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Service

Body Repairs

Amarok 2011

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Edition 10.2010

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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

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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.
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All rights reserved.


No reproduction without prior agreement from publisher.
Copyright 2010 Volkswagen AG, Wolfsburg

D3E8027D416

Amarok 2011
Body Repairs - Edition 10.2010

Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1.1
1.2
1.3
2
3
4
5
5.1
5.2
5.3
5.4
5.5
5.6
6
6.1
6.2
6.3
6.4
6.5
6.6
7
7.1
7.2
7.3
7.4
7.5

Key vehicle data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Moulded foam elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Galvanized body parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body panel gaps/shut lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body - centre, vehicles with double cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body - centre, vehicles with single cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body - rear, vehicles with double cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body - rear, vehicles with single cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body add-on parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Double cab frame dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Single cab frame dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Double cab box dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Single cab box dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Double cab load surface dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Single cab load surface dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alignment jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alignment bracket fixture overview of complete vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alignment bracket fixture overview of vehicle chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. Volkswagen AG
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Alignment bracket fixture overview of vehiclelkcab
swa . . . . . . . . . . . . . .do. e.s.no. . . . . . . . . . . . . . .
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Alignment bracket fixture overview of vehicle
cab . . . . . . . . . . . . . . . . . . t.gu. a.ra. . . . . . . . . . .
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1
1
1
3
3
4
5
7
8
8
9
10
11
12
13
15
15
21
23
28
31
34
36
36
36
37
38
39

50 - Body - front . . . . . . . . . . . . . . . .s a.ut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .or .ac . . . . . 41


s

Renewing cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing deformation element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing headlight mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing wing connecting plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing connection piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing upper wheel housing longitudinal member . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41
42
43
46
46
46
47
50
50
50
53
57
57
58
59
62
62
62
64
66
66

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1
1.1
1.2
2
2.1
2.2
2.3
3
3.1
3.2
3.3
4
4.1
4.2
4.3
5
5.1
5.2
5.3
6
6.1

Contents

Amarok 2011
Body Repairs - Edition 10.2010
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing front wheel housing . . . . . . n. A. G. ..V.ol.ks. w. a.g.en. A. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gd
ge
Removing . . . . . . . . . . . . . . . .V.ol.ks.w.a. . . . . . . . . . . . . . . . o.e.s n. o.t . . . . . . . . . . . . . . . . . . . . . .
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y
Installing . . . . . . . . . . . . .is.e.d b. . . . . . . . . . . . . . . . . . . . . . . . . . . . .ar.an. . . . . . . . . . . . . . . . . . .
tee
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Renewing front part of alongitudinal
member - part section 1- . . . . . . . .or.a . . . . . . . . . . . . . . .
c
s
Removing . . . . . . . .s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing longitudinal member - part section 2- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing longitudinal member complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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6.2
6.3
7
7.1
7.2
8
8.1
8.2
9
9.1
9.2
10
10.1
10.2

66
68
71
71
72
75
75
77
81
81
83
89
90
97

51 - Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

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Contents

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ii

Renewing roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing front cross member for roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing roof reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing rear roof cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing rear window frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing hinge pillar (A-pillar) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing hinge pillar (A-pillar) reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing centre pillar (B-pillar) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing centre pillar (B-pillar) reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing lock pillar (C-pillar) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
do
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1
1.1
1.2
1.3
2
2.1
2.2
3
3.1
3.2
4
4.1
4.2
5
5.1
5.2
6
6.1
6.2
7
7.1
7.2
7.3
8
8.1
8.2
8.3
9
9.1
9.2
9.3
10
10.1
10.2
10.3
11
11.1

110
110
112
113
117
117
118
121
121
122
125
125
126
129
130
131
135
135
136
139
140
141
142
148
149
149
150
154
155
155
157
160
161
161
163
166
167

Amarok 2011
Body Repairs - Edition 10.2010
11.2
11.3
12
12.1
12.2

Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing mounting bracket for front seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

167
170
174
174
175

53 - Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178


1
1.1
1.2
2
2.1
2.2
3
3.1
3.2

Renewing rear cross panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing rear longitudinal member - part section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing rear side panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

178
179
180
184
184
186
190
191
194

rrectness of i
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Contents

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Contents

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Amarok 2011
Body Repairs - Edition 10.2010

Amarok 2011
Body Repairs - Edition 10.2010

00

Technical data

Key vehicle data

1.1

Vehicle identification number


Note

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If components into which the vehicle ID number (chassis number) is stamped are renewed in the event of
damage, a surveyor must be involved prior to repair.

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Vehicle identification number (chassis number) on the body:


The vehicle identification number (chassis number) is visibly
stamped into the lower left windscreen flange -arrow A-.

1. Key vehicle data

Amarok 2011
Body Repairs - Edition 10.2010
Vehicle identification number (chassis number) on the vehicle
frame:
The vehicle identification number (chassis number) is visibly
stamped into the right vehicle frame
longitudinal member
AG. Volkswagen AG d
-arrow B-.
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According to the legislation in Brazil, Argentina and Mexico, a shortened vehicle ID number (chassis num

ber) is located at 3 further points within the vehicle.

The additional identification consists of an identification plate which cannot be removed without destroying
rrectness of i
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spec
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it.

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Additional, shortened vehicle identification number (chassis num


ber) for Brazil, Argentina and Mexico:
The vehicle identification number (chassis number) is stuck on
to the right wheel housing in the engine compartment
-arrow A-.
The vehicle identification number (chassis number) is stuck on
to the right front passenger seat -arrow C-.

Rep. gr.00 - Technical data

1.2

Identification plate

The identification plate -arrow- is stuck on the left B-pillar.

Vehicle data sticker


r
fo
ng

The vehicle data sticker -arrow- is located in the footwell on


the driver's side.

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1.3

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The vehicle identification number (chassis number) is stuck on


to the right B-pillar -arrow B-.

Amarok 2011
- Edition 10.2010

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Body
Repairs
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1. Key vehicle data

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Amarok 2011
Body Repairs - Edition 10.2010

Safety instructions
WARNING

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Rep. gr.00 - Technical data

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Before beginning any cutting, alignment or dent removal, refer


to safety notes in the binder General information, body repairs
and general body repairs.

Amarok 2011
Body Repairs - Edition 10.2010

Moulded foam elements


Note

Various body cavities in the Amarok 2010 have been fitted

with moulded foam elements.

The moulded foam elements reduce the amount of driving

noise that is transmitted into the interior.

The moulded elements are fitted during body shell construc

tion and increase their volume in the paint shop drying oven
at approx.180C, after priming.

The exact locations of these moulded foam elements are ad

ditionally shown at the beginning of the respective repair de


scriptions.

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4 - Lower A-pillar
Moulded foam element
between A-pillar outer
skin and A-pillar rein
forcement.
Moulded foam element
between A-pillar rein
forcement and inner
panel.

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

3 - Lower B-pillar
Moulded foam element
between B-pillar outer
skin and B-pillar rein
forcement.
Moulded foam element
between B-pillar rein
forcement and inner
panel.

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2 - Lower C-pillar
Moulded foam element
between C-pillar outer
skin and C-pillar rein
forcement.
Moulded foam element
between C-pillar rein
forcement and inner
panel.

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1 - Upper A-pillar
Moulded foam element
between A-pillar outer
skin and A-pillar rein
forcement.
Moulded foam element
between A-pillar rein
forcement and inner
panel.

As these temperatures cannot be achieved under normal work


shop conditions, proceed as follows:
Remove foam material remains on vehicle.

3. Moulded foam elements

Amarok 2011
Body Repairs - Edition 10.2010
Restore the paint work structure. If necessary, apply two coats
(wet in wet) of glass/paint primer -D 009 200 02- (apply the
second coat in the opposite direction) - flash-off time of about
10 minutes.
Prerequisites
Before continuing with this procedure, ensure that the part for
replacement is correctly prepared e.g. cut and adapt to fit,
corrosion protection measures.
Renewing moulded foam element
a
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Fix moulded foam element to vehicle.
yV
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AG.

Rep. gr.00 - Technical data

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rrectness of i
t to the co
nform
spec
at
i
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o
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in t
his

Carry out cavity preservation on repair area after painting ve


hicle.

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n

Do not do perform shielded arc welding within 15 mm on either


side of moulded foam element.

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Secure new part (e.g. A-pillar)
ut in position. Apply gentle pres
sure to contact new part in sarea
of moulded foam element and
sa
weld in.

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Wrap moulded foam element with sealing cord -AKD 497 010
04 R10- all round.
. Volkswagen AG
gen AG

Amarok 2011
Body Repairs - Edition 10.2010

Galvanized body parts

The vehicle consists partly of body panels galvanized on one or


both sides!

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Before carrying out body repairs observe the following information


General Information; Body Repairs, General Body Repairs .

4. Galvanized body parts

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Amarok 2011
Body Repairs - Edition 10.2010

Body panel gaps/shut lines


Note

Use setting gauge -3371- to set or check shut lines.

5.1

Body - front

A - 2.5 mm + 1.5 mm
B - 3.0 mm + 0.5 mm
C - 5.0 mm 0.5 mm
D - 2.0 mm 1.0 mm
E - 10.5 mm + 1.0 mm
F - 4.0 mm + 1.0 mm

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Rep. gr.00 - Technical data

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G - 8.7 mm + 2.0 mm

Amarok 2011
Body Repairs - Edition 10.2010

5.2

Body - centre, vehicles with double cab

H - 0.5 mm 0.3 mm
I - 4.2 mm 0.5 mm
J - 5.0 mm 0.75 mm
K - 7.0 mm 1.0 mm

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L - 34.5 mm 1.5 mm

5. Body panel gaps/shut lines

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Amarok 2011
Body Repairs - Edition 10.2010

5.3

Body - centre, vehicles with single cab

J - 5.0 mm 0.75 mm
K - 7.0 mm 1.0 mm
M - 2.5 mm 0.3 mm
Q - 3.0 mm 0.3 mm
R - 35.0 mm 5.0 mm

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Rep. gr.00 - Technical data

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10

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Amarok 2011
Body Repairs - Edition 10.2010

5.4

Body - rear, vehicles with double cab

B - 3.0 mm + 0.5 mm
M - 2.5 mm 0.3 mm
N - 20.0 mm 5.0 mm
P - 2.0 mm 0.5 mm
R - 35.0 mm 5.0 mm

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5. Body panel gaps/shut lines

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V - 1.0 mm 0.3 mm

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O - 6.0 mm 1.0 mm

11

Prote
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Amarok 2011
Body Repairs - Edition 10.2010

5.5

Body - rear, vehicles with single cab

B - 3.0 mm + 0.5 mm
O - 6.0 mm 1.0 mm
P - 2.0 mm 0.5 mm

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Rep. gr.00 - Technical data

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Amarok 2011
Body Repairs - Edition 10.2010

5.6

Body add-on parts

S - 1.0 mm + 0.5 mm / - 1.0 mm


Shut line between wheel
cover and body part.

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T - 3.0 mm 1.0 mm
Height difference be
tween wheel cover and
drop sides.

5. Body panel gaps/shut lines

13

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Amarok 2011
Body Repairs - Edition 10.2010

AG. Volkswagen AG d
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Rep. gr.00 - Technical data

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14

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un
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U - 10.5 mm 3.0 mm
Shut line between rear
bumper and drop sides.

Amarok 2011
Body Repairs - Edition 10.2010

Body dimensions
Note

Dimensions only given for checking purposes. The alignment

bracket set is definitive. Bolts, screws, plugs, trim and attached


components must be removed before starting the measuring
process.

Use Telescopic gauge -VAS 5159- or Telescopic gauge -VAS

5160- to determine body dimensions.

6.1

Double cab frame dimensions

6.1.1

Front frame dimensions

Frame dimensions between front frame longitudinal members


Ma a - 1,320 mm 4.0 mm
Dimension between cab
mounting 2
Ma b - 1,015 mm 3.0 mm
Dimension between
suspension strut mount
ings
Ma c - 660 mm 3.0 mm
Dimension diagonally
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Ma d - 645 mm 3.0
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Dimension sbetween
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sembly mountings

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Ma e - 1,040 mm 4.0 mm
Dimension between cab
mounting 1

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Front lower frame dimensions

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Ma f - 800 mm 3.0 mm
Inner dimension be
tween frame longitudi
nal members

6. Body dimensions

15

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Amarok 2011 d by Vo
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Body Repairs - hEdition
10.2010
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Ma a - 800 mm 3.0 mm
Inner dimension be
tween frame longitudi
nal members

Ma b - 815 mm 2.0 mm
Dimension between an
ti-roll bar bolting points

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Rep. gr.00 - Technical data

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Ma c - 840 mm 2.0 mm
Dimension between
front axle mountings

Amarok 2011
Body Repairs - Edition 10.2010

6.1.2

Centre frame dimensions

Lower centre frame dimensions


Ma a - 780 mm 2.0 mm
Dimension between
front axle rear mount
ings
Ma b - 810 mm 3.0 mm
Dimension between
gearbox mountings
Ma c - 490 mm 2.5 mm
Dimension between re
bound strap bolting
points

rrectness of i
t to the co
nf
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spec
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Upper centre frame dimensions

6. Body dimensions

17

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AG.

Prote
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C
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Amarok 2011
Body Repairs - Edition 10.2010
Ma a - 1,340 mm 4.0 mm
Dimension between cab
mounting 3

un
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ng

urposes, in part or in wh
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Ma e - 910 mm 3.0 mm
Inner dimension be
tween frame rear longi
tudinal members

AG.

Prote
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by

Rep. gr.00 - Technical data

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18

rrectne
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form
spec
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Ma d - 1,100 mm 4.0 mm
Dimension between
load surface bolting
point 3

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Ma c - 1,100 mm 4.0 mm
Dimension between
load surface bolting
point 2

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Co
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Ma b - 1,100 mm 4.0 mm
Dimension between
load surface bolting
point 1

Amarok 2011
Body Repairs - Edition 10.2010

6.1.3

Rear frame dimensions

Upper centre frame dimensions


Ma a - 1,340 mm 4.0 mm
Dimension between cab
mounting 3
Ma b - 1,100 mm 4.0 mm
Dimension between
load surface bolting
point 1
Ma c - 1,100 mm 4.0 mm
Dimension between
load surface bolting
point 2
Ma d - 1,100 mm 4.0 mm
Dimension between
load surface bolting
point 3
Ma e - 910 mm 3.0 mm
Inner dimension be
tween frame rear longi
tudinal members

rrectness of i
t to the co
nf
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m
spec
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wit

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l purpos
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Rear diagonal frame dimensions

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m
en

6. Body dimensions

19

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by

AG.

Prote
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by c
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C
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Amarok 2011
Body Repairs - Edition 10.2010
Ma a - 1,345 mm 4.0 mm
Dimension diagonally
between load surface
bolting point 1 on left
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ris 4.0 mm
Ma b - 1,658 mm
tho
u
a diagonally
Dimension
ss
between load surface
bolting point 1 on right
and load surface bolting
point 3 on left

Ma c - 1,195 mm 4.0 mm
Dimension diagonally
between load surface
bolting point 2 on left
and load surface bolting
point 3 on right
Ma d - 1,488 mm 2.5 mm
Dimension between
front leaf spring mount
ing and rear leaf spring
mounting

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20

Amarok 2011
Body Repairs - Edition 10.2010

Single cab frame dimensions

6.2.1

Front frame dimensions


pe
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6.2

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Frame dimensions between front frame longitudinal members


Ma a - 1,320 mm 4.0 mm
Dimension between cab
mounting 2
Ma b - 1,015 mm 3.0 mm
Dimension between
suspension strut mount
ings
Ma c - 660 mm 3.0 mm
Dimension diagonally
between assembly
mountings
r
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Ma f - 800 mm 3.0 mm
Inner dimension be
tween frame longitudi
nal members

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Ma e - 1,040 mm 4.0 mm
Dimension between cab
mounting 1

do
c
um
en

Ma d - 645 mm 3.0 mm
Dimension between as
sembly mountings

Front lower frame dimensions

6. Body dimensions

21

Amarok 2011
Body Repairs - Edition 10.2010
Ma a - 800 mm 3.0 mm
Inner dimension be
tween frame longitudi
nal members

es, in part or in w
l purpos
hole
ercia
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at
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his

Prote
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by

Centre frame dimensions were not yet available at time of going


to print!

6.2.3

Rear frame dimensions

Note

Rear frame dimensions were not yet available at time of going to


print!

22

Rep. gr.00 - Technical data

AG.

Note

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Centre frame dimensions

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6.2.2

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Ma c - 840 mm 2.0 mm
Dimension between
front axle mountings

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Ma b - 815 mm 2.0 mm
Dimension between an
ti-roll bar bolting points

Amarok 2011
Body Repairs - Edition 10.2010

6.3

Double cab box dimensions

6.3.1

AG. Volkswagen AG d
Front box dimensions
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Front engine compartment
box dimensions
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Ma - 956 mm 1.0 mm
Dimension between
lock carrier bolting
points
Ma - 1,412 mm 2.0 mm
Dimension between
lamp carriers
Ma - 982 mm 2.0 mm
Dimension between
wheel housings
Ma - 758 mm 2.0 mm
Dimension wing mount
ing flange

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Ma - 1,742 mm 2.0 mm
Dimension diagonally
between left wing
mounting flange at rear
and right wing mounting
flange at front

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AG.

Prote
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by
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C
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Front box dimensions

6. Body dimensions

23

Amarok 2011
Body Repairs - Edition 10.2010

es, in part or in w
l purpos
hole
ercia
, is n
m
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a
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f
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spec
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wit

Ma - 943 mm 2.0 mm
Dimension between
middle of lamp carriers

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Ma - 1,500 mm 2.0 mm
Dimension between
lower part of front lamp
carriers

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Ma - 935 mm 1.0 mm
Dimension between up
per part of lamp carriers
Ma - 217 mm 2.0 mm
Dimension cross mem
ber to lamp carrier
Ma - 270 mm 2.0 mm
Dimension cross mem
ber to lamp carrier

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by
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Rep. gr.00 - Technical data

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24

thi
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Front end box dimensions

AG. Volkswagen AG d
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f
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Ma - 950 mm 3.0 mm
Dimension between Apillar and front end

Amarok 2011
Body Repairs - Edition 10.2010

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

Ma - 1,067 mm 2.0 mm
Dimension between Apillar and front end

thi
sd
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cu
m
en

6. Body dimensions

25

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AG.

Prote
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by
c
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rig
ht
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C
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Amarok 2011
Body Repairs - Edition 10.2010

6.3.2

Centre box dimensions

Centre box dimensions


Ma - 1,870 mm 3.0 mm
Dimension between Apillars
Ma - 1,870 mm 3.0 mm
Dimension between Bpillars
Ma - 420 mm 2.0 mm: Di
mension
Upper door hinge to low
er door hinge on A-pillar
Ma - 445 mm 2.0 mm
Upper door hinge to low
er door hinge on B-pillar

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Rep. gr.00 - Technical data

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26

rrectness of i
t to the co
nform
spec
at
i
h re
o
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wit
in t
his

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l purpos
hole
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ss

Amarok 2011
Body Repairs - Edition 10.2010

6.3.3

Rear box dimensions

Rear box dimensions


Ma - 1,195 mm 2.0 mm
Dimension between
roof side members
Ma - 1,465 mm 2.0 mm
Dimension rear panel
aperture
Ma - 340 mm 2.0 mm
Dimension rear window
aperture
Ma - 1,524 mm 3.0 mm
Dimension between
side members

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
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wit

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l purpos
hole
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nl
f
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6. Body dimensions

27

AG.

Prote
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by

c
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p
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C
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Amarok 2011
Body Repairs - Edition 10.2010

6.4

Single cab box dimensions

6.4.1

Front box dimensions

Front engine compartment box dimensions

un
le

r
fo
ng

Ma - 1,742 mm 2.0 mm
Dimension diagonally
between left wing
mounting flange at rear
and right wing mounting
flange at front

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p

Ma - 758 mm 2.0 mm
Dimension wing mount
ing flange

Prote
cted
by

Rep. gr.00 - Technical data

AG.

28

agen
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Vo
by

c
o
p
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gh
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.
C
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Front box dimensions

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
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c
um
en

Ma - 982 mm 2.0 mm
Dimension between
wheel housings

ility
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an
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Ma - 1,412 mm 2.0 mm
Dimension between
lamp carriers

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ht
rig
py
Co
t.

Ma - 956 mm 1.0 mm
Dimension between
lock carrier bolting
points

Amarok 2011
Body Repairs - Edition 10.2010
Ma - 1,500 mm 2.0 mm
Dimension between
lower part of front lamp
carriers
Ma - 943 mm 2.0 mm
Dimension between
middle of lamp carriers
Ma - 935 mm 1.0 mm
Dimension between up
per part of lamp carriers

AG. Volkswagen AG d
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Ma - 217 mm 2.0 mm
Dimension cross mem
ber to lamp carrier

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AG.

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C
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Front end box dimensions

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

Ma - 270 mm 2.0 mm
Dimension cross mem
ber to lamp carrier

6. Body dimensions

29

Amarok 2011
Body Repairs - Edition 10.2010
Ma - 950 mm 3.0 mm
Dimension between Apillar and front end

n AG. Volkswagen AG do
es n
wage
s
k
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or
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ac
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ss

6.4.2

Centre box dimensions

Note

Centre box dimensions were not yet available at time of going to


print!

6.4.3

Rear box dimensions

Note

AG.

Prote
cted
by

Rep. gr.00 - Technical data

agen
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by

c
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gh
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.
C
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30

ht
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Rear box dimensions were not yet available at time of going to


print!

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
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urposes, in part or in wh
ole,
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un
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Ma - 1,067 mm 2.0 mm
Dimension between Apillar and front end

Amarok 2011
Body Repairs - Edition 10.2010

6.5

Double cab load surface dimensions

6.5.1

Upper load surface dimensions

Outer/inner load surface dimensions

do
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en

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com

Ma - 2,122 mm 2.0 mm
Diagonal dimension for
load surface

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Ma - 1,810 mm 2.0 mm
Dimension outer side of
load area side panel

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Ma - 1,547 mm 2.0 mm
Dimension inner side of
load area side panel

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by

AG.

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by

c
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Lashing eye deviations

6. Body dimensions

31

Amarok 2011
Body Repairs - Edition 10.2010
Ma - 1,574 mm 2.0 mm
Dimension between
lashing eyes
Ma - 1,656 mm 2.0 mm
Diagonal dimension be
tween lashing eyes

ht
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py
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by

AG.

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by

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Rep. gr.00 - Technical data

do
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32

rrectness of i
t to the co
nform
spec
at
i
h re
o
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wit
in t
his

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l purpos
hole
ercia
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Amarok 2011
Body Repairs - Edition 10.2010

6.5.2

Lower load surface dimensions

Lower load surface deviations

es, in part or in w
l purpos
hole
ercia
, is n
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Ma - 1,653 mm 2.0 mm
Dimension between
rear part of wheel hous
ings

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spec
at
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Ma - 1,420 mm 2.0 mm
Dimension lower part of
tailboard aperture

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Co
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Ma - 1,663 mm 2.0 mm
Dimension between
front part of wheel hous
ings

6. Body dimensions

33

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by

AG.

Prote
cted
by
c
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rig
ht
.
C
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Amarok 2011
Body Repairs - Edition 10.2010

6.5.3

Rear load surface dimensions

Rear load surface deviations


Ma - 1,421 mm 2.0 mm
Dimension lower part of
tailboard aperture
Ma - 1,362 mm 2.0 mm
Dimension between Dpillars
Ma - 1,421 mm 2.0 mm
Dimension upper part of
tailboard aperture
Ma - 381mm 1.0 mm
Dimension tail light
aperture

6.6

Single cab load surface dimensions

6.6.1

Upper load surface dimensions

Note

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
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erm
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t
a
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f
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n

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Upper load surface dimensions were not yet available at time of


going to print!

Lower load surface dimensions

Prote
cted
by

Rep. gr.00 - Technical data

AG.

34

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Lower load surface dimensions were not yet available at time of


going to print!

ht
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Co
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Note

do
c
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en

6.6.2

Amarok 2011
Body Repairs - Edition 10.2010

6.6.3

Rear load surface dimensions

Rear load surface deviations


Ma - 1,421 mm 2.0 mm
Dimension lower part of
tailboard aperture
Ma - 1,362 mm 2.0 mm
Dimension between Dpillars
Ma - 1,421 mm 2.0 mm
Dimension upper part of
tailboard aperture
Ma - 381mm 1.0 mm
Dimension tail light
aperture

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

es, in part or in w
l purpos
hole
ercia
, is n
m
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thi
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6. Body dimensions

35

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Co
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by

AG.

Prote
cted
by

c
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.
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Amarok 2011
Body Repairs - Edition 10.2010

Alignment jig

7.1

Tools

Special tools and workshop equipment required


Alignment jig -V.A.G 1920/1 Measurement and alignment system -VAS 6526-Basis Measurement and alignment system -VAS 6527-Profi Measurement and alignment system -VAS 6527-Profi-Plus. Volkswage
n AG
wage

ks 6637 Alignment bracket set Amaroky-VAS


Vol
b
ed

ris
Portal gauge supplement,
ho Amarok -VAS 5007/48es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
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o
e
t
a
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f
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n

Alignment bracket fixture overview of complete vehicle

Alignment bracket fixture overview of complete vehicle with align


ment bracket set Amarok -VAS 6637-

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

ht
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AG.

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by
c
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rig
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Rep. gr.00 - Technical data

do
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36

ility
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7.2

t
au
ss

n AG d
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c

Amarok 2011
Body Repairs - Edition 10.2010
Note

Detailed information on setting up the alignment bracket set can be found in the installation plans enclosed with
the alignment bracket set.

7.3

Alignment bracket fixture overview of vehicle chassis

Alignment bracket fixture overview of vehicle chassis


with align
G. Volkswagen AG d
ment bracket set Amarok -VAS 6637- lkswagen A
oes
n

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ua
ran
tee
or
ac

rrectness of i
t to the co
nf
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m
spec
atio
h re
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wit

es, in part or in w
l purpos
hole
ercia
, is n
m
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or
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a
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a
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thi
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by

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.
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Note

Detailed information on setting up the alignment bracket set can be found in the installation plans enclosed with
the alignment bracket set.

7. Alignment jig

37

Amarok 2011
Body Repairs - Edition 10.2010

7.4

Alignment bracket fixture overview of vehicle cab

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s
s
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f
i
t to the co
n
form
spec
atio
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wit
i
n
thi
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urposes, in part or in wh
ole,
cial p
is n
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a
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un
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Alignment bracket fixture overview of vehicle cab with alignment


bracket set Amarok -VAS 6637-

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AG.

Prote
cted
by

c
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.
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Note

Detailed information on setting up the alignment bracket set can be found in the installation plans enclosed with
the alignment bracket set.

38

Rep. gr.00 - Technical data

Amarok 2011
Body Repairs - Edition 10.2010

7.5

Alignment bracket fixture overview of vehicle cab

Alignment bracket fixture overview of front of vehicle cab with


alignment bracket set Amarok -VAS 5007/48-

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

Alignment bracket fixture overview of rear of vehicle cab with


alignment bracket set Amarok -VAS 5007/48-

do
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en

es, in part or in w
l purpos
hole
ercia
, is n
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7. Alignment jig

39

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by

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.
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r
fo
ng

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
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en

urposes, in part or in wh
ole,
cial p
is n
mer
m
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or
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t
a
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v
i
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d
p

un
le

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ht
rig
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Co
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Amarok 2011
Body Repairs - Edition

AG. Volkswagen AG d
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10.2010 tho
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by

AG.

Prote
cted
by c
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Note

Detailed information on setting up the portal gauge supplementary set can be found in the installation plans
enclosed with the portal gauge set.

40

Rep. gr.00 - Technical data

Amarok 2011
Body Repairs - Edition 10.2010

50

Body - front

RO: 50 34 55 00

Renewing cross member

WARNING

Observe safety notes!

AG. Volkswagen AG d
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Co
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te o
iva
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fo
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rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s

es, in part or in w
l purpos
hole
ercia
, is n
m
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com

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rm
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d

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un
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Safety notes General Information; Body Repairs, General Body


Repairs ; Safety notes

1. Renewing cross member

41

agen
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by

AG.

Prote
cted
by c
o
p
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gh
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C
op
yi

Amarok 2011
Body Repairs - Edition 10.2010

1.1

Removing

Carry out the following work:


Note
The bolt for the cross member support -1- was discontinued in production as of July 2010 . Instead the

front cross member support was welded to the frame longitudinal member -2- in production.

If a cross member with bolted support requires replacement, the support must be welded to the new cross

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by

AG.

Prote
cted
by
c
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py
rig
ht
.
C
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Models July 2010; undo bolt -1- of cross member support.


Models July 2010 : separate original joint of cross member
support.
Separate original joint of cross member from front.
Remove cross member from frame.

42

Rep. gr.50 - Body - front

do
c
um
en

r
te o
iva
r
rp
fo
g
n

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s

es, in part or in w
l purpos
hole
ercia
, is n
m
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com

pe
rm
itte
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un
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member when installing the cross member. The bolting point in the frame longitudinal member must be
closed with weld and the support is then welded in position.

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ht
rig
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Co
t.

r
te o
iva
r
rp
fo
g
n

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s

es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com

pe
rm
itte
d

ility
ab
y li
an
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un
le

Amarok 2011
Body Repairs - Edition 10.2010

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Vo
by

AG.

Prote
cted
by

c
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p
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gh
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.
C
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Remove remaining material -1- on frame longitudinal mem


bers.
Grind welding surfaces and welding edges down to bare met
al.

1.2

Installing

1.2.1

Preparing new part

Replacement part
Cross member
Carry out the following work:

1. Renewing cross member

43

un
le
Rep. gr.50 - Body - front

Prote
cted
by

44

AG.

Grind support down to bare metal.

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.
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Grind welding edges back to bare metal from inside.

do
c
um
en

r
te o
iva
r
rp
fo
g
n

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s

es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com

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rm
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ht
rig
py
Co
t.

Amarok 2011
Body Repairs - Edition 10.2010

Amarok 2011
Body Repairs - Edition 10.2010

1.2.2

Welding in

Carry out the following work:


Note
It is no longer permissible to bolt the cross member support to the frame longitudinal member.
If a cross member with bolted support was installed in the vehicle, the threaded connection in the frame

longitudinal member must be closed with weld before installing the new cross member.

Then the support must be welded to the frame longitudinal member, SG continuous weld seam.

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
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du
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o
nl
f
e
ng

ility
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an
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ht
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Co
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by

AG.

Prote
cted
by
c
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py
rig
ht
.
C
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Adapt new part using alignment bracket set and fix in place.
Weld in cross member, SG continuous weld seam.
Weld in support, SG continuous weld seam.

1. Renewing cross member

45

Amarok 2011
Body Repairs - Edition 10.2010
RO: 50 34 55 10

Renewing deformation element

WARNING

Observe safety notes!


Safety notes General Information; Body Repairs, General Body
Repairs ; Safety notes

2.1

Tools

Special tools and workshop equipment required


Resistance spot welder -VAS 6239 A Resistance spot welder -VAS 6535 Accessory pack -VAS 6535 /1-

2.2

Removing

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cted
by

c
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.
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Rep. gr.50 - Body - front

ht
rig
py
Co
t.

46

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
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c
erm
or
e
t
a
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v
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d
p

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un
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Carry out the following work:

Separate original

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a
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Remove remaining material.


Grind welding edges back to bare metal.

2.3

Installing

The use of different types and different thicknesses of steel re


quires that one of the welding units (inverter) listed under Tools
must be used for proper spot welding 2.1 Tools, page 46 .
AG.

Preparing replacement part

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by
c
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2.3.1

ht
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Co
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fo
ng

Note

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p

un
le

ility
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Remove deformation element from body.

Amarok 2011
- Edition 10.2010

Replacement part
Deformation element
Carry out the following work:
Grind welding surfaces on both sides back to bare metal.

2. Renewing deformation element

47

Amarok 2011
Body Repairs - Edition 10.2010

2.3.2

Welding in

Carry out the following work:

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
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o
nl
f
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ng

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Adapt new part on both sides according to -dimension a- and


fix in place.
Dimension a = 270 mm

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Co
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AG.

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cted
by

c
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C
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Rep. gr.50 - Body - front

thi
sd
o
cu
m
en

48

Amarok 2011
Body Repairs - Edition 10.2010

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
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iv
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nl
f
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ng

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C
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Weld in deformation element, RP spot weld seam.

AG.

2. Renewing deformation element

49

Prote
cted
by

Amarok 2011
Body Repairs - Edition 10.2010
RO: 50 60 55 00

Renewing headlight mounting

WARNING

Observe safety notes!


Safety notes General Information; Body Repairs, General Body
Repairs ; Safety notes

3.1

Tools

Special tools and workshop equipment required


Resistance spot welder -VAS 6239 A Resistance spot welder -VAS 6535 Accessory pack -VAS 6535 /1-

3.2

Removing

Deformation element already removed


2 Renewing deformation element, page 46 .
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Rep. gr.50 - Body - front

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Amarok 2011
Body Repairs - Edition 10.2010

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Prote
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Separate original joint.

3. Renewing headlight mounting

51

Amarok 2011
Body Repairs - Edition 10.2010

rrectness of i
t to the co
nform
spec
at
i
h re
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wit
in t
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52

Rep. gr.50 - Body - front

AG.

Remove headlight mounting -2- from body.

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Heat bonding surface -1- with hot air blower -V.A.G 1416- .

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Separate original joint.

do
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Unscrew bolt -1- for cab mounting.

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Remove remaining material.

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rrectness of i
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com

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un
le

Amarok 2011
Body Repairs - Edition 10.2010

Grind bonding surface and welding surfaces on both sides


back to bare metal.

3.3

Installing
Note

The use of different types and different thicknesses of steel re


quires that one of the welding units (inverter) listed under Tools
must be used for proper spot welding 3.1 Tools, page 50 .

3.3.1

Preparing replacement part

Replacement parts
Headlight mounting
Body adhesive 2K adhesive -D 180 KD3 A2Carry out the following work:

3. Renewing headlight mounting

53

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Drill specified holes in new part, 7.0 mm.

AG.

Rep. gr.50 - Body - front

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Prote
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by
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54

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Grind welding surfaces on both sides back to bare metal.

rrectne
s
s
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form
spec
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ole,
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Amarok 2011
Body Repairs - Edition 10.2010

Amarok 2011
Body Repairs - Edition 10.2010

3.3.2

Welding in

Carry out the following work:


Apply body adhesive 2K adhesive -D 180 KD3 A2- to bonding
surface.
Note
Apply adhesive bead sufficiently thickly so that optimal bond

ing with the body is guaranteed.

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New part must be welded in within 90 minutes or adhesion
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Prote
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by

c
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adhesive will be impaired.

3. Renewing headlight mounting

55

Amarok 2011
Body Repairs - Edition 10.2010
Adapt new part with vehicle standing on its wheels or on align
ment bracket set and hold in position.
Check fit with all add-on parts.

AG. Volkswagen AG d
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Install bolt -1- for cab mounting.


Weld in headlight mounting, SG plug weld seam.

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Prote
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by c
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Rep. gr.50 - Body - front

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56

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Install deformation element 2.3 Installing, page 47 .

rrectness of i
t to the co
nform
spec
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un
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Weld in headlight mounting, RP spot weld seam and SG plug


weld seam.

Amarok 2011
Body Repairs - Edition 10.2010
RO: 50 53 55 00

Renewing wing connecting plate

WARNING

Observe safety notes!


Safety notes General Information; Body Repairs, General Body
Repairs ; Safety notes
1 - Bonded areas
2 - Cutting point
The parting cut is per
mitted for other forms of
damage.

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Tools

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4.1

rrectness of i
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Special tools and workshop equipment required


Resistance spot welder -VAS 6239 A Resistance spot welder -VAS 6535 Accessory pack -VAS 6535 /1-

4. Renewing wing connecting plate

57

Removing

r
fo
ng

Remove wing connecting plate from body.

58

Rep. gr.50 - Body - front

Prote
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by

Heat bonded areas with hot air blower -V.A.G 1416- .

AG.

Separate original joint.

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c
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Bend up metal tab -1-.

rrectne
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i
t to the co
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form
spec
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ole,
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Carry out the following work:

un
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4.2

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Amarok 2011
Body Repairs - Edition 10.2010

Amarok 2011
Body Repairs - Edition 10.2010

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Prote
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by c
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p
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Remove remaining material.


Grind bonding surfaces and welding surfaces on both sides
back to bare metal.

4.3

Installing
Note

The use of different types and different thicknesses of steel re


quires that one of the welding units (inverter) listed under Tools
must be used for proper spot welding 4.1 Tools, page 57 .

4.3.1

Preparing replacement part

Replacement parts
Wing connecting plate
Body adhesive 2K adhesive -D 180 KD3 A2-

4. Renewing wing connecting plate

59

Amarok 2011
Body Repairs - Edition 10.2010
Carry out the following work:
Drill specified holes in new part, 7.0 mm.
Grind welding surfaces on both sides back to bare metal.

4.3.2

Welding in

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Rep. gr.50 - Body - front

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60

ht
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Apply body adhesive 2K adhesive -D 180 KD3 A2- to bonding


surface.

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s
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i
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form
spec
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ole,
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Carry out the following work:

Amarok 2011
Body Repairs - Edition 10.2010
Note
Apply adhesive bead sufficiently thickly so that optimal bonding with the body is guaranteed.

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Adapt new part with vehicle standing on its wheels or on align


ment bracket set and fix in position.

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Co
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c
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p
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Check fit with all add-on parts.

do
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rrectness of i
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nform
spec
a
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thi
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l purpos
hole
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com

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New part must be welded in within 90 minutes or adhesion of adhesive will be impaired.

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Weld in wing connecting plate, RP spot weld seam and SG


plug weld seam.
AG.

Prote
cted
by

Bend metal tab -1- back.

4. Renewing wing connecting plate

61

Amarok 2011
Body Repairs - Edition 10.2010
RO: 50 53 55 10

Renewing connection piece

WARNING

Observe safety notes!

5.1

Tools

Special tools and workshop equipment required


Resistance spot welder -VAS 6239 A Resistance spot welder -VAS 6535 Accessory pack -VAS 6535 /1-

5.2

Removing
Note

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
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urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
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p

un
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Safety notes General Information; Body Repairs, General Body


Repairs ; Safety notes

ility
ab
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AG. Volkswagen AG d
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Rep. gr.50 - Body - front

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Prote
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by c
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C
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62

ht
rig
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Co
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Make parting cuts with pneumatic jig-saw -V.A.G 1523- only. Do not damage inner reinforcements.

do
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Co
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un
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r
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rrectness of i
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nform
spec
a
t
i
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wit
thi
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l purpos
hole
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Carry out the following work:

AG. Volkswagen AG d
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Amarok 2011
nte
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h
Body Repairs - Edition 10.2010
ut
ra
a
c
s
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by

AG.

Prote
cted
by
c
o
py
rig
ht
.
C
op
yi

Make parting cut.


Separate original joint.
Heat bonding surface -1- with hot air blower -V.A.G 1416- .
Remove connection piece from body.
Remove remaining material.
Grind bonding surfaces and welding surfaces on both sides
back to bare metal.

5. Renewing connection piece

63

Amarok 2011
Body Repairs - Edition 10.2010

5.3

Installing
Note

The use of different types and different thicknesses of steel re


quires that one of the welding units (inverter) listed under Tools
must be used for proper spot welding 5.1 Tools, page 62 .

5.3.1

Preparing replacement part

Replacement parts
A-pillar reinforcement
Body adhesive 2K adhesive -D 180 KD3 A2Carry out the following work:
Transfer dimension for parting cut from body and carry out.
Drill out connection piece from A-pillar reinforcement.
Punch specified holes in new part, 7.0 mm.
Grind bonding surface back to bare metal.

Carry out the following work:

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

Welding in

ility
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5.3.2

es, in part or in w
l purpos
hole
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m
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Grind welding surfaces on both sides back to bare

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Apply body adhesive 2K adhesive -D 180 KD3 A2- to bonding


surface.

Apply adhesive bead sufficiently thickly so that optimal bond


c
o
p
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gh
t.
C
op
yi

New part must be welded in within 90 minutes or adhesion of

Prote
cted
by

Rep. gr.50 - Body - front

AG.

64

agen
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by

adhesive will be impaired.

ht
rig
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Co
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ing with the body is guaranteed.

thi
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Note

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Prote
cted
by c
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C
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AG.

Check fit with bolt-on parts.

ht
rig
py
Co
t.

Adapt new part with vehicle standing on its wheels or on align


ment bracket set and fix in position.

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
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c
um
en

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p

ility
ab
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an
pt
ce

un
le

Amarok 2011
Body Repairs - Edition 10.2010

Weld in connection piece, RP spot weld seam, SG plug weld


seam and SG continuous weld seam.
Seal cavity after welding work.

5. Renewing connection piece

65

Amarok 2011
Body Repairs - Edition 10.2010
RO: 50 72 55 70

Safety notes General Information; Body Repairs, General Body


Repairs ; Safety notes

6.1

Tools

Special tools and workshop equipment required


Resistance spot welder -VAS 6239 A Accessory pack -VAS 6535 /1-

6.2

Removing

Deformation element already removed


2 Renewing deformation element, page 46

Headlight mounting already removed


3 Renewing headlight mounting, page 50

Wing connecting plate already removed


4 Renewing wing connecting plate, page 57

Connection piece already removed


5 Renewing connection piece, page 62

r
fo
ng

AG.

Prote
cted
by

Rep. gr.50 - Body - front

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66

c
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p
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C
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Carry out the following work:

ht
rig
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Co
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Resistance spot welder -VAS 6535-

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en

Observe safety notes!

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
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p

WARNING

ility
ab
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an
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ce

Renewing upper wheel housing lon


gitudinal member
un
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Amarok 2011
Body Repairs - Edition 10.2010

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
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iv
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du
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f
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ng

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an
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ht
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Co
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Prote
cted
by
c
o
py
rig
ht
.
C
op
yi

Separate original joint.

Remove upper longitudinal member for wheel housing from


body.

6. Renewing upper wheel housing longitudinal member

67

AG.

un
le

6.3

Installing
Note

The use of different types and different thicknesses of steel re


quires that one of the welding units (inverter) listed under Tools
must be used for proper spot welding 6.1 Tools, page 66 .

6.3.1

Preparing replacement part

Replacement part
Upper longitudinal member for wheel housing

68

Rep. gr.50 - Body - front

AG.

Grind welding surfaces on both sides back to bare metal.

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Remove remaining material.

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Co
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Amarok 2011
Body Repairs - Edition 10.2010

Amarok 2011
Body Repairs - Edition 10.2010
Carry out the following work:
Grind welding surfaces on both sides back to bare metal.

es, in part or in w
l purpos
hole
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Welding in

rrectness of i
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at
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wit
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his

Carry out the following work:

do
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Adapt new part with vehicle standing on its wheels or on align


ment bracket set and fix in position.
Check fit with bolt-on parts.
Weld in upper longitudinal member for wheel housing, RP spot
weld seam and SG plug weld seam.
6. Renewing upper wheel housing longitudinal member

69

Amarok 2011
Body Repairs - Edition 10.2010
Install wing connecting plate 4.3 Installing, page 59 .

Install connection piece 5.3 Installing, page 64 .

Install headlight mounting 3.3 Installing, page 53 .

Install deformation element 2.3 Installing, page 47 .

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Rep. gr.50 - Body - front

ht
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70

rrectne
s
s
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f
i
t to the co
n
form
spec
atio
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thi
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ole,
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or
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un
le

Renewing front wheel housing

WARNING

Observe safety notes!

Safety notes General Information; Body Repairs, General Body


Repairs ; Safety notes

7.1

Removing

Deformation element already removed


2 Renewing deformation element, page 46

Headlight mounting already removed


3 Renewing headlight mounting, page 50

Wing connecting plate already removed


4 Renewing wing connecting plate, page 57

Connection piece already removed


5 Renewing connection piece, page 62

Upper longitudinal member for wheel housing already re


moved
6 Renewing upper wheel housing longitudinal member,
page 66 .

do
c
um
en

Amarok 2011
Body Repairs - Edition 10.2010

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

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l purpos
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RO: 50 74 55 00

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by

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Carry out the following work:

7. Renewing front wheel housing

71

Amarok 2011
Body Repairs - Edition 10.2010

es, in part or in w
l purpos
hole
ercia
, is n
m
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Separate original joint.

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

Remove front wheel housing from body.


Remove remaining material.

Grind welding surface on both sides back to bare metal.

Front wheel housing

72

Rep. gr.50 - Body - front

Prote
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by
c
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ht
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Replacement part

AG.

Preparing replacement part

agen
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7.2.1

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Installing

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7.2

Amarok 2011
Body Repairs - Edition 10.2010
Carry out the following work:
Punch holes in new part, 7.0 mm.

7.2.2

Welding in

ht
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Co
t.

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ng

Carry out the following work:

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
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wit
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thi
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ole,
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Grind welding surface on both sides back to bare metal.

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AG.

Prote
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by c
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p
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gh
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C
op
yi

Adapt new part with vehicle standing on its wheels or on align


ment bracket set and fix in position.
Check fit with bolt-on parts.
Weld in front wheel housing, SG plug weld seam.

7. Renewing front wheel housing

73

Amarok 2011
Body Repairs - Edition 10.2010

Install upper longitudinal member for wheel housing


6.3 Installing, page 68 .

Install wing connecting plate 4.3 Installing, page 59 .

Install connection piece 5.3 Installing, page 64 .

Install headlight mounting 3.3 Installing, page 53 .

Install deformation element 2.3 Installing, page 47 .

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Rep. gr.50 - Body - front

do
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74

rrectness of i
t to the co
nform
spec
at
i
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n
wit
in t
his

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hole
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Amarok 2011
Body Repairs - Edition 10.2010
RO: 50 80 55 00

Renewing front part of longitudinal


member - part section 1-

WARNING

Observe safety notes!


Safety notes General Information; Body Repairs, General Body
Repairs ; Safety notes

8.1

Removing

Cross member already removed


1 Renewing cross member, page 41 .
Note

Parting cut must be straight.

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Carry out the following work:

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AG.

Prote
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by

c
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gh
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C
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yi

8. Renewing front part of longitudinal member - part section 1-

75

Amarok 2011
Body Repairs - Edition 10.2010

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

es, in part or in w
l purpos
hole
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Carry out parting cut -1- as per -dimension a-.


Dimension a = 60 mm from mounting bracket
Remove front section of longitudinal member.

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Rep. gr.50 - Body - front

do
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76

ht
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Co
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un
le

r
fo
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rrectne
s
s
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f
i
t to the co
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form
spec
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wit
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ole,
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Amarok 2011
Body Repairs - Edition 10.2010

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by

AG.

Prote
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by

c
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p
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gh
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C
op
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Remove remaining material.


Grind welding surface back to bare metal.

8.2

Installing

8.2.1

Preparing replacement part

Replacement part
Front longitudinal member complete
Carry out the following work:

8. Renewing front part of longitudinal member - part section 1-

77

Amarok 2011
Body Repairs - Edition 10.2010

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

es, in part or in w
l purpos
hole
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, is n
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Transfer parting cut -1- from body to new part.


Make parting cut -1-.

Grind welding surface back to bare metal.

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Co
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Prote
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by
c
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rig
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.
C
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yi

Rep. gr.50 - Body - front

do
c
um
en

78

Amarok 2011
Body Repairs - Edition 10.2010

8.2.2

Welding in

Carry out the following work:

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
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c
erm
or
e
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nl
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Adapt new part to vehicle standing on alignment bracket set


and fix in place.

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by

AG.

Note

Prote
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by
c
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py
rig
ht
.
C
op
yi

Dimension a = 3.5 mm + 0.5 mm

ht
rig
py
Co
t.

Weld parting cut all round in front section of longitudinal mem


ber -1- adhering to -air gap dimension a-, SG continuous weld
seam.

thi
sd
o
cu
m
en

Check fit with adjacent parts.

Adherence to -air gap dimension a- is vital to guarantee proper through-welding.


Before welding longitudinal member, check welder settings; weld several test seams and check roots of

test weld seams (correct welding parameters if necessary).

SG continuous weld seam must not be reworked (ground or smoothed)!


Carry out cavity preservation on front longitudinal member.
8. Renewing front part of longitudinal member - part section 1-

79

Amarok 2011
Body Repairs - Edition 10.2010

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Prote
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by

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Rep. gr.50 - Body - front

ht
rig
py
Co
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80

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en

urposes, in part or in wh
ole,
cial p
is n
mer
m
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o
c
erm
or
e
t
a
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v
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d
p

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ab
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an
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un
le

Install front cross member 1.2 Installing, page 43 .

Amarok 2011
Body Repairs - Edition 10.2010
RO: 50 79 55 02

Renewing longitudinal member - part


section 2-

WARNING

Observe safety notes!


Safety notes General Information; Body Repairs, General Body
Repairs ; Safety notes

9.1

Removing

Cross member already removed


1 Renewing cross member, page 41 .
Note

Parting cut must be straight.


Carry out the following work:

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

es, in part or in w
l purpos
hole
ercia
, is n
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ht
rig
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Co
t.

9. Renewing longitudinal member - part section 2-

81

agen
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Vo
by

AG.

Prote
cted
by c
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p
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gh
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C
op
yi

Amarok 2011
Body Repairs - Edition 10.2010

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

es, in part or in w
l purpos
hole
ercia
, is n
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AG.

Prote
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by

82

Rep. gr.50 - Body - front

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c
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C
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Remove longitudinal member.

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Co
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Dimension a = 60 mm from mounting bracket

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Carry out parting cut -1- as per -dimension a-.

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com

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un
le

Amarok 2011
Body Repairs - Edition 10.2010

Remove remaining material.

Grind welding surface back to bare metal.

9.2

Installing

9.2.1

Preparing replacement part

Replacement parts

Front longitudinal member complete

do
c
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en

ht
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Co
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Carry out the following work:

r
te o
iva
r
rp
fo
g
n

Mounting bracket for front for cab mounting

9. Renewing longitudinal member - part section 2-

83

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by

Grind welding surface back to bare metal.

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c
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C
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yi

Make parting cut -1-.

Grind welding edges of mounting bracket back to bare metal.

84

Rep. gr.50 - Body - front

ht
rig
py
Co
t.

Transfer parting cut -1- from body to new part.

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
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urposes, in part or in wh
ole,
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is n
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a
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Amarok 2011
Body Repairs - Edition 10.2010

Amarok 2011
Body Repairs - Edition 10.2010

9.2.2

Producing longitudinal member reinforcement


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s
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f
i
t to the co
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form
spec
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ole,
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Carry out the following work:

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c
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rig
ht
.
C
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yi

Using in-house material, produce longitudinal member rein


forcement according to deviations -a-, -b- and -c-.
Dimension a = 90 mm
Dimension b = 40 mm
Dimension c = 60 mm
Grind welding edges of longitudinal member reinforcement
back to bare metal.

9. Renewing longitudinal member - part section 2-

85

AG. Volkswagen AG d
Amarok 2011
agen
oes
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not
l
o
V
Body Repairs - Edition 10.2010
gu
by

or
ac

r
fo
ng

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
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n
wit
i
n
thi
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urposes, in part or in wh
ole,
cial p
is n
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or
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t
a
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v
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p

Carry out the following work:

ss

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Welding in

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Co
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9.2.3

ara
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ed
ris
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h
t
au

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AG.

Prote
cted
by c
o
p
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gh
t.
C
op
yi

Adapt new part to vehicle standing on alignment bracket set


and fix in place.
Check fit with adjacent parts.
Weld parting cut all round in longitudinal member -1- adhering
to -air gap dimension a-, SG continuous weld seam.
Dimension a = 3.5 mm + 0.5 mm
Note
Adherence to -air gap dimension a- is vital to guarantee proper through-welding.
Before welding longitudinal member, check welder settings; weld several test seams and check roots of

test weld seams (correct welding parameters if necessary).

SG continuous weld seam must not be reworked (ground or smoothed)!

86

Rep. gr.50 - Body - front

AG. Volkswagen AG d
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Adapt longitudinal member reinforcement -1- to longitudinal


member -2- and fix in position.

ht
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Co
t.

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fo
ng

Weld in longitudinal member reinforcement -1- all round, SG


continuous weld seam.

rrectne
s
s
o
f
i
t to the co
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form
spec
atio
h re
n
wit
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ole,
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p

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Amarok 2011
Body Repairs - Edition 10.2010

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9. Renewing longitudinal member - part section 2-

87

olkswagen AG
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by
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Weld in mounting bracket, SG continuous weld seam.


Carry out cavity preservation on front longitudinal member.
Install front cross member 1.2 Installing, page 43 .

88

Rep. gr.50 - Body - front

do
c
um
en

Adapt mounting bracket -1- to fit and fix in position.

ht
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Co
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a
ss

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Amarok 2011
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Body Repairs - Edition
se

Amarok 2011
Body Repairs - Edition 10.2010
RO: 50 79 55 00

10

Renewing longitudinal member com


plete

WARNING

Observe safety notes!


Safety notes General Information; Body Repairs, General Body
Repairs ; Safety notes
AG. Volkswagen AG d
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1 - Longitudinal member
ara
d
nte
ise
r
plete
o
eo
h
t
u
ra
a
c
Slid intossmiddle
part of
pe
rm
itte
d

un
le

ility
ab
y li
an
pt
ce

frame and welded.

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s

es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com

2 - Cab mounting
Welded to longitudinal
member.
Replaced during repairs
as well.
3 - Suspension strut mounting
Welded to longitudinal
member.
Replaced during repairs
as well.

agen
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by

AG.

Prote
cted
by

c
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C
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6 - Brake line mounting


Welded to longitudinal
member.
Replaced during repairs
as well.

ht
rig
py
Co
t.

5 - Anti-roll bar mounting


Welded to longitudinal
member.
Replaced during repairs
as well.

do
c
um
en

r
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iva
r
rp
fo
g
n

4 - Mounting bracket
Welded to longitudinal
member.
Replaced during repairs
as well.

7 - Reinforcement
Welded to longitudinal
member.
Replaced during repairs as well.
8 - Mounting for engine mounting
Welded to longitudinal member.
Replaced during repairs as well.
9 - Bracket
Welded to suspension strut.
For ABS hydraulic unit -N55- and ABS control unit -J104- .
Replaced during repairs as well.
10. Renewing longitudinal member complete

89

Amarok 2011
Body Repairs - Edition 10.2010
10 - Mounting for cross member for gearbox mounting
Welded to longitudinal member.
Replaced during repairs as well.
11 - Reinforcing plate
Welded to longitudinal member and frame.
AG. Volkswagen AG d
Replaced during repairs as well.
agen
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Removing

ility
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Caution

ss

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l purpos
hole
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erm
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a
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10.1

ot g
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rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

The frame of the Amarok and the parts fitted on it are welded
using SG continuous weld seams.
When separating individual welded seams, ensure that the
weld edges of adjacent parts are not damaged.
If the weld edges of separated parts do not lie on the frame
when rewelding, then replace these parts.

The cab must be separated from the frame for this repair. Re
moving cab General body repairs, exterior; Rep. gr. 55 ;
Cab .

Cross member already removed


1 Renewing cross member, page 41 .

agen
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by

AG.

Prote
cted
by c
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C
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Rep. gr.50 - Body - front

ht
rig
py
Co
t.

90

do
c
um
en

Carry out the following work:

Amarok 2011
Body Repairs - Edition 10.2010

es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n

ility
ab
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an
pt
ce

AG. Volkswagen AG d
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l
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by
ara
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nte
is
r
o
eo
h
ut
ra
a
c
s
s

Separate original joint of anti-roll bar mounting -1-.

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

Remove anti-roll bar mounting -1- from longitudinal member


and cross member.
Remove material remains on cross member.
Grind welding surfaces on cross member down to bare metal.

do
c
um
en

ht
rig
py
Co
t.

agen
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by

10. Renewing longitudinal member complete

91

AG.

Prote
cted
by c
o
p
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gh
t.
C
op
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Amarok 2011
Body Repairs - Edition 10.2010

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng

ility
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n AG. Volkswagen AG do
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ir se
tee
o
h
t
or
u
ac
a
ss

Separate original joints of cross members -1- and -2-.


Note

Ensure the weld edges of the cross member are not damaged when separating the SG continuous weld

seams.

If the weld edges of the separated cross member do not lie on the longitudinal member when rewelding,

then replace this part.

ht
rig
py
Co
t.

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by

AG.

Prote
cted
by

c
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.
C
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Rep. gr.50 - Body - front

thi
sd
o
cu
m
en

92

Amarok 2011
Repairs - Edition 10.2010

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng

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n AG. Volkswagen AG do
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or Body
u
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a
ss

thi
sd
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Co
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by

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Prote
cted
by

c
o
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gh
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.
C
op
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Separate original joints of reinforcement -1- and remove from


frame.
Separate original joints of cross members -2- and -3- from be
low.
Note
Ensure the weld edges of the cross member are not damaged when separating the SG continuous weld

seams.

If the weld edges of the separated cross members do not lie on the longitudinal member when rewelding,

then replace these parts.

10. Renewing longitudinal member complete

93

Amarok 2011
Body Repairs - Edition 10.2010

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

Separate original joint of reinforcement -1- and remove from


frame.
Undo bolts -3- on both sides and remove middle part -2- of
cross member.

agen
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by

AG.

Prote
cted
by c
o
p
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gh
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C
op
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Rep. gr.50 - Body - front

ht
rig
py
Co
t.

94

thi
sd
o
cu
m
en

es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
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o
nl
f
e
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AG. Volkswagen AG d
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ht
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c
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.
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Separate original joint of longitudinal member to middle part


of frame all round.

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
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v
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r
d
p

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an
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un
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Amarok 2011
Body Repairs - Edition 10.2010

AG.

10. Renewing longitudinal member complete

95

Prote
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by

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Rep. gr.50 - Body - front

ht
rig
py
Co
t.

96

do
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um
en

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te o
iva
r
rp
fo
g
n

Separate longitudinal member -1- from frame and pull out of


middle part of frame.

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s

es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com

pe
rm
itte
d

ility
ab
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an
pt
ce

un
le

Amarok 2011
Body Repairs - Edition 10.2010

Amarok 2011
Body Repairs - Edition 10.2010

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
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du
p
or
nl
f
e
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ac
a
ss

Remove material remains from cross members -1- and -2- and
from middle part of frame -3-.
Grind welding surfaces back to bare metal.

Front longitudinal member complete

Prote
cted
by

c
o
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.
C
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Replacement parts

AG.

Preparing new part

agen
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10.2.1

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Co
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Installing

do
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en

10.2

Front mounting bracket


Anti-roll bar mounting
Reinforcement
Brake line mounting
Suspension strut mounting
Cab mounting
Mounting for cross member for gearbox mounting
Mounting for engine mounting
10. Renewing longitudinal member complete

97

Amarok 2011
Body Repairs - Edition 10.2010
Bracket for hydraulic unit
Reinforcing plate
Carry out the following work:
Grind weld surfaces on front longitudinal member -1- down to
bare metal.

ility
ab
y li
an
pt
ce

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AG.

Prote
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by
c
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py
rig
ht
.
C
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Rep. gr.50 - Body - front

ht
rig
py
Co
t.

98

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

Grind welding edges of anti-roll bar mounting -1- down to bare


metal.

do
c
um
en

es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n

Grind welding
metal.

AG. Volkswagen AG d
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not
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edges of
mounting
bracket
-1down
to bare
b
ara
d
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is
r
o
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h
ut
ra
a
c
s
s

Amarok 2011
Body Repairs - Edition 10.2010
Grind welding edges of reinforcing -1- down to bare metal.

n AG. Volkswagen AG do
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a
ss

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s

es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com

pe
rm
itte
d

ility
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an
pt
ce

un
le

Grind welding edges of brake line mounting -1- down to bare


metal.

Grind welding edges of cab mounting -1- down to bare metal.

do
c
um
en

r
te o
iva
r
rp
fo
g
n

Grind welding edges of suspension strut mounting -1- down to


bare metal.

ht
rig
py
Co
t.

agen
lksw
Vo
by

10. Renewing longitudinal member complete

99

AG.

Prote
cted
by

c
o
p
yri
gh
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.
C
op
yi

Amarok 2011
Body Repairs - Edition 10.2010
Grind welding edges of mounting for cross member for gear
box mounting -1- down to bare metal.

Grind welding edges of mounting for engine mounting -1down to bare metal.

Grind welding edges of hydraulic unit bracket -1- down to bare


metal.

es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng

ility
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an
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ce

AG. Volkswagen AG d
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nte
is
r
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h
ut
ra
a
c
s
s

Grind welding edges of reinforcing panel -1- down to bare


metal.

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

ht
rig
py
Co
t.

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Vo
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AG.

Prote
cted
by c
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p
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C
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Rep. gr.50 - Body - front

thi
sd
o
cu
m
en

100

es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n

Carry out the following work:

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
do
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um
en

ht
rig
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Co
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Welding in

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10.2.2

n AG. Volkswagen AG do
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b
d
ran
ir se
tee
o
Body Repairs - Edition
10.2010
h
t
or
u
ac
a
ss

agen
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Vo
by

AG.

Prote
cted
by

c
o
p
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gh
t
.
C
op
yi

Grind welding surfaces -2- on new part down to bare metal.


Adapt longitudinal member -1- to frame positioned on align
ment bracket set -3- and fix in place.
Note
Before welding longitudinal member, check welder settings;

weld several test seams and check roots of test weld


seams (correct welding parameters if necessary).

SG continuous weld seam must not be reworked (ground or

smoothed)!

10. Renewing longitudinal member complete

101

n AG. Volkswagen AG do
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ss

r
fo
ng

agen
lksw
Vo
by

AG.

Prote
cted
by

c
o
p
yri
gh
t
.
C
op
yi

Weld cross member -3- to front longitudinal member -1-, SG


continuous weld seam.
Weld cross member -2- to front longitudinal member -1-, SG
continuous weld seam.
Note

For clarity, the alignment jig with alignment bracket set is not shown in the following figures.

102

Rep. gr.50 - Body - front

ht
rig
py
Co
t.

Weld longitudinal member -1- to middle part of frame -4- all


round, SG continuous weld seam.

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p

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an
pt
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un
le

Amarok 2011
Body Repairs - Edition 10.2010

AG. Volkswagen AG d
agen
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l
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ise
r
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a
c
s
s

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s

es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com

pe
rm
itte
d

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an
pt
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un
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Amarok 2011
Body Repairs - Edition 10.2010

Weld cross member -3- to front longitudinal member -1- from


below, SG continuous weld seam.
ht
rig
py
Co
t.

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Vo
by

AG.

Prote
cted
by

10. Renewing longitudinal member complete

do
c
um
en

r
te o
iva
r
rp
fo
g
n

Weld cross member -2- to front longitudinal member -1- from


below, SG continuous weld seam.

103

c
o
p
yri
gh
t.
C
op
yi

Amarok 2011
Body Repairs - Edition 10.2010

Rep. gr.50 - Body - front

AG.

104

agen
lksw
Vo
by

Prote
cted
by c
o
p
yri
gh
t.
C
op
yi

Weld in mounting for cross member for gearbox mounting


-3- all round, SG continuous weld seam.

ht
rig
py
Co
t.

Adapt mounting for cross member for gearbox mounting -3using alignment bracket set and fix in place.

do
c
um
en

Position reinforcing panel -1- on longitudinal member -2- and


weld in all round, SG continuous weld seam.

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
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Amarok 2011
Body Repairs - Edition 10.2010

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

es, in part or in w
l purpos
hole
ercia
, is n
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Prote
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Weld in mounting for engine mounting -2- all round, SG con


tinuous weld seam.

do
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Adapt mounting for engine mounting -2- using alignment


bracket set and fix new part -1- in place.

10. Renewing longitudinal member complete

105

AG. Volkswagen AG d
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Adapt mounting bracket -1- and anti-roll bar mounting -3- us


ing alignment bracket set and fix in place.
Adapt reinforcing -2- to fit and fix in position.

AG.

Rep. gr.50 - Body - front

agen
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cted
by c
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106

ht
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Co
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Weld in new parts -1-, -2- and -3-, SG continuous weld seam.

rrectne
s
s
o
f
i
t to the co
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form
spec
atio
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ole,
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un
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Amarok 2011
Body Repairs - Edition 10.2010

Amarok 2011
Body Repairs - Edition 10.2010

es, in part or in w
l purpos
hole
ercia
, is n
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spec
atio
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wit

Adapt cab mounting -2- using alignment bracket set on front


longitudinal member -1- and fix in place.
Weld in cab mounting -2-, SG continuous weld seam.

thi
sd
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Co
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AG.

Prote
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by

10. Renewing longitudinal member complete

107

c
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C
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Amarok 2011
Body Repairs - Edition 10.2010

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

es, in part or in w
l purpos
hole
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AG.

Prote
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by

Weld in suspension strut mounting -1- and brake line mounting


-3-, SG continuous weld seam.

108

Rep. gr.50 - Body - front

ht
rig
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Co
t.

Adapt brake line mounting -3- and fix in place, using dimen
sions of old part as an aid.

do
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en

Adapt suspension strut mounting -1- using alignment bracket


set on front longitudinal member -2- and fix in place.

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un
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Amarok 2011
Body Repairs - Edition 10.2010

Adapt hydraulic unit bracket -1- to suspension strut mounting


-2- and fix in place, using dimensions of old part as an aid.
Weld in hydraulic unit bracket -1-, SG continuous weld seam.
Carry out cavity preservation on front longitudinal member
-3-.

do
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Co
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r
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Install front cross member 1.2 Installing, page 43 .

10. Renewing longitudinal member complete

109

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by

AG.

Prote
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gh
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C
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Amarok 2011
Body Repairs - Edition 10.2010

Body - centre

ility
ab
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RO: 51 03 55 00, 51 03 55 20

Renewing roof

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

WARNING

Observe safety notes!


Safety notes General Information; Body Repairs, General Body
Repairs ; Safety notes
1 - Roof

2 - Bonded areas of C-pillar


3 - Bonded areas of roof cross
members

Resistance spot welder -VAS 6239 A Resistance spot welder -VAS 6535 Accessory pack -VAS 6535 /1-

110

Rep. gr.51 - Body - centre

AG.

Special tools and workshop equipment required

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Tools

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1.1

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a
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f
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n

51

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Amarok 2011
Body Repairs - Edition 10.2010
Pneumatic cartridge gun -V.A.G 1761/1-

AG. Volkswagen AG d
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form
spec
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ole,
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un
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Setting gauge -3371-

1. Renewing roof

111

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AG.

Prote
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rig
ht
.
C
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Amarok 2011
Body Repairs - Edition 10.2010

1.2

Removing

n AG. Volkswagen AG do
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Prote
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112

Rep. gr.51 - Body - centre

AG.

Remove roof -1- from body.

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Release bonded joints of C-pillars Item 2 (page 110) and to


front and rear roof cross members Item 3 (page 110) . To
release, heat bonded surfaces with hot air blower -V.A.G
1416- .

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Separate original joint.

do
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rrectness of i
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spec
a
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Carry out the following work:

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Remove adhesive residues and grind bonding surfaces back


to bare metal.
Grind welding surfaces on both sides back to bare metal.

1.3

Installing
Note

The use of different types and different thicknesses of steel re


quires that one of the welding units (inverter) listed under Tools
must be used for proper spot welding 1.1 Tools, page 110 .

1.3.1

Preparing replacement part

1K assembly adhesive -D 190 MKD A3-

AG.

Prote
cted
by

Carry out the following work:

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2K body adhesive -D 180 KD3 A2-

ht
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Co
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Roof

r
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ng

Replacement parts

rrectne
s
s
o
f
i
t to the co
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form
spec
atio
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ole,
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p

Remove remaining material.

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un
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Amarok 2011
Body Repairs - Edition 10.2010

1. Renewing roof

113

Amarok 2011
Body Repairs - Edition 10.2010

un
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Grind bonding surfaces down to bare


inside).

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metal
ut on one side (from
ra
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Welding in

rrectness of i
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spec
a
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i
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wit
thi
s

Note

es, in part or in w
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hole
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1.3.2

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Grind welding surfaces on both sides back to bare metal.

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ht
.
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Rep. gr.51 - Body - centre

do
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114

ht
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Carry out the following work:

r
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iva
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rp
fo
g
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To ensure sufficient sturdiness, the RP weld points must be set


as far as possible from the outer edge of the welding flange.

Amarok 2011
Body Repairs - Edition 10.2010

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

es, in part or in w
l purpos
hole
ercia
, is n
m
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erm
or
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a
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iv
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f
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cted
by c
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C
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AG.

Apply 2K body adhesive -D 180 KD3 A2- to bonding surfaces


-4-.

thi
sd
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cu
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en

Apply 1K assembly adhesive -D 190 MKD A3- to bonding sur


faces -1-, -2- and -3-.

Note
Apply adhesive beads sufficiently thickly so that optimal bonding with the body is guaranteed.
New part must be welded in within 90 minutes or adhesion of adhesive will be impaired.

1. Renewing roof

115

Amarok 2011
Body Repairs - Edition 10.2010

Set roof joint gap Item L (page 9) on both sides with setting
gauge -3371- .
Check fit with all add-on parts.

AG.

Rep. gr.51 - Body - centre

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Prote
cted
by c
o
p
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gh
t.
C
op
yi

116

ht
rig
py
Co
t.

Weld in roof, RP spot weld seam.

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

Adapt new part with vehicle standing on its wheels or on align


ment bracket set and fix in position.

thi
sd
o
cu
m
en

es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
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iv
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f
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AG. Volkswagen AG d
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a
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Amarok 2011
Body Repairs - Edition 10.2010
RO: 51 07 55 70

Renewing front cross member for


roof

WARNING

Observe safety notes!


Safety notes General Information; Body Repairs, General Body
Repairs ; Safety notes

Removing

Roof already removed 1

ility
ab
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an
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ce

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
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iv
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nl
f
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ng

Carry out the following work:

AG. Volkswagen AG d
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Renewing roof,
nte
ise page 110 .
r
o
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t
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ra
a
c
s
s

thi
sd
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cu
m
en

ht
rig
py
Co
t.

2.1

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by

AG.

Prote
cted
by

c
o
p
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gh
t.
C
op
yi

Separate original joint.


Remove front cross member -1- from body.

2. Renewing front cross member for roof

117

un
le

r
fo
ng

Installing

2.2.1

Preparing new part

Replacement parts
Front roof cross member

118

Rep. gr.51 - Body - centre

AG.

2.2

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by

Prote
cted
by c
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p
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gh
t.
C
op
yi

Grind welding surfaces on both sides back to bare metal.

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
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v
i
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d
p

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Remove remaining material.

ht
rig
py
Co
t.

Amarok 2011
Body Repairs - Edition 10.2010

AG. Volkswagen AG d
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is
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a
c
s
s

Amarok 2011
Body Repairs - Edition 10.2010
Carry out the following work:
Grind welding surfaces on both sides down to bare metal.

2.2.2

Welding in

Note

To ensure sufficient sturdiness, the RP weld points must be set


as far as possible from the outer edge of the welding flange.

r
fo
ng

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
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p

un
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Co
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Carry

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outs athe
following work:
s

2. Renewing front cross member for roof

119

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Vo
by

AG.

Prote
cted
by

c
o
p
yri
gh
t
.
C
op
yi

Amarok 2011
Body Repairs - Edition 10.2010

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
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du
rp
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nl
f
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ng

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AG. Volkswagen AG d
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ise
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h
t
u
ra
a
c
s
s

Adapt front cross member -1- with vehicle standing on its


wheels or on alignment bracket set and fix in position.
Weld in front roof cross member, RP spot weld seam.
Install roof 1.3 Installing, page 113 .

ht
rig
py
Co
t.

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lksw
Vo
by

AG.

Prote
cted
by

c
o
p
yri
gh
t.
C
op
yi

Rep. gr.51 - Body - centre

thi
sd
o
cu
m
en

120

Amarok 2011
Body Repairs - Edition 10.2010
RO: 51 08 55 70

Renewing roof reinforcement

WARNING

Observe safety notes!


Safety notes General Information; Body Repairs, General Body
Repairs ; Safety notes

3.1

Removing

Roof already removed 1 Renewing roof, page 110 .

AG. Volkswagen AG d
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c
s
s

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Vo
by

AG.

Prote
cted
by c
o
p
yri
gh
t.
C
op
yi

Remove roof reinforcing -1- from body.

ht
rig
py
Co
t.

Separate original joint.

do
c
um
en

r
te o
iva
r
rp
fo
g
n

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s

es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com

pe
rm
itte
d

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an
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un
le

Carry out the following work:

3. Renewing roof reinforcement

121

AG. Volkswagen AG d
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r
fo
ng

Installing

3.2.1

Preparing new part

Replacement parts
Roof reinforcement

122

Rep. gr.51 - Body - centre

AG.

3.2

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Prote
cted
by c
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p
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gh
t.
C
op
yi

Grind welding surfaces on both sides down to bare metal.

ht
rig
py
Co
t.

Remove remaining material.

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p

ility
ab
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an
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ce

un
le

Amarok 2011
Body Repairs - Edition 10.2010

Amarok 2011
Body Repairs - Edition 10.2010
Carry out the following work:
Grind welding surfaces on both sides down to bare metal.

3.2.2

Welding in

Note

To ensure sufficient sturdiness, the RP weld points must be set


as far as possible from the outer edge of the welding flange.

es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng

ility
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an
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ce

AG. Volkswagen AG d
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h
ut
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a
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s

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

Carry out the following work:

thi
sd
o
cu
m
en

3. Renewing roof reinforcement

123

ht
rig
py
Co
t.

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lksw
Vo
by

AG.

Prote
cted
by c
o
p
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gh
t.
C
op
yi

Amarok 2011
Body Repairs - Edition 10.2010

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng

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AG. Volkswagen AG d
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AG.

124

Rep. gr.51 - Body - centre

agen
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Vo
by

Prote
cted
by c
o
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gh
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C
op
yi

Install roof 1.3 Installing, page 113 .

ht
rig
py
Co
t.

Weld in roof reinforcement, RP spot weld seam.

thi
sd
o
cu
m
en

Adapt roof reinforcing -1- with vehicle standing on its wheels


or on alignment bracket set and fix in position.

Amarok 2011
Body Repairs - Edition 10.2010
RO: 51 09 55 70

Renewing rear roof cross member

WARNING

Observe safety notes!


Safety notes General Information; Body Repairs, General Body
Repairs ; Safety notes

Removing

Roof already removed 1

ility
ab
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an
pt
ce

rrectness of i
t to the co
nf
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m
spec
atio
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wit

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l purpos
hole
ercia
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a
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iv
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f
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ng

Carry out the following work:

AG. Volkswagen AG d
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Renewing roof,
page
110
.
b
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ht
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4.1

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by

AG.

Prote
cted
by

c
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C
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Separate original joint.


Remove rear cross member -1- from body.

4. Renewing rear roof cross member

125

un
le

Installing

4.2.1

Preparing new part

Replacement parts
Rear roof cross member

126

Rep. gr.51 - Body - centre

AG.

4.2

agen
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by

Prote
cted
by
c
o
py
rig
ht
.
C
op
yi

Grind welding surfaces on both sides down to bare metal.

do
c
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en

r
te o
iva
r
rp
fo
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n

rrectness of i
t to the co
nform
spec
a
t
i
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wit
thi
s

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l purpos
hole
ercia
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com

pe
rm
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d

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Remove remaining material.

ht
rig
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Co
t.

Amarok 2011
Body Repairs - Edition 10.2010

AG. Volkswagen AG d
agen
oes
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b
ara
d
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is
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h
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a
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s
s

Amarok 2011
Body Repairs - Edition 10.2010
Carry out the following work:
Grind welding surfaces on both sides down to bare metal.

4.2.2

Welding in

Note

ht
rig
py
Co
t.

agen
lksw
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by

AG.

Prote
cted
by
c
o
py
rig
ht
.
C
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yi

4. Renewing rear roof cross member

do
c
um
en

r
te o
iva
r
rp
fo
g
n

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s

Carry out the following work:

es, in part or in w
l purpos
hole
ercia
, is n
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com

pe
rm
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d

ss

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un
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To ensure sufficient sturdiness, the RP weld points must be set


AG. Volkswagen AG d
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as far as possible from the outer edge of the welding flange. olkswagen
no

127

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a
ss

AG.

Prote
cted
by

Install roof 1.3 Installing, page 113 .

128

Rep. gr.51 - Body - centre

agen
lksw
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by

c
o
p
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gh
t
.
C
op
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Weld in rear cross member for roof, RP spot weld seam.

ht
rig
py
Co
t.

Adapt rear cross member -1- with vehicle standing on its


wheels or on alignment bracket set and fix in position.

do
c
um
en

r
te o
iva
r
rp
fo
g
n

rrectness of i
t to the co
nform
spec
a
t
i
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n in
wit
thi
s

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l purpos
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ercia
, is n
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com

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un
le

Amarok 2011
Body Repairs - Edition 10.2010

Amarok 2011
Body Repairs - Edition 10.2010
RO: 51 13 55 00, 51 13 55 20

Renewing rear window frame

WARNING

Observe safety notes!


Safety notes General Information; Body Repairs, General Body
Repairs ; Safety notes
1 - Rear window frame

AG. Volkswagen AG d
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do
c
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en

ht
rig
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Co
t.

r
te o
iva
r
rp
fo
g
n

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s

es, in part or in w
l purpos
hole
ercia
, is n
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com

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rm
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d

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un
le

2 - Bonded areas

agen
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by

AG.

5. Renewing rear window frame

129

Prote
cted
by

c
o
p
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gh
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C
op
yi

un
le

Remove rear window frame from body.

130

Rep. gr.51 - Body - centre

AG.

Release bonded joints -1-. To release, heat bonded surfaces


with hot air blower -V.A.G 1416- .

agen
lksw
Vo
by

Prote
cted
by
c
o
py
rig
ht
.
C
op
yi

Separate original joint.

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en

r
fo
ng

Carry out the following work:

urposes, in part or in wh
ole,
cial p
is n
mer
m
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erm
or
e
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a
itte
v
i
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Removing

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5.1

ht
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Co
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Amarok 2011
Body Repairs - Edition 10.2010

AG. Volkswagen AG d
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b
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d
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is
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h
ut
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a
c
s
s

Amarok 2011
Body Repairs - Edition 10.2010

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

es, in part or in w
l purpos
hole
ercia
, is n
m
m
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erm
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a
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ac
a
ss

5.2.1

Preparing replacement part

Prote
cted
by

Installing

AG.

5.2

agen
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c
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gh
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.
C
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Grind welding surfaces on both sides back to bare metal.

ht
rig
py
Co
t.

Remove adhesive residues and grind bonding surfaces down


to bare metal.

thi
sd
o
cu
m
en

Remove remaining material.

Replacement parts
Rear window frame
2K body adhesive -D 180 KD3 A2Carry out the following work:

5. Renewing rear window frame

131

Amarok 2011
Body Repairs - Edition 10.2010

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng

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AG. Volkswagen AG d
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b
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h
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a
c
s
s

Rep. gr.51 - Body - centre

AG.

132

agen
lksw
Vo
by

Prote
cted
by
c
o
py
rig
ht
.
C
op
yi

Grind welding surfaces on both sides back to bare metal.

ht
rig
py
Co
t.

Grind bonding surfaces down to bare metal on one side (from


inside).

thi
sd
o
cu
m
en

Punch specified holes in new part, 7.0 mm.

Amarok 2011
Body Repairs - Edition 10.2010

5.2.2

Welding in

AG. Volkswagen AG d
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rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s

Apply 2K body adhesive -D 180 KD3 A2- to bonding surfaces.


Note

r
te o
iva
r
rp
fo
g
n

Apply adhesive beads sufficiently thickly so that optimal bonding with the body is guaranteed.
New part must be welded in within 90 minutes or adhesion of adhesive will be impaired.
do
c
um
en

ht
rig
py
Co
t.

es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com

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rm
itte
d

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ab
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an
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ce

un
le

Carry out the following work:

5. Renewing rear window frame

133

agen
lksw
Vo
by

AG.

Prote
cted
by c
o
p
yri
gh
t.
C
op
yi

Amarok 2011
Body Repairs - Edition 10.2010

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
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du
rp
o
nl
f
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AG. Volkswagen AG d
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h
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a
c
s
s

Rep. gr.51 - Body - centre

AG.

134

agen
lksw
Vo
by

Prote
cted
by c
o
p
yri
gh
t.
C
op
yi

Weld in rear window frame, RP spot weld seam and SG plug


weld seam.

ht
rig
py
Co
t.

Check fit with rear-view window.

thi
sd
o
cu
m
en

Adapt new part with vehicle standing on its wheels or on align


ment bracket set and fix in position.

Amarok 2011
Body Repairs - Edition 10.2010
RO: 51 14 55 70

Renewing cross
member
G. Volkswagen

AG do
es n
ot g
ua
ran
tee
or
ac

urposes, in part or in wh
ole,
cial p
is n
mer
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erm
or
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a
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v
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p

un
le

ility
ab
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Observe

nA
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olks
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WARNING
ed
ris
o
th
au
safety
notes!
ss

6.1

Removing

Rear window frame already removed


5 Renewing rear window frame, page 129 .

ht
rig
py
Co
t.

r
fo
ng

Carry out the following work:

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en

Safety notes General Information; Body Repairs, General Body


Repairs ; Safety notes

agen
lksw
Vo
by

AG.

Prote
cted
by

c
o
p
yri
gh
t
.
C
op
yi

Separate original joint.


Remove cross member -1- from body.

6. Renewing cross member

135

Amarok 2011
Body Repairs - Edition 10.2010

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng

ility
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an
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n AG. Volkswagen AG do
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b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss

Remove remaining material.


Grind welding surfaces on both sides down to bare metal.

Installing

6.2.1

Preparing new part

Replacement parts

AG.

Prote
cted
by

Rep. gr.51 - Body - centre

agen
lksw
Vo
by

c
o
p
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gh
t
.
C
op
yi

136

ht
rig
py
Co
t.

Cross member

thi
sd
o
cu
m
en

6.2

Amarok 2011
Body Repairs - Edition 10.2010
Carry out the following work:
Grind welding surfaces on both sides down to bare metal.

Welding in

Note

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

To ensure sufficient sturdiness, the RP weld points must be set


as far as possible from the outer edge of the welding flange.

ility
ab
y li
an
pt
ce

Carry out the following work:

do
c
um
en

es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n

6.2.2

n AG. Volkswagen AG do
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ir se
tee
o
h
t
or
u
ac
a
ss

6. Renewing cross member

137

ht
rig
py
Co
t.

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lksw
Vo
by

AG.

Prote
cted
by

c
o
p
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gh
t
.
C
op
yi

Amarok 2011
Body Repairs - Edition 10.2010

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng

ility
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an
pt
ce

AG. Volkswagen AG d
agen
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ara
d
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nte
is
r
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h
ut
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a
c
s
s

Rep. gr.51 - Body - centre

AG.

138

agen
lksw
Vo
by

Prote
cted
by c
o
p
yri
gh
t.
C
op
yi

Install rear window frame 5.2 Installing, page 131 .

ht
rig
py
Co
t.

Weld in cross member, RP spot weld seam.

thi
sd
o
cu
m
en

Adapt cross member -1- with vehicle standing on its wheels or


on alignment bracket set and fix in position.

Amarok 2011
Body Repairs - Edition 10.2010
RO: 51 37 55 00, 51 37 55 02

Renewing hinge pillar (A-pillar)

WARNING

Observe safety notes!


Welding, parting using spark generating machines/tools or tin
ning in foam treated areas creates gases which are particularly
hazardous to health and environment. Therefore, refrain from
using these processes under all circumstances.
Safety notes General Information; Body Repairs, General Body
Repairs ; Safety notes
Note
wagother
en AG forms of damage.
Specified parting cuts -1- to -5- can be
combined
n AG. Volksfor
doe
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s no
t

ks
Vol

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Description for other forms ofeddamage
must be derived from this gaccordingly.
ra

nte
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c

double cab

es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng

ility
ab
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an
pt
ce

Assembly overview for

ris
ho
ut
a
vehicles
with
ss

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

1 - Upper parting cut


Carry out as per dimen
sion -a-.
Dimension a = 400 mm

2 - Parting cut for partial re


newal
The parting cut is per
mitted for other forms of
damage
3 - Parting cut for partial re
newal
The parting cut is per
mitted for other forms of
damage

agen
lksw
Vo
by

AG.

Prote
cted
by c
o
p
yri
gh
t.
C
op
yi

5 - Parting cut for side member


Carry out as per dimen
sion -c-.

ht
rig
py
Co
t.

Dimension b = 250 mm

thi
sd
o
cu
m
en

4 - Parting cut for side member


Carry out as per dimen
sion -b-.

Dimension c = 750 mm
6 - Moulded foam element
Reduces the amount of
driving noise transmit
ted into the interior.
Moulded foam elements
must be inserted again
and must not be left out
page 5 .

7. Renewing hinge pillar (A-pillar)

139

Amarok 2011
Body Repairs - Edition 10.2010
7 - Bonded area
Cannot be restored in event of repair.
8 - Wing retainer
Renewing wing retainer page 146 .
Assembly overview for vehicles with single cab
1 - Upper parting cut
Carry out as per dimen
sion -a-.
Dimension a = 400 mm
2 - Parting cut for partial re
newal
The parting cut is per
mitted for other forms of
damage
3 - Parting cut for partial re
newal
The parting cut is per
mitted for other forms of
damage
4 - Parting cut for side member
Carry out as per dimen
sion -b-.
Dimension b = 250 mm
5 - Parting cut for side member
Carry out as per dimen
sion -c-.

n AG. Volkswagen AG do
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Dimension c = 750 mm sed
ran
ir
tee
o
h
t
or
u
ac
a
6 - Moulded foam element
ss

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng

ility
ab
y li
an
pt
ce

Reduces the amount of


driving noise transmit
ted into the interior.
Moulded foam elements
must be inserted again
and must not be left out
page 5 .

7 - Bonded area
Cannot be restored in event of repair.
8 - Wing retainer
Renewing wing retainer page 146 .

7.1

Tools

Special tools and workshop equipment required


Resistance spot welder -VAS 6239 Ac
o
p
yri
gh
t
.
C
op
yi

Prote
cted
by

Rep. gr.51 - Body - centre

AG.

140

agen
lksw
Vo
by

Accessory pack -VAS 6535 /1-

ht
rig
py
Co
t.

Resistance spot welder -VAS 6535-

thi
sd
o
cu
m
en

Pneumatic sabre saw -V.A.G 1523B-

Amarok 2011
Body Repairs - Edition 10.2010
MIG brazing and welding system -VAS 6382-

7.2

Removing

For vehicles with single and double cab


Note
Make parting cuts with pneumatic jig-saw -V.A.G 1523B- only.
Parting cuts must be straight.
Do not damage inner reinforcements when carrying out part

ing cuts.

AG. Volkswagen AG d
agen
oes
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b
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ise
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o
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a
c
s
s

ht
rig
py
Co
t.

r
fo
ng

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p

ility
ab
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an
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ce

un
le

Carry out the following work:

agen
lksw
Vo
by

AG.

Prote
cted
by

c
o
p
yri
gh
t.
C
op
yi

Mark parting cut -1- as per Item 1 (page 139) (400 mm from
top edge of windscreen aperture) and cut.
Mark parting cut -2- as per Item 4 (page 139) (250 mm from
centre of hole) and cut.
Separate original joint.

7. Renewing hinge pillar (A-pillar)

141

Amarok 2011
Body Repairs - Edition 10.2010
Release bonded joint Item 7 (page 139) . To release, heat
bonded surface with hot air blower -V.A.G 1416- .
Remove hinge pillar (A-pillar) from body.

Remove adhesive residues and grind bonding surfaces down


to bare metal.
Grind welding surfaces on both sides down to bare metal.
Prepare moulded foam elements -1- for installation
page 5 .

7.3

Installing

Note

The use of different types and different thicknesses of steel re


quires that one of the welding units (inverter) listed under Tools
must be used for proper spot welding 7.1 Tools, page 140 .
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Rep. gr.51 - Body - centre

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Co
t.

142

rrectness of i
t to the co
nform
spec
at
i
h re
o
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wit
in t
his

Remove remaining material.

do
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en

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l purpos
hole
ercia
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a
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Amarok 2011
Body Repairs - Edition 10.2010

7.3.1

Preparing new part, vehicles with dou


ble cab

Replacement parts
Side panel
Wing retainer

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an
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do
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en

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Co
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rrectness of i
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a
t
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wit
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com

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un
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Carry out

AG. Volkswagen AG d
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b
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the following
d
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h
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Prote
cted
by
c
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rig
ht
.
C
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Transfer parting cuts -1- and -2- from body to new part.
Make parting cuts and remove shaded area.
Drill specified holes in new part, 7.0 mm.
Prepare wing retainer, drill holes, 7.0 mm.
Grind welding surfaces on both sides back to bare metal.

7.3.2

Preparing new part, vehicles with single


cab

Replacement parts
Side panel
7. Renewing hinge pillar (A-pillar)

143

Amarok 2011
Body Repairs - Edition 10.2010
Wing retainer

n AG. Volkswagen AG do
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ua
b
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ran
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tee
o
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t
or
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ac
a
ss

Transfer parting cuts -1- and -2- from body to new part.
Make parting cuts and remove shaded area.
Drill specified holes in new part, 7.0 mm.
Prepare wing retainer, drill holes, 7.0 mm.

AG.

Prote
cted
by

Rep. gr.51 - Body - centre

agen
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c
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144

ht
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r
fo
ng

Grind welding surfaces on both sides back to bare metal.

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
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thi
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urposes, in part or in wh
ole,
cial p
is n
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erm
or
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un
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Carry out the following work:

Amarok 2011
Body Repairs - Edition 10.2010

7.3.3

Welding in

For vehicles with single and double cab


Note
To ensure sufficient sturdiness, the RP weld points must be

set as far as possible from the outer edge of the welding flange.

MIG brazed seams are permitted at the parting cuts shown in

the illustration.

AG. Volkswagen AG d
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rrectness of i
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spec
a
t
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wit
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hole
ercia
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Carry out the following work:

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AG.

Prote
cted
by c
o
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gh
t.
C
op
yi

Adapt new part with vehicle standing on its wheels or on align


ment bracket set and fix in position.
Check fit with all add-on parts.
Weld in hinge pillar (A-pillar), RP spot weld seam, SG plug
weld seam and SG stitch weld seam.
7. Renewing hinge pillar (A-pillar)

145

Amarok 2011
Body Repairs - Edition 10.2010
Optically process visible weld joints.
Use 2K filler to smooth out rough spots.

7.3.4

Renewing wing retainer

AG. Volkswagen AG d
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rrectness of i
t to the co
nform
spec
a
t
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h re
o
n in
wit
thi
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l purpos
hole
ercia
, is n
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com

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un
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Carry out the following work:

Position wing with wing retainer on body -1-.


Adapt wing to vehicle (door in position on vehicle).
Remove door.

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by

AG.

Prote
cted
by c
o
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C
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Rep. gr.51 - Body - centre

ht
rig
py
Co
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146

do
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en

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iva
r
rp
fo
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Tack weld wing retainer from wheel housing -2-.

Amarok 2011
Body Repairs - Edition 10.2010
Remove wing.

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rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s

es, in part or in w
l purpos
hole
ercia
, is n
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com

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rm
itte
d

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Weld in wing retainer, SG plug weld seam.

agen
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by

7. Renewing hinge pillar (A-pillar)

147

AG.

Prote
cted
by
c
o
py
rig
ht
.
C
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yi

Amarok 2011
Body Repairs - Edition 10.2010
RO: 51 38 55 70

Renewing hinge pillar (A-pillar) rein


forcement

WARNING

Observe safety notes!


Welding, parting using spark generating machines/tools or tin
ning in foam treated areas creates gases which are particularly
hazardous to health and environment. Therefore, refrain from
using these processes under all circumstances.
Safety notes General Information; Body Repairs, General Body
Repairs ; Safety notes

Hinge pillar (A-pillar) already removed


7 Renewing hinge pillar (A-pillar), page 139

es, in part or in w
l purpos
hole
ercia
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erm
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1 - Upper moulded foam ele


ment
AG. Volkswagen AG d
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Reduces the amount of Volksw
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driving noise transmit
e
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is
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ted into the interior.
eo
h
ut
ra
a
c
s
Moulded foam
s elements
must be inserted again
and must not be left out
page 5 .

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

2 - Lower moulded foam ele


ment
Reduces the amount of
driving noise transmit
ted into the interior.
Moulded foam elements
must be inserted again
and must not be left out
page 5 .
3 - Bonded area

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cted
by
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rig
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C
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Rep. gr.51 - Body - centre

do
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en

148

Amarok 2011
Body Repairs - Edition 10.2010

8.1

Tools

es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
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c
erm
or
e
t
a
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iv
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f
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AG. Volkswagen AG d
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Special tools and workshop equipment
required
y
b
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nte
ise
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Resistance spot welder -VAS
6239
Ah
t
u
ra
a
c
s
s
Resistance spot welder -VAS
6535-

Accessory pack -VAS 6535 /1-

Removing

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

8.2

Carry out the following work:

thi
sd
o
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en

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rig
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Co
t.

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by

AG.

Prote
cted
by

c
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C
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Separate original joint.


Release bonded joint -1-. To release, heat bonded surface
with hot air blower -V.A.G 1416- .
Remove hinge pillar (A-pillar) reinforcement from body.

8. Renewing hinge pillar (A-pillar) reinforcement

149

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Vo
by

AG.

Prote
cted
by

c
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p
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gh
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C
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Remove adhesive residues and grind bonding surface back to


bare metal.
Grind welding surfaces on both sides down to bare metal.
Prepare moulded foam elements -1- and -2- for installation
page 5 .

8.3

Installing
Note

The use of different types and different thicknesses of steel re


quires that one of the welding units (inverter) listed under Tools
must be used for proper spot welding 8.1 Tools, page 149 .

8.3.1

Preparing replacement part

Replacement parts
Hinge pillar (A-pillar) reinforcement
2K body adhesive -D 180 KD3 A2-

150

Rep. gr.51 - Body - centre

ht
rig
py
Co
t.

Remove remaining material.

do
c
um
en

r
te o
iva
r
rp
fo
g
n

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s

es, in part or in w
l purpos
hole
ercia
, is n
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ot
com

pe
rm
itte
d

un
le

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AG. Volkswagen AG d
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Amarok 2011 rise
nte
o
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h
Body Repairs - aEdition
10.2010
ut
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Amarok 2011
Body Repairs - Edition 10.2010

AG. Volkswagen AG d
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rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s

es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com

pe
rm
itte
d

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ab
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an
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ce

un
le

Carry out the following work:

Drill out hinge pillar (A-pillar) reinforcement upper part and re


move shaded area.
Punch and drill specified holes in new part, 7.0 mm.

agen
lksw
Vo
by

Prote
cted
by c
o
p
yri
gh
t.
C
op
yi

To ensure sufficient sturdiness, the RP weld points must be set


as far as possible from the outer edge of the welding flange.

do
c
um
en

Note

Welding in

ht
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Co
t.

8.3.2

r
te o
iva
r
rp
fo
g
n

Grind welding surfaces on both sides back to bare metal.

AG.

8. Renewing hinge pillar (A-pillar) reinforcement

151

Amarok 2011
Body Repairs - Edition 10.2010
Carry out the following work:
Apply 2K body adhesive -D 180 KD3 A2- to bonding surfaces.
Note
Apply adhesive beads sufficiently thickly so that optimal bond

ing with the body is guaranteed.

New part must be welded in within 90 minutes or adhesion of

adhesive will be impaired.

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
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erm
o
e
t
a
itte
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nl
f
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n

ility
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AG. Volkswagen AG d
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by

AG.

Prote
cted
by

c
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C
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yi

Rep. gr.51 - Body - centre

ht
rig
py
Co
t.

152

do
c
um
en

Adapt new part with vehicle standing on its wheels or on align


ment bracket set and fix in position.

Amarok 2011
Body Repairs - Edition 10.2010

es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
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du
p
or
nl
f
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g
n

ility
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Hinge pillar (A-pillar) 7.3 Installing, page 142

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
do
c
um
en

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AG.

Prote
cted
by

c
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C
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ht
rig
py
Co
t.

AG. Volkswagen AG d
agen
oes
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V
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y
Check fit with all add-on parts.
b
ara
d
nte
ise
r
o
eo
h
Weld in hinge pillar (A-pillar) reinforcement,
RP spot weld
t
u
ra
a
c
s
seam, SG plug weld seam and SG
continuous
weld
seam.
s

8. Renewing hinge pillar (A-pillar) reinforcement

153

Amarok 2011
Body Repairs - Edition 10.2010
RO: 51 41 55 00

Renewing centre pillar (B-pillar)

WARNING

Observe safety notes!


G. Volkswagen AG d
oes
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ara
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c

ss

ility
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an
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un
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A
agen
Welding, parting using spark generating machines/tools or tin
lksw
o
V
ning in foam treated areas creates gases which are particularly
by
ed
hazardous to health and environment. Therefore, refrain from
ris
o
th
using these processes under all circumstances.
au

Specified parting cuts -1- to -5- and -7- can be combined for other forms of damage.

3 - Parting cut for side member


Carry out as per dimen
sion -e-.
Dimension e = 520 mm
4 - Parting cut for side member
Carry out as per dimen
sion -c-.
Dimension c = 680 mm
The parting cut is per
mitted for other forms of
damage
5 - Parting cut for side member
Carry out as per dimen
sion -b-.
Dimension b = 160 mm
6 - Moulded foam element
Reduces the amount of
driving noise transmit
ted into the interior.

154

Rep. gr.51 - Body - centre

Prote
cted
by

The parting cut is per


mitted for other forms of
damage

AG.

Dimension d = 250 mm

agen
lksw
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2 - Parting cut for side member


Carry out as per dimen
sion -d-.

c
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.
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Dimension a = 150 mm

ht
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py
Co
t.

1 - Upper parting cut


Carry out as per dimen
sion -a-.

r
fo
ng

Description for other forms of damage must be derived from this accordingly.

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en

Note

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p

Safety notes General Information; Body Repairs, General Body


Repairs ; Safety notes

Amarok 2011
Body Repairs - Edition 10.2010
Moulded foam elements must be inserted again and must not be left out page 5 .
7 - Centre parting cut
The parting cut is permitted for other forms of damage

9.1

Tools

Special tools and workshop equipment required


Pneumatic sabre saw -V.A.G 1523B Resistance spot welder -VAS 6239 A-

9.2

Removing

Make parting cuts with pneumatic jig-saw -V.A.G 1523B- only.


Parting cuts must be straight.
Do not damage inner reinforcements when carrying out part

ing cuts.

ht
rig
py
Co
t.

r
fo
ng

Carry out the following work:

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en

Note

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un
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urposes, in part or in wh
ole,
cial p
is n
mer
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ot p
o
c
erm
or
e
t
a
itte
v
i
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d
p

n AG. Volkswagen AG do
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Resistance spot welder -VAS 6535ot g
o
yV
ua
b
ran
ed
s
i
tee
Accessory pack -VAS 6535 /1- hor
t
or
u
ac
a
MIG brazing and welding system
ss -VAS 6382-

agen
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Vo
by

9. Renewing centre pillar (B-pillar)

155

AG.

Prote
cted
by

c
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.
C
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pe
rm
itte
d

AG. Volkswagen AG d
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es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s

Mark parting cut -1- as per Item 1 (page 154) (150 mm from
top edge of roof side member) and cut.

ility
ab
y li
an
pt
ce

un
le

Amarok 2011
Body Repairs - Edition 10.2010

Mark parting cut -2- as per Item 3 (page 154) (520 mm from
reference edge) and cut.
Mark parting cut -3- as per Item 5 (page 154) (160 mm from
centre of hole) and cut.
Separate original joint.

agen
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by

AG.

Prote
cted
by
c
o
py
rig
ht
.
C
op
yi

Rep. gr.51 - Body - centre

ht
rig
py
Co
t.

156

do
c
um
en

r
te o
iva
r
rp
fo
g
n

Remove centre pillar (B-pillar) from body.

Amarok 2011
Body Repairs - Edition 10.2010

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng

ility
ab
y li
an
pt
ce

AG. Volkswagen AG d
agen
oes
ksw
not
l
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V
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b
ara
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nte
ise
r
o
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h
t
u
ra
a
c
s
s

thi
sd
o
cu
m
en

ht
rig
py
Co
t.

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lksw
Vo
by

AG.

Prote
cted
by

c
o
p
yri
gh
t.
C
op
yi

Remove remaining material.


Grind welding surfaces on both sides down to bare metal.
Prepare moulded foam element -1- for installation page 5 .

9.3

Installing
Note

The use of different types and different thicknesses of steel re


quires that one of the welding units (inverter) listed under Tools
must be used for proper spot welding 9.1 Tools, page 155 .

9.3.1

Preparing replacement part

Replacement parts
Side panel
Carry out the following work:

9. Renewing centre pillar (B-pillar)

157

AG. Volkswagen AG d
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not
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b
ara
d
nte
ise
r
o
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h
t
u
ra
a
c
s
s

Transfer parting cuts -1-, -2- and -3- from body to new part.
Make parting cuts and remove shaded area.
Drill specified holes in new part, 7.0 mm.

Welding in

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by

AG.

Prote
cted
by

Note

c
o
p
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gh
t.
C
op
yi

9.3.2

To ensure sufficient sturdiness, the RP weld points must be

set as far as possible from the outer edge of the welding flange.

MIG brazed seams are permitted at the parting cuts shown in

the illustration.

Carry out the following work:

158

Rep. gr.51 - Body - centre

ht
rig
py
Co
t.

r
fo
ng

Grind welding surfaces on both sides back to bare metal.

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en

urposes, in part or in wh
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Amarok 2011
Body Repairs - Edition 10.2010

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AG.

Prote
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Check fit with all add-on parts.

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t.

Adapt new part with vehicle standing on its wheels or on align


ment bracket set and fix in position.

rrectne
s
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form
spec
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n
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ole,
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a
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un
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Amarok 2011
Body Repairs - Edition 10.2010

Weld in centre pillar (B-pillar), RP spot weld seam, SG plug


weld seam and SG stitch weld seam.
Optically process visible weld joints.
Use 2K filler to smooth out rough spots.

9. Renewing centre pillar (B-pillar)

159

Amarok 2011
Body Repairs - Edition 10.2010
RO: 51 42 55 70

10

Renewing centre pillar (B-pillar) rein


forcement

WARNING

Observe safety notes!


Welding, parting using spark generating machines/tools or tin
ning in foam treated areas creates gases which are particularly
hazardous to health and environment. Therefore, refrain from
using these processes under all circumstances.
Safety notes General Information; Body Repairs, General Body
Repairs ; Safety notes

Centre pillar (B-pillar) already removed


9 Renewing centre pillar (B-pillar), page 154
Note

es, in part or in w
l purpos
hole
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m
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Description for other forms of damage must be derived from this accordingly.

rrectness of i
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spec
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wit

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Rep. gr.51 - Body - centre

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160

of damage.

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Specified parting cut -1-

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Amarok 2011
Body Repairs - Edition 10.2010

AG. Volkswagen AG d
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Dimension a = 200 mm

un
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1 - Upper parting cut


Carry out as per dimen
sion -a-.

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wit
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2 - Middle pillar (B-pillar) rein


forcement
3 - Parting cut for side member
Parting at this point is
permitted for other
forms of damage.
4 - Parting cut for side member

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10.1

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5 - Moulded foam element


Reduces the amount of
driving noise transmit
ted into the interior.
Moulded foam elements
must be inserted again
and must not be left out
page 5 .

Tools

Special tools and workshop equipment required


Pneumatic sabre saw -V.A.G 1523B Resistance spot welder -VAS 6239 A Resistance spot welder -VAS 6535 Accessory pack -VAS 6535 /1-

10.2

Removing
Note

Make parting cut using body saw -V.A.G 1523B- only!


Parting cut must be straight.
Carry out the following work:

10. Renewing centre pillar (B-pillar) reinforcement

161

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Prote
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by
c
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rig
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Mark parting cut -1- as per Item 1 (page 161) (200 mm from
top edge of roof side member) and cut.
Separate original joint.
Remove centre pillar (B-pillar) reinforcement from body.

162

Rep. gr.51 - Body - centre

do
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r
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iva
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rrectness of i
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spec
a
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wit
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Amarok 2011
Body Repairs - Edition 10.2010

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Remove remaining material.

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un
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Amarok 2011
Body Repairs - Edition 10.2010

Prepare moulded foam element -1- for installation page 5 .

Prote
cted
by

10.3.1

AG.

The use of different types and different thicknesses of steel re


quires that one of the welding units (inverter) listed under Tools
must be used for proper spot welding 10.1 Tools, page 161 .

agen
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Note

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Installing

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10.3

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r
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Grind welding surfaces on both sides down to bare metal.

Preparing replacement part

Replacement parts
Middle pillar (B-pillar) reinforcement
Carry out the following work:

10. Renewing centre pillar (B-pillar) reinforcement

163

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Transfer parting cut -1- from body to new part.


Make parting cut and remove shaded area.
Drill specified holes in new part, 7.0 mm.
Grind welding surfaces on both sides back to bare metal.

10.3.2

Welding in

Note

AG.

Prote
cted
by

Rep. gr.51 - Body - centre

agen
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c
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164

ht
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Carry out the following work:

do
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r
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iva
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rp
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To ensure sufficient sturdiness, the RP weld points must be set


as far as possible from the outer edge of the welding flange.

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
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wit
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Amarok 2011
Body Repairs - Edition 10.2010

AG. Volkswagen AG d
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Adapt new part with vehicle standing on its wheels or on align


ment bracket set and fix in position.
Check fit with all add-on parts.

Weld in centre pillar (B-pillar) reinforcement, RP spot weld


seam, SG plug weld seam and SG continuous weld seam.

r
fo
ng

Centre pillar (B-pillar) 9.3 Installing, page 157

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form
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urposes, in part or in wh
ole,
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a
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Amarok 2011
Body Repairs - Edition 10.2010

10. Renewing centre pillar (B-pillar) reinforcement

165

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RO: 51 39 55 20

Renewing lock pillar (C-pillar)

WARNING

Observe safety notes!

Welding, parting using spark generating machines/tools or tin


ning in foam treated areas creates gases which are particularly
hazardous to health and environment. Therefore, refrain from
using these processes under all circumstances.

Note

r
fo
ng

Safety notes General Information; Body Repairs, General Body


Repairs ; Safety notes

Specified parting cuts -1- and -4- to -6- can be combined for other forms of damage.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi

3 - Moulded foam element


Reduces the amount of
driving noise transmit
ted into the interior.
Moulded foam elements
must be inserted again
and must not be left out
page 5 .
4 - Lower parting cut
Parting cut is permitted
for other forms of dam
age.
5 - Parting cut for side member
Carry out as per dimen
sion -a-.
Dimension a = 250 mm
6 - Parting cut for side member
Parting cut is permitted
for other forms of dam
age.
Carry out as per dimen
sion -b-.
Dimension b = 520 mm

166

Rep. gr.51 - Body - centre

AG.

2 - Bonded area
Cannot be restored in
event of repair.

agen
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by

1 - Upper parting cut


Can be positioned in this
area depending on
damage.

ht
rig
py
Co
t.

Description for other forms of damage must be derived from this accordingly.

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
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wit
i
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thi
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11

urposes, in part or in wh
ole,
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m
ot p
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erm
or
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t
a
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v
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Amarok 2011
Body Repairs - Edition

AG. Volkswagen AG d
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10.2010
c
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Amarok 2011

11.1

Tools

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l purpos
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Special tools and workshop equipment

- Edition 10.2010
agen ARepairs
AG. VolkswBody
G do
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Pneumatic sabre saw -V.A.G 1523B-

Resistance spot welder -VAS 6239 A-

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

Resistance spot welder -VAS 6535 Accessory pack -VAS 6535 /1-

MIG brazing and welding system -VAS 6382-

11.2

Removing
Note

Make parting cuts with pneumatic jig-saw -V.A.G 1523B- only.


Parting cuts must be straight.

Do not damage inner reinforcements when carrying out part


Carry out the following work:

thi
sd
o
cu
m
en

ing cuts.

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rig
py
Co
t.

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by

11. Renewing lock pillar (C-pillar)

167

AG.

Prote
cted
by
c
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rig
ht
.
C
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yi

Amarok 2011
Body Repairs - Edition 10.2010
AG. Volkswagen AG d
agen
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Parting cut -2- as per Item 5 (page
166)
.
Mark
(250
mm
from
o
eo
h
ut
ra
reference edge) and cut.
a
c
s
s

Mark parting cut -1- and carry out.

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

es, in part or in w
l purpos
hole
ercia
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ot p
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erm
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t
a
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Separate original joint.

AG.

Bend metal edge of rear window frame -3- upwards in


-direction of arrow-.
Release underlying, original joint of lock pillar (C-pillar).
Release remaining original joint.
Remove lock pillar (C-pillar) from body.

168

Rep. gr.51 - Body - centre

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Prote
cted
by
c
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rig
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C
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Separate original joint along metal edge of rear window frame


-3-.

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Mark parting cut -1- and carry out.

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Release bonded joint -2-. To release, heat bonded surface


with hot air blower -V.A.G 1416- .

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rig
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Co
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Remove remaining section of lock pillar (C-pillar) -1-.

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
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urposes, in part or in wh
ole,
cial p
is n
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or
e
t
a
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v
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p

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un
le

Amarok 2011
Body Repairs - Edition 10.2010

11. Renewing lock pillar (C-pillar)

169

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by

AG.

Prote
cted
by

c
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.
C
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n AG. Volkswagen AG do
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by

AG.

Prote
cted
by

c
o
p
yri
gh
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.
C
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yi

Remove remaining material.


Drill holes for installation in rear window frame, 5.0 mm.
Grind welding surfaces on both sides down to bare metal.
Prepare moulded foam element -1- for installation page 5 .

11.3

Installing
Note

The use of different types and different thicknesses of steel re


quires that one of the welding units (inverter) listed under Tools
must be used for proper spot welding 11.1 Tools, page 167 .

11.3.1

Preparing replacement part

Replacement parts
Side panel
Carry out the following work:

170

Rep. gr.51 - Body - centre

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
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c
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en

urposes, in part or in wh
ole,
cial p
is n
mer
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or
e
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a
itte
v
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d
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un
le

Amarok 2011
Body Repairs - Edition 10.2010

Amarok 2011
Body Repairs - Edition 10.2010

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
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AG.

Prote
cted
by

c
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p
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gh
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.
C
op
yi

Transfer parting cuts -1- and -2- from body to new part.
Make parting cuts and remove shaded area.
Drill specified holes in new part, 7.0 mm.
Grind welding surfaces on both sides back to bare metal.

11.3.2

Welding in

Note
To ensure sufficient sturdiness, the RP weld points must be

set as far as possible from the outer edge of the welding flange.

MIG brazed seams are permitted at the parting cuts shown in

the illustration.

Carry out the following work:

11. Renewing lock pillar (C-pillar)

171

AG. Volkswagen AG d
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Co
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by

AG.

Prote
cted
by
c
o
py
rig
ht
.
C
op
yi

Adapt new part with vehicle standing on its wheels or on align


ment bracket set and fix in position.
Check fit with all add-on parts.
Weld in lock pillar (C-pillar), RP spot weld seam, SG plug weld
seam and SG stitch weld seam.

172

Rep. gr.51 - Body - centre

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
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d
p

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an
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un
le

Amarok 2011
Body Repairs - Edition 10.2010

Amarok 2011
Body Repairs - Edition 10.2010

thi
sd
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cu
m
en

ht
rig
py
Co
t.

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AG.

Prote
cted
by c
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p
yri
gh
t.
C
op
yi

Weld in lock pillar (C-pillar), RP spot weld seam, SG plug weld


seam and SG stitch weld seam.

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng

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AG. Volkswagen AG d
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a
c
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After welding in lock pillar (C-pillar), smooth SG plug weld


seams in area -1-.
Bend metal edge of rear window frame -2- back in
-direction of arrow-.
Weld metal edge of rear window frame -2-, SG plug weld
seam.
Optically process visible weld joints.
Use 2K filler to smooth out rough spots.

11. Renewing lock pillar (C-pillar)

173

Amarok 2011
Body Repairs - Edition 10.2010
RO: 51 70 55 20

12

Renewing mounting bracket for front


seat

WARNING

Observe safety notes!


Safety notes General Information; Body Repairs, General Body
Repairs ; Safety notes

12.1

Removing

Carry out the following work:

es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

Separate original joint.

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AG.

Prote
cted
by

c
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p
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gh
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.
C
op
yi

Rep. gr.51 - Body - centre

ht
rig
py
Co
t.

174

do
c
um
en

Remove mounting bracket for front seat -1- from body.

Amarok 2011
Body Repairs - Edition 10.2010

es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
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du
rp
o
nl
f
e
ng

Remove remaining material.

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AG. Volkswagen AG d
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h
ut
ra
a
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s

12.2

Installing

12.2.1

Preparing new part

Replacement parts

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

Grind welding surfaces down to bare metal.

Mounting bracket for front seat

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AG.

Prote
cted
by
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rig
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Carry out the following work:

12. Renewing mounting bracket for front seat

175

Amarok 2011
Body Repairs - Edition 10.2010

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

es, in part or in w
l purpos
hole
ercia
, is n
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ss

Grind welding surfaces on both sides down to bare metal.

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cted
by

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Rep. gr.51 - Body - centre

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Co
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176

thi
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Punch specified holes in new part, 7.0 mm.

Amarok 2011
Body Repairs - Edition 10.2010

12.2.2

Welding in

n AG. Volkswagen AG do
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r
fo
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Adapt mounting bracket for front seat -1- to fit and fix in posi
tion.
Weld in mounting bracket for front seat, SG plug weld seam.

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
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n
wit
i
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thi
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ole,
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un
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Carry out the following work:

ht
rig
py
Co
t.

12. Renewing mounting bracket for front seat

177

agen
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by

AG.

Prote
cted
by

c
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gh
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.
C
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Amarok 2011
Body Repairs - Edition 10.2010

53

Body - rear

RO: 53 05 55 00

Renewing rear cross panel


. Volkswagen AG
gen AG
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Observe safety notes!

un
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WARNING

a
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au

rrectness of i
t to the co
nform
spec
a
t
i
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wit
thi
s

1 - Bonded areas

es, in part or in w
l purpos
hole
ercia
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m
ot
com

Safety notes General Information; Body Repairs, General Body


Repairs ; Safety notes

agen
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by

AG.

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by c
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Rep. gr.53 - Body - rear

ht
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Co
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178

do
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en

r
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iva
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rp
fo
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n

2 - Rear cross panel

Amarok 2011
Body Repairs - Edition 10.2010

1.1

Removing

Carry out the following work:

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

es, in part or in w
l purpos
hole
ercia
, is n
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ut
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s
s

Separate original joint.

Release bonded joints -1-. To release, heat bonded surfaces


with hot air blower -V.A.G 1416- .
Remove rear cross panel from load surface.

thi
sd
o
cu
m
en

ht
rig
py
Co
t.

1. Renewing rear cross panel

179

agen
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Vo
by

AG.

Prote
cted
by
c
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py
rig
ht
.
C
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un
le

r
fo
ng

Grind welding surfaces on both sides back to bare metal.

1.2

Installing

1.2.1

Preparing replacement part

Replacement parts
Rear cross panel
2K body adhesive -D 180 KD3 A2Carry out the following work:

180

Rep. gr.53 - Body - rear

AG.

Remove adhesive residues and grind bonding surfaces down


to bare metal.

agen
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by

Prote
cted
by
c
o
py
rig
ht
.
C
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Remove remaining material.

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
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urposes, in part or in wh
ole,
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Co
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Amarok 2011
Body Repairs - Edition 10.2010

AG. Volkswagen AG d
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Co
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rrectness of i
t to the co
nform
spec
a
t
i
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wit
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l purpos
hole
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com

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un
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Amarok 2011
Body Repairs - Edition 10.2010

agen
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by

AG.

Prote
cted
by
c
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py
rig
ht
.
C
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Grind bonding surfaces down to bare metal on one side (from


inside).
Grind welding surfaces on both sides back to bare metal.

1. Renewing rear cross panel

181

Amarok 2011
Body Repairs - Edition 10.2010

1.2.2

Welding in

Carry out the following work:

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

Apply 2K body adhesive -D 180 KD3 A2- to bonding surfaces.


Note

Apply adhesive beads sufficiently thickly so that optimal bonding with the body is guaranteed.
New part must be welded in within 90 minutes or adhesion of adhesive will be impaired.

agen
lksw
Vo
by

AG.

Prote
cted
by

c
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p
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C
op
yi

Rep. gr.53 - Body - rear

ht
rig
py
Co
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182

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cu
m
en

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l purpos
hole
ercia
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or
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AG. Volkswagen AG d
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Adapt new part to fit and fix in position.

ht
rig
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Co
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r
fo
ng

Weld in rear cross panel, RP spot weld seam.

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
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urposes, in part or in wh
ole,
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is n
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or
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t
a
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v
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un
le

Amarok 2011
Body Repairs - Edition 10.2010

1. Renewing rear cross panel

183

agen
lksw
Vo
by

AG.

Prote
cted
by c
o
p
yri
gh
t.
C
op
yi

Amarok 2011
Body Repairs - Edition 10.2010
RO: 53 48 55 70

Renewing rear longitudinal member part section

WARNING

Observe safety notes!

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AG. Volkswagen AG d
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l purpos
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or
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t
a
itte
iv
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o
nl
f
e
ng

Safety notes General Information; Body Repairs, General Body


Repairs ; Safety notes

Load surface already removed General body repairs, ex


terior; Rep. gr. 55 ; Load surface .

Carry out the following work:

Prote
cted
by c
o
p
yri
gh
t.
C
op
yi

Rep. gr.53 - Body - rear

thi
sd
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cu
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en

184

AG.

Parting cut must be straight.

agen
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by

Note

ht
rig
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Co
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Removing

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

2.1

ht
rig
py
Co
t.

un
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r
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ng

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
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v
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p

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an
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AG. Volkswagen AG d
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Amarok
ara
d
nte
ise
r
o
Body
Repairs
Edition
10.2010
eo
h
t
u
ra
a
c
s
s

agen
lksw
Vo
by

AG.

Prote
cted
by

c
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p
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C
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yi

Mark parting cut as per -dimension a- and cut.


Dimension a = 90 mm from mounting bracket
Remove longitudinal member.

2. Renewing rear longitudinal member - part section

185

AG. Volkswagen AG d
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b
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nte
is
r
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h
ut
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a
c
s
s

Installing

2.2.1

Preparing replacement part

Replacement part
Rear longitudinal member complete
Mounting bracket
Carry out the following work:

186

Rep. gr.53 - Body - rear

AG.

2.2

agen
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Prote
cted
by
c
o
py
rig
ht
.
C
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yi

Grind welding surface back to bare metal.

ht
rig
py
Co
t.

Remove remaining material.

do
c
um
en

r
te o
iva
r
rp
fo
g
n

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s

es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com

pe
rm
itte
d

ility
ab
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an
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ce

un
le

Amarok 2011
Body Repairs - Edition 10.2010

Amarok 2011
Body Repairs - Edition 10.2010

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

Transfer parting cut -1- from body to new part.


Make parting cut -1-.
Remove shaded area.
Grind welding surfaces down to bare metal.
Grind welding surfaces of mounting bracket back to bare met
al.

do
c
um
en

es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
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du
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nl
f
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n

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AG. Volkswagen AG d
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h
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a
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s

ht
rig
py
Co
t.

2. Renewing rear longitudinal member - part section

187

agen
lksw
Vo
by

AG.

Prote
cted
by
c
o
py
rig
ht
.
C
op
yi

Amarok 2011
Body Repairs - Edition 10.2010

2.2.2

Welding in

Carry out the following work:

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
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n

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ce

AG. Volkswagen AG d
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ise
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a
c
s
s

do
c
um
en

ht
rig
py
Co
t.

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lksw
Vo
by

AG.

Prote
cted
by

c
o
p
yri
gh
t.
C
op
yi

Adapt new part to vehicle standing on alignment bracket set


and fix in place.
Check fit with adjacent parts.
Weld parting cut all round in rear longitudinal member -1- ad
hering to -air gap dimension a-, SG continuous weld seam.
Dimension a = 3.5 mm + 0.5 mm
Note
Adherence to -air gap dimension a- is vital to guarantee proper through-welding.
Before welding longitudinal member, check welder settings; weld several test seams and check roots of

test weld seams (correct welding parameters if necessary).

SG continuous weld seam must not be reworked (ground or smoothed)!

188

Rep. gr.53 - Body - rear

Amarok 2011
Body Repairs - Edition 10.2010

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
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du
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o
nl
f
e
ng

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ce

AG. Volkswagen AG d
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sd
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ht
rig
py
Co
t.

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lksw
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by

AG.

Prote
cted
by
c
o
py
rig
ht
.
C
op
yi

Adapt rear mounting bracket for load surface -1- to fit and fix
in position page 19 .
Weld in rear mounting bracket with longitudinal member -2-,
SG continuous weld seam.
Carry out cavity preservation on rear longitudinal member.

2. Renewing rear longitudinal member - part section

189

Amarok 2011
Body Repairs - Edition 10.2010
RO: 53 55 55 20

Renewing rear side panel

WARNING

Observe safety notes!


Safety notes General Information; Body Repairs, General Body
Repairs ; Safety notes

Load surface already removed General body repairs, ex


terior; Rep. gr. 55 ; Load surface .

1 - Bonded areas
2 - Parting cut for partial re
newal
Parting cut is permitted
for other forms of dam
age.

ht
rig
py
Co
t.

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lksw
Vo
by

AG.

Prote
cted
by

c
o
p
yri
gh
t
.
C
op
yi

Rep. gr.53 - Body - rear

do
c
um
en

190

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
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nl
f
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ss

Amarok 2011
Body Repairs - Edition 10.2010

3.1

Removing

AG. Volkswagen AG d
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fo
ng

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lksw
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AG.

Prote
cted
by
c
o
py
rig
ht
.
C
op
yi

Release bonded joints -1-, -2- and -3-. To release, heat bon
ded surfaces with hot air blower -V.A.G 1416- .

ht
rig
py
Co
t.

Separate original joint.

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p

ility
ab
y li
an
pt
ce

un
le

Carry out the following work:

3. Renewing rear side panel

191

urposes, in part or in wh
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p

Drill open original joint -2- through 2 material thicknesses.


Release bonded joint -1-. To release, heat bonded surface
with hot air blower -V.A.G 1416- .
Remove rear side panel from load surface.
Release original joint from bracket -2-.

AG.

Rep. gr.53 - Body - rear

agen
lksw
Vo
by

Prote
cted
by c
o
p
yri
gh
t.
C
op
yi

192

ht
rig
py
Co
t.

r
fo
ng

Release bonded joint -1-. To release, heat bonded surface


with hot air blower -V.A.G 1416- .

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en

Separate original joint.

AG. Volkswagen AG d
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h
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ility
ab
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an
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ce

un
le

Amarok 2011
Body Repairs - Edition 10.2010

Amarok 2011
Body Repairs - Edition 10.2010
Remove bracket -2- from load surface.

Remove remaining material.


Remove adhesive residues and grind bonding surfaces down
to bare metal.
Grind welding surfaces on both sides back to bare metal.

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n

ility
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ce

AG. Volkswagen AG d
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V
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b
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d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s

do
c
um
en

3. Renewing rear side panel

193

ht
rig
py
Co
t.

agen
lksw
Vo
by

AG.

Prote
cted
by

c
o
p
yri
gh
t.
C
op
yi

n AG. Volkswagen AG do
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wage
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ot g
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ran
ir se
tee
o
h
t
or
u
ac
a
ss

Replacement parts
Rear side panel
2K body adhesive -D 180 KD3 A2Carry out the following work:

194

Rep. gr.53 - Body - rear

Prote
cted
by

Preparing replacement part

AG.

3.2.1

agen
lksw
Vo
by

c
o
p
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gh
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.
C
op
yi

Installing

ht
rig
py
Co
t.

3.2

do
c
um
en

r
te o
iva
r
rp
fo
g
n

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s

es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com

pe
rm
itte
d

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Amarok 2011
Body Repairs - Edition 10.2010

Amarok 2011
Body Repairs - Edition 10.2010

Grind welding surfaces on both sides back to bare metal.

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Grind bonding surfaces -1- to -6- down to bare metal on one


side (from inside).

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3. Renewing rear side panel

195

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Amarok 2011
Body Repairs - Edition 10.2010

3.2.2

Welding in

Carry out the following work:

rrectness of i
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es, in part or in w
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Apply adhesive beads sufficiently thickly so that optimal bonding with the body is guaranteed.
AG.

New part must be welded in within 90 minutes or adhesion of adhesive will be impaired.

196

Rep. gr.53 - Body - rear

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Note

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Apply 2K body adhesive -D 180 KD3 A2- to bonding surfaces.

Amarok 2011
Body Repairs - Edition 10.2010

es, in part or in w
l purpos
hole
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Check fit with adjacent parts.

Weld in rear of side panel, RP spot weld seam.

rrectness of i
t to the co
nform
spec
at
i
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in t
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Adapt rear side

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ut -1- to fit and fix in position.
ra
panel
a
c
s
s

3. Renewing rear side panel

197

agen
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by

AG.

Prote
cted
by
c
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rig
ht
.
C
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Amarok 2011
Body Repairs - Edition 10.2010

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng

ility
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n AG. Volkswagen AG do
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ir se
tee
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or
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ss

Prote
cted
by

Rep. gr.53 - Body - rear

AG.

198

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Use 2K filler to smooth out rough spots.

ht
rig
py
Co
t.

Optically process visible weld joints.

thi
sd
o
cu
m
en

Weld in rear side panel, RP spot weld seam, SG plug weld


seam and SG continuous weld seam.