

– Remove the entire front wheelhouse -1- from the body.


– Completely remove glue residues.
– Drill holes for the GS plug weld seam, ∅ 8 mm.
Caution

New part
♦ Front wheelhouse
♦ Reinforcement, wheelhouse

– Drill holes for the SG plug weld seam.

Note
The detailed information can be found in the design plan enclosed

with the straightening bracket set.

– Mark 3 holes -arrows- for shock absorber mounting straight‐

ening bracket set .
– Remove straightening bracket set .
– Drill 3 holes for shock absorber mounting, ∅ 10 mm.
– Increase size of hole e.g. with a step drill, -a- ∅ 34 mm.
6.4 Part welding
Caution


– Weld in the new part, RP spot seam and inert gas shielded
plug weld.

– Weld the wheelhouse -1- from outside and insides; SG plug

weld seam (inert gas shielded).

7 Replacing the front wheelhouse -

part-
Caution

Inner upper frame side rail already separated.
1 - Wheelhouse
❑ Front wheelhouse
2 - Wheelhouse reinforcement
3 - Adhesive area
7. Replacing the front wheelhouse -part- 51

7.2 Removing
Caution


– Remove wheelhouse reinforcement -2- from front wheelhouse
-1-.


– Remove the entire front wheelhouse -1- from the body.
Caution

New part
♦ Front wheelhouse, part -1-
♦ Wheelhouse reinforcement -2-
♦ 2K epoxy adhesive - DA 001 730 A2-

– Create holes for the GS plug weld seam, ∅ 8 mm.

7.4 Part welding
Caution

Note
The new part must be welded within 90 minutes as otherwise the adhesion of the glue may be poor.

– Apply 2K epoxy adhesive - DA 001 730 A2- .


– Weld in front wheelhouse -1-, RP spot weld seam and SG plug

weld seam (inert gas shielded).

– Weld in wheelhouse reinforcement -2- to front wheelhouse

-1-, SG plug weld seam (inert gas shielded).

8 Replacing front frame side rail -part-

8.1 Removing
Caution

Support block for assembly carrier already removed.
– Detach original welding for front frame side rail -1-.


Caution

New part
♦ Frame side rail
8. Replacing front frame side rail -part- 59

1 - Front frame side rail

– Carefully detach frame
side rail reinforcement
-4- and support block for
assembly carrier -3-.
Use these parts for rein‐
stallation.
– Separate rear section.
2 - Headlight holder
❑ Not included under
spare parts for frame
side rail, use if necessa‐
ry
3 - Support block for assembly
carrier
– Detach from frame side
rail.
❑ cannot be detached
from frame side rail with‐
out being destroyed.
❑ to install the front frame
side rail unit again, order
separately and also use
– Drill holes for the GS
plug weld seam, ∅ 8
mm.
4 - Frame side rail reinforce‐

ment
– Detach from frame side
rail.
❑ cannot be detached
from frame side rail with‐
out being destroyed.
❑ to install the front frame side rail unit again, order separately and also use
8.3 Part welding
Caution


– Weld in front frame side rail -1-, GS plug weld seam (shielding
gas) and RP spot weld seam.
– Fit and attach the headlight holder -2-.
– Weld in headlight holder -2-, RP spot weld seam.

9 Replacing front frame side rail -part-

Caution

1 - Front frame side rail

2 - Separation cut
❑ -a- = 110 mm

9.2 Removing
Caution

– Place and carry out the separation cuts.

110 mm

Caution

New part
♦ Front frame side rail

– Transfer separating cut to new part and cut to the required

dimensions.
9.4 Part welding
Caution


– Fit and fix the new part -1-. For this purpose, the vehicle is
– Butt weld the separation cut as a GS continuous seam.
– Weld the remaining joint, RP spot seam.

51 – Body - centre
1 Replacing the roof
⇒ “1.1 Tools”, page 67
⇒ “1.4 Setting roof countersinking”, page 70
⇒ “1.5 Gluing in the roof”, page 72
1.1 Tools
♦ E.g. compressed air pistol - V.A.G 1761/1-
♦ E. g. cartridge heater - V.A.G 1939 A-
♦ E. g. double cartridge gun - VAS 5237-
♦ E.g. setting gauge - 3371-
♦ E.g. tensioning strap - T10038-
♦ E.g. suction cup - V.A.G 1344-
♦ E.g. Power knife - V.A.G 1561/A- or compressed air cutter -
VAS 5177- and e.g. cutting discs - V.A.G 1361/25- or -V.A.G
1361/26- .
♦ E.g., milling machine for cutting the laser welding seam - VAS
6319- .
1.2 Removing
Caution

Note
♦ Attach textile adhesive tape to the left and right of the roof frame rail parallel to the laser soldered seams.
This reduces the risk of damage and contamination during the repair.
♦ When cutting, observe a distance of 15 mm from the roof frame rail so that it is not damaged during work.
♦ When carrying out the separation cuts, ensure that the panels located at the rear are not damaged.
1. Replacing the roof 67

– Cut out the roof roughly parallel to the laser soldered seams.
– Loosen the original welding with centre roof cross member.
– Loosen the original welding with the rear roof cross member.
– Remove the roof from the body.
Note
♦ When removing the rest of the roof, the roof frame rail must not be damaged.
♦ Do not use any cutting or grinding discs.
– Remove roof residues on both sides.

– Carefully remove the material residue from the soldered
seams on the left and right of the roof frame rails.
– Remove all residues of adhesive and sealing compound from
the roof cross members and roof reinforcements.
68 Rep. gr.51 - Body - centre

Caution

⇒ General information lacquer; 00 technical data; General infor‐

mation; Pretreatment of the adhesive surface when replacing
laser-welded roofs
New part
♦ Roof
♦ 1K assembly glue - D 190 MKD A3- (approx. 2 cartridges)
♦ 2K body glue - D 180 003 M2- (approx. 4 sets of cartridges)
♦ Glue sealing mass - AKD 476 KD5 05-
♦ Hollow space sealing - AKR 321 M15 4-
Note
♦ In order to ensure a perfect and permanent roof repair, it is

absolutely essential to comply with the following work proce‐
dure.
♦ At this point, we must emphasise the duty of care while car‐
rying out this repair in order to exclude any possible faulty
workmanship.
– Thoroughly degrease contact surfaces to be ground before

grinding.
– Grind off the adhesive surfaces on the left and right of the door
frame that come into contact with the 2K body adhesive to
achieve flawless adhesive adhesion.
– Carefully degrease the contact surfaces on the door frame af‐
ter grinding.

– Thoroughly degrease contact surfaces to be ground on the

roof before grinding.
– Slightly grind the left and right adhesive surfaces on the roof
that come in contact with 2K body adhesive .
This ensures that the 2K body glue - D 180 003 M2- can form a
good bonding with the adhesive surfaces.
– Thoroughly degrease the contact surfaces after grinding.
– 2 Attach the suction cup - V.A.G 1344- to the outside of the
roof.
– Place the roof on the roof frames.
– Check fit of roof with sliding roof and tailgate.
1.4 Setting roof countersinking
Caution


Note
♦ The tensioning straps -1- prevent the roof from lifting off the roof frame or sliding during the gluing procedure.
♦ The tensioning straps must not be tightened too firmly, in order to avoid damage.
♦ The dimension -a- can be determined by tensioning or loosening the tensioning straps because the roof
must lie lower in relation to the side parts.
♦ Use the setting gauge - 3371- to check dimension -a-.
– Check the fit with component parts.
– Tension for example the tensioning straps - T10038- at right
angles across the roof in the areas shown in order to vary the
height of the roof.
– Fix roof on the window cutout for sliding roof and on the rear
using the clamping tongs.
– Check the roof line to the roof rails.

Dimension -a- = 4.5 mm ± 0.5 mm

– If necessary put a few pieces of felt in place to balance the roof
frame.
1.5 Gluing in the roof

⇒ “1.5.1 Without sliding roof”, page 72
⇒ “1.5.2 With sliding roof”, page 78
1.5.1 Without sliding roof
Caution

– Remove the roof.

– Clean the adhesive surface on the roof and the vehicle with
silicone remover - LVM 020 100 A5- .
Note
♦ The adhesives must be applied very quickly.

♦ The processing time must absolutely be observed.
♦ Use the compressed air or electrical cartridge guns in order to
apply the adhesive.
– Cut off approx. 2 mm from the nozzle -B- for the corresponding
glue bead geometry.
Note
At this point, we must emphasise the duty of care while carrying

out this repair in order to exclude any possible faulty workman‐
ship.

– Adhesie body bonds, depending on the type of adhesive used.

Area with reinforcement for variant with roof rack -A-.

– Apply the 1K assembly glue - D 190 MKD A3- -1- e.g. with the
compressed air gun - V.A.G 1761/1- , in the area of the roof
rails.
Dimension -a- = approx. 12 mm
Dimension -b- = approx. 14 mm

– Apply the 1K assembly glue - D 190 MKD A3- , for example

with the compressed air gun - V.A.G 1761/1- on the inside of
the roof parallel to the left and right roof flange.
Note
♦ The processing time of the 2K body glue - D 180 003 M2- is

approximately 90 min.
♦ Immediately remove the excess 2K body glue - D 180 003 M2-
on the adhesive surfaces. The 2K body glue - D 180 003 M2-
can only be removed mechanically after hardening.

– Cut off the first level of the static mixer -A- in order to obtain
the corresponding glue bead cross section.
– For example, operate the double cartridge gun - VAS 5237-
without static mixer until the adhesive evenly flows out of both
chambers of the cartridge connector.
– Screw the static mixer onto the cartridge connector.
– Apply the first 100 mm of glue on a piece of adhesive tape and
only then begin to apply it on the vehicle.
– Fill up the area with the 2K body glue - D 180 003 M2- using
for example the double cartridge gun - VAS 5237- .

– Moisten the roof ridges with 2K body glue - D 180 003 M2- .
– Immediately place on the roof and align.
– Fix the roof at the window cutout for sliding roof using the grip‐
ping pliers and in the tailgate cutout as well as in the centre
area using the tensioning straps.
– Check the roof line to the roof rails and adjust if necessary
⇒ “1.4 Setting roof countersinking”, page 70 .
– Immediately remove the excess 2K body glue - D 180 003 M2-
on the roof edge with a cloth soaked in silicone remover - LVM
020 100 A5- .
Note
♦ After gluing in, the vehicle must stand on a flat surface for 8-10 hours at ambient temperature (at least 15 °
C) so that the glue components can harden (minimum hardening time).
♦ Only after the end of the minimum hardening time, it is possible to continue working on the vehicle.

1.5.2 With sliding roof
Caution

– Remove the roof.

– Clean the adhesive surface on the roof and the vehicle with
silicone remover - LVM 020 100 A5- .
Note
♦ The adhesives must be applied very quickly.

♦ The processing time must absolutely be observed.
♦ Use the compressed air or electrical cartridge guns in order to
apply the adhesive.
– Cut off approx. 2 mm from the nozzle -B- for the corresponding
glue bead geometry.
Note
At this point, we must emphasise the duty of care while carrying

out this repair in order to exclude any possible faulty workman‐
ship.

– Adhesie body bonds, depending on the type of adhesive used.

Area with reinforcement for variant with roof rack -A-.

– Apply the 1K assembly glue - D 190 MKD A3- -1- e.g. with the
compressed air gun - V.A.G 1761/1- , in the area of the roof
rails.

– Apply the 1K assembly glue - D 190 MKD A3- , for example

with the compressed air gun - V.A.G 1761/1- on the inside of
the roof parallel to the left and right roof flange.
Note
♦ The processing time of the 2K body glue - D 180 003 M2- is

approximately 90 min.
♦ Immediately remove the excess 2K body glue - D 180 003 M2-
on the adhesive surfaces. The 2K body glue - D 180 003 M2-
can only be removed mechanically after hardening.

– Cut off the first level of the static mixer -A- in order to obtain
the corresponding glue bead cross section.
– For example, operate the double cartridge gun - VAS 5237-
without static mixer until the adhesive evenly flows out of both
chambers of the cartridge connector.
– Screw the static mixer onto the cartridge connector.
– Apply the first 100 mm of glue on a piece of adhesive tape and
only then begin to apply it on the vehicle.
– Fill up the area with the 2K body glue - D 180 003 M2- using
for example the double cartridge gun - VAS 5237- .

– Moisten the roof ridges with 2K body glue - D 180 003 M2- .
– Immediately place on the roof and align.
– Fix the roof at the window cutout for sliding roof using the grip‐
ping pliers and in the tailgate cutout as well as in the centre
area using the tensioning straps.
– Check the roof line to the roof rails and adjust if necessary
⇒ “1.4 Setting roof countersinking”, page 70 .
– Immediately remove the excess 2K body glue - D 180 003 M2-
on the roof edge with a cloth soaked in silicone remover - LVM
020 100 A5- .
Note
♦ After gluing in, the vehicle must stand on a flat surface for 8-10 hours at ambient temperature (at least 15 °
C) so that the glue components can harden (minimum hardening time).
♦ Only after the end of the minimum hardening time, it is possible to continue working on the vehicle.

1.6 Part welding
Caution

– Weld in the roof -1- in cutout for the sliding roof and in cutout
for the rear window, RP spot weld seam.
– Perform precision sealing of the connection -2- with adhesive
sealant - AKD 476 KD5 05- in the original form at the bonded
joint between roof and roof frame rail.
– After painting, perform cavity sealing on the roof -arrow- with
preservation wax - AKR 321 M15 4- .

2 Replacing outer A pillar -cutoff part-

⇒ “2.3 Moulded foam parts”, page 87
2.1 Removing
Caution

Note
When carrying out the separation cuts, ensure that the panels located at the bottom are not damaged.
2. Replacing outer A pillar -cutoff part- 85

– Position and make the separating cuts according to the dam‐

age e.g. as shown in the figure.
Caution

New part
♦ A-pillar
♦ Moulded foam part

dimensions.

Note
♦ The new part must be welded within 90 minutes as otherwise the adhesion of the glue may be poor.
♦ The holes for the hinge attachment must be cleaned from adhesive after gluing in.
2.3 Moulded foam parts
Caution

Observe the repair instructions.

Moulded foam parts: ⇒ General Information; Body Repairs, Gen‐
eral Body Repairs ; Basic Instructions, moulded foam parts
2. Replacing outer A pillar -cutoff part- 87

– Replace moulded foam part ⇒ “4 Foam moulds”, page 4 .
2.4 Part welding
Caution

– Weld the separation cuts, an inert gas shielded full weld.
– Weld in the new part, RP spot weld seam, SG plug weld seam
and SG continuous seam (staggered).

3 Replacing reinforcement of A-pillar -

part-
3.1 Removing
Caution

Outer A-pillar already removed.
– Perform separation cut on the A-pillar reinforcement, as

shown.
3. Replacing reinforcement of A-pillar - part- 89

– Loosen original welding from inside and outside.

– Remove reinforcement of A-pillar.
Caution

New part
♦ Reinforcement of A-pillar
♦ Moulded foam parts

dimensions.

Note
– Make sure the adhesive areas are free of dust and grease.
Caution


3. Replacing reinforcement of A-pillar - part- 91

3.4 Part welding
Caution

– Weld in the new part, SG plug weld seam, SG continuous
seam (staggered) and RP spot weld seam inverter.
– Weld in the new part from inside, GS plug weld seam.

4 Replacing outer B-pillar -cutoff part-

4.1 Removing
Caution

Note
4. Replacing outer B-pillar -cutoff part- 93

– Arrange and make the separation cuts according to the dam‐

age e.g. -1-
– Remove residues.
Caution

New part
♦ Outer B-pillar
– Transpose the separation cut onto the new part and cut or cut
depending on damage, e.g. -1-.

4.3 Part welding
Caution

Note
♦ The new part must be welded within 90 minutes as otherwise

the adhesion of the glue may be poor.
♦ The holes for the hinge attachment and the locking clamp must
be cleaned of adhesive after gluing in.
– Apply 2K epoxy adhesive - DA 001 730 A2- in the original

areas.
4. Replacing outer B-pillar -cutoff part- 95


– Weld in the B-pillar, RP spot seam inverter.
– Weld the separation cuts or cut, e.g. -1-, GS continuous seam.

5 Replacing reinforcement of B pillar

5.1 Removing
Caution

Outer panels already removed.

♦ Welding point loosening tool e.g. -V.A.G 1731- and replace‐
ment breaker for high-strength panels e.g. -V.A.G 1731/3-
5. Replacing reinforcement of B pillar 97

Note
– Apply separation cut in top section.

– Loosen the original welding from the inside.
Caution

New part
♦ Reinforcement of B-pillar


– Cut top of new part to correct dimensions.
– Drill holes for the SG plug weld seam at bottom.

– Weld reinforcement for seat belt fastening, RP spot seam in‐

verter.
Note

areas.
Caution



5.4 Part welding
Caution

Note
The new part must be welded within 90 minutes as otherwise the

adhesion of the glue may be poor.
– Weld in the new part, GS plug weld seam.
– Carefully weld separation cut at top, SG continuous seam.

– Weld in the new part from inside, GS plug weld seam.

6 Replacing the outside bottom side rail

-cutoff part-
6.1 Removing
Caution


– Grind through the outer side on the rear wheel arch.
6. Replacing the outside bottom side rail -cutoff part- 103

Caution

New part
♦ Outer side rail
– Transpose the cut points onto the new part and cut to the re‐
quired dimensions.
– Make sure the adhesive areas are free of dust and grease.
Note


areas.
6.3 Part welding
Caution

6. Replacing the outside bottom side rail -cutoff part- 105

– Adjust the new part and fix.

– Weld in the bottom side rail, RP spot seam and inert gas shiel‐
ded plug weld.
– Flange rear wheel arch strip.
– Wipe off excess glue and seal rear wheel arch.

7 Replace the bottom side rail rein‐

forcement
7.1 Removing
Caution

Reinforcement of B pillar already separated.

7. Replace the bottom side rail reinforcement 107

7.2 Part welding
Caution


– Weld in new part, RP spot seam inverter.

8 Replace seat belt holder

8.1 Removing
Caution

Bottom side rail reinforcement already removed.

8. Replace seat belt holder 109

8.2 Part welding
Caution

Note
– Apply 2K epoxy adhesive - DA 001 730 A2- from inside in the

original areas before welding in.

– Weld in new part, RP spot seam inverter.

9 Replacing rear bottom side rail rein‐

forcement
9.1 Removing
Caution

Bottom side rail -part- already removed.

9. Replacing rear bottom side rail reinforcement 111

Caution

New part
♦ Reinforcement of rear bottom side rail
9.3 Part welding
Caution


– Weld in the reinforcement of bottom side rail, RP spot weld
seam and SG plug weld seam.
9. Replacing rear bottom side rail reinforcement 113

53 – Body - rear
1 Replacing outer rear side part -cutoff
part-
1.1 Removing
Caution

Note
When carrying out the separation cuts, do not damage the inside panels.
114 Rep. gr.53 - Body - rear


– Grind through the outer edge of the wheel arch.
– Loosen the original welding in the tailgate cutout.
– Make sure that the border area on the wheel arch is free from
dust and grease.
Caution

New part
♦ Outer rear side part – wing
1. Replacing outer rear side part -cutoff part- 115

– Transpose the cut points onto the new part and cut to the re‐
quired dimensions.
– Make holes ∅ 8 mm for GS plug weld seam.
– Slightly grind out the adhesive surfaces.
– Make sure the border areas are free of dust and grease.
Caution



1.4 Part welding
Caution

Note
♦ The new part must be welded within 90 minutes as otherwise

the adhesion of the glue may be poor.
♦ 2K epoxy adhesive - DA 001 730 A2- must be applied on the
right side part wing in the area of the fuel filler neck before
welding in.
– Apply 2K epoxy adhesive - DA 001 730 A2- in the border area

of the wheelhouse.
1. Replacing outer rear side part -cutoff part- 117

– Weld in the side panel, GS plug weld seam, GS continuous
seam and RP spot weld seam.
– Restore the bond in the tailgate cutout, SG plug weld seam.
– Crimp the wheel arch strip.
– Wipe off excess glue and seal wheel arch.

2 Replacing the outer wheelhouse

2.1 Removing
Caution

Outer panels already removed.
– Position and make the separating cuts -1- according to the

damage e.g. as shown in the figure.
2. Replacing the outer wheelhouse 119

2.2 Part welding
Caution

New part
♦ The wheel house on the outside
– Attach the wheel house on the outside

– Attach the wing at the rear and check the size of the gaps.
– Remove the rear wing.
– Weld the separation cuts -1-, an inert gas shielded full seam.

3 Replacing the support of the tail light

3.1 Removing
Caution

Outer rear side part - wing already separated.

3. Replacing the support of the tail light 121

3.2 Part welding
Caution

New part
♦ Support of tail light
– Fit the new parts and fix.
– Check the fit of the tail light with the tailgate and the side part.
– Weld the support of the tail light, RP spot weld seam and SG
plug weld seam.

4 Replacing sealing channel -part-

4.1 Removing
Caution

– Perform separation cut of sealing channel, depending on dam‐

age.
4. Replacing sealing channel -part- 123

Caution

New part
♦ Sealing channel

dimensions.

4.3 Part welding
Caution


– Weld in the part, RP spot weld seam.
4. Replacing sealing channel -part- 125

5 Replacing the separation reinforce‐

ment
5.1 Removing
Caution

Sealing channel already removed.



5.2 Part welding
Caution


– Weld in the new part, an RP spot seam.
5. Replacing the separation reinforcement 127

6 Replacing the reinforcement of the

sealing channel
6.1 Removing
Caution

Separation reinforcement already separated.


6.2 Part welding
Caution

New part
♦ Reinforcement of sealing channel
– Weld reinforcement of sealing channel, RP spot weld seam.
6. Replacing the reinforcement of the sealing channel 129

7 Replacing the end cover cross mem‐

ber
7.1 Removing
Caution



7.2 Part welding
Caution

New part
♦ End cover cross member

– Weld in the new part, an RP spot seam.
7. Replacing the end cover cross member 131

8 Replacing the end cover plate

8.1 Removing
Caution

End cover cross member already removed.


8.2 Part welding
Caution

New part
♦ Rear panel
– Check closing of the tailgate.
– Weld end cover plate, GS plug weld seam and RP spot weld
seam.
8. Replacing the end cover plate 133

9 Replacing the end luggage compart‐

ment floor -part-
9.1 Removing
Caution

Reinforcements of the sealing channel already removed.

End cover plate already removed.
– Carry out the separation cut -4- as shown.


– Take the left luggage compartment floor panel -3- and right
floor panel -2- out of the vehicle.
– Remove luggage compartment floor -1- from the vehicle.
Note
The residual foam must be removed before carrying out grinding.
Caution

New part
♦ Luggage compartment floor -1-
♦ Right floor panel -2-
♦ Left floor panel -3-
♦ Cross member -4-
♦ Mounting bracket -5-
9. Replacing the end luggage compartment floor -part- 135


– Transport the separation cuts onto the new part -1- and cut to
size.
– Grind off the welding surfaces of the mounting bracket -5-.
– Grind off the welding surfaces.
– Only slightly grind out the adhesive surfaces on which welding
is not necessary.
Caution



9.4 Part welding
Caution

Note
– Install moulded foam part -1-.

9. Replacing the end luggage compartment floor -part- 137

– Adjust and fix new parts -1-, -2- and -3-. For this purpose, the
vehicle is standing on its wheels or on the straightening brack‐
et set .
– Weld on left floor panel -1-, right floor panel -3- and rear lug‐
gage compartment floor -2-, SG plug weld seam (shielding
gas) and RP spot weld seam.
– Weld in mounting bracket -4-, RP spot weld seam.
– Weld cross member -5- to luggage compartment floor, RP spot
weld seam.
– Weld the separation line, SG full seam (insert gas shielded).

10 Replacing rear frame side rail -part-

Caution

Luggage compartment floor already removed.
1 - The rear frame side rail

2 - Separation cut
Partial renewal
Cut point is only permitted for
part replacement.
3 - Moulded foam part
4 - Mounting bracket
❑ must be removed before
removing the frame side
rail reinforcement -5-
5 - Frame side rail reinforce‐
ment
10. Replacing rear frame side rail -part- 139

10.2 Removing
Caution

– Detach original welding on mounting bracket -2-

– Remove mounting bracket -2- from rear frame side rail -1-.
– Carefully mark the separating cut -3- on the rear frame side
rail -1-.
Dimension -a- = 125 mm

– Detach original welding of the frame side rail reinforcement

-3-.
– Perform straight separating cut -2- on the rear frame side rail
-1-.
– Remove the rear frame side rail -1- from the body.


– Grind the welding surfaces clean.
Caution

Spare parts when using single parts

♦ Cover plate for frame side rail
♦ Mounting bracket
♦ Frame side rail reinforcement
♦ Frame side rail
Spare parts when using the complete frame side rail unit
♦ Frame side rail unit
♦ Frame side rail reinforcement

– Detach original welding of the mounting bracket -3-.

– Remove the mounting bracket -3- from the new parts -1-.
Note
♦ Detach mounting bracket -3- from new part -1- so that it can be used again for installation.
♦ The frame side rail reinforcement -4- must always be replaced.
– Transpose the separation cut -2- from the body and cut the
new parts.
– Detach the original welding of the frame side rail reinforcement
-4- from the new part -1-.
– Grind off the welding surfaces on the new part -1- and -5-.

10.4 Part welding
Caution

Welding when using the complete frame side rail unit

– Fit and attach new parts -1-. For this purpose, the vehicle is
– Butt weld the separation cut -3-, SG full seam (inert gas shiel‐
ded).
Note
GS full seam (inert gas shielded) must not be reworked (ground or smoothed)!
– Fit and attach the frame side rail reinforcement -4-.

– Weld in the frame side rail reinforcement -4-, SG plug weld

seam (inert gas shielded).
– Fit and attach the mounting bracket -2-.
– Weld mounting bracket -2- on both sides, SG plug weld seam
(inert gas shielded).
Welding when using single parts
– Fit and attach the cover plate for frame side rail.
– Weld cover plate for frame side rail, SG full seam (insert gas
shielded).

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Service

Service Department. Technical Information

5.3 Part welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

7.2 Part welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

53 - Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

1.1 Fundamentals of bodywork repair

Follow the general notes! ⇒ General Information; Body Re‐

⇒ General Information; Body Repairs, General Body Repairs ;

2 Vehicle identification data

2.1 Vehicle identification number

1 - Vehicle identification num‐

2 Rep. gr.00 - Technical data

3.1 Safety measures

Observe the safety instructions in the binder general notes,

4.1 Position of the moulded foam parts

4.2 Replace the moulded foam part

4 Rep. gr.00 - Technical data

5 Galvanised body parts, high/ultra

Repairs may only be carried out in accordance with the instruc‐

5. Galvanised body parts, high/ultra high-strength and hot-formed body panels 5

6 Rep. gr.00 - Technical data

5. Galvanised body parts, high/ultra high-strength and hot-formed body panels 7

6.1 Front body

8 Rep. gr.00 - Technical data

6.2 Middle body

Volkswagen Technical Site: http://vwts.ru http://vwts.info

-a- = 3.5 mm ± 0.5 mm

6.3 Rear body

Volkswagen Technical Site: http://vwts.ru http://vwts.info

10 Rep. gr.00 - Technical data

-a- = 3.5 mm ± 0.5 mm

7 Vehicle body dimensions

7.1 Front body

– In order to determine the body dimensions, use for example

12 Rep. gr.00 - Technical data

-a- = 1153 mm ± 2.0 mm

7.2 Middle body

– In order to determine the body dimensions, use for example

7. Vehicle body dimensions 13

Dimension between the A-, B- and C-pillars

-a- = 1542 mm ± 2.0 mm

14 Rep. gr.00 - Technical data

-a- = 1510 mm ± 2.0 mm

7.3 Rear body

– In order to determine the body dimensions, use for example

7. Vehicle body dimensions 15

-a- = 1074 mm ± 2.0 mm

16 Rep. gr.00 - Technical data

-a- = 645 mm ± 2.0 mm

7.4 Body platform at the front

– In order to determine the body dimensions, use for example

7. Vehicle body dimensions 17

-a- = 970 mm ± 2.0 mm

7.5 Body platform in the middle

– In order to determine the body dimensions, use for example

18 Rep. gr.00 - Technical data

-a- = 1551 mm ± 2.0 mm

7.6 Body platform at the rear

7. Vehicle body dimensions 19

– In order to determine the body dimensions, use for example

Volkswagen Technical Site: http://vwts.ru http://vwts.info

20 Rep. gr.00 - Technical data

8.1 List of tools