BODY COLLISION REPAIR - CABRIOLET

• HEADINGS
  • 00 - General, Technical Data, Materials
    • Vehicle identification data
      • The type plate and vehicle identification number (VIN)
      • Vehicle data plate
    • Welding, definitions and symbols
      • Definitions
      • Symbols
    • Body panel gaps/mating lines
      • Body, front
      • Body, center
      • Body, rear
    • Body dimensions
      • Floor group, front
      • Floor group, center
      • Floor group, rear
      • Body, front
      • Body, center
      • Body, rear
    • Bonded joints
      • Bonded joints
      • Spot-welded bonded joints
      • Inspecting and repairing bonded joints
      • Repair methods for replacing body parts
      • Repair methods for bonded joints
        • Body, front
        • Body, center
        • Body, rear
    • Straightening jig
      • Straightening jig
      • Supplement for quattro versions
      • Portal gauge
  • 50 - Body - Front
    • Intermediate piece, partial replacement
      • Cutting locations
      • Replacement parts
      • Welding in
    • Longitudinal member for upper wheel housing, replacement
      • Longitudinal member for upper wheel housing, replacement
      • Longitudinal member for upper wheel housing, replacement
        • Cutting locations
        • Replacement part
        • Welding in
    • Front longitudinal member, partial replacement
      • Front longitudinal member, partial replacement
        • Cutting locations
        • Replacement part
        • Welding in
    • Front longitudinal member, replacement
      • Front longitudinal member, replacement
        • Cutting locations
        • Replacement parts
        • Welding in
  • 51 - Body - Center, Chassis, Roof
    • Outer roof frame, replacement
      • Cutting locations
      • Replacement part
      • Welding in
    • Side frame, replacement
      • Side frame, replacement
      • Side frame, replacement
        • Cutting locations
        • Replacement part
        • Welding in
    • Replacing A-pillar
      • Replacing A-Pillar
      • Replacing A-Pillar
        • Cutting locations
        • Replacement parts
        • Welding in
    • Reinforcement tube, replacement
      • Reinforcement tube, replacement
      • Reinforcement tube, replacement
        • Cutting locations
        • Replacement part
        • Welding in
    • Outer side member, replacement
      • Outer side member, replacement
        • Cutting locations
        • Replacement part
        • Welding in
    • Floor plate, partial replacement
      • Floor plate, partial replacement
        • Cutting locations
        • Replacement part
        • Welding in
  • 53 - Body - Rear
    • Rear cross panel, upper section, replacement
      • Cutting locations
      • Replacement part
      • Welding in
    • Rear cross panel, inner section, replacement
      • Rear cross panel, inner section, replacement
      • Rear cross panel, inner section, replacement
        • Cutting locations
        • Replacement part
        • Welding in
    • Rear cross panel, replacement
      • Rear cross panel, replacement
      • Rear cross panel, replacement
        • Cutting locations
        • Replacement part
        • Welding in
    • Tail light mounting, replacement
      • Tail light mounting, replacement
      • Tail light mounting, replacement
        • Cutting locations
        • Replacement part
        • Welding in
    • Replacing side panel
      • Replacing Side Panel
        • Cutting locations
        • Replacement parts
        • Welding in
    • Rear wheel housing, replacement
      • Rear wheel housing, replacement
      • Rear wheel housing, replacement
        • Cutting locations
        • Replacement part
        • Welding in
• FIGURES
  • Fig. 1: Locating Type Plate And Vehicle Identification Number
  • Fig. 2: Identifying Vehicle Data Sticker
  • Fig. 3: Symbols For Welding Operations
  • Fig. 4: Body Panel Gaps/Mating Lines - Body, Front
  • Fig. 5: Body Panel Gaps/Mating Lines - Body, Center
  • Fig. 6: Body Panel Gaps/Mating Lines - Body, rear
  • Fig. 7: Body dimensions - Floor Group, Front
  • Fig. 8: Body Dimensions - Floor Group, Center
  • Fig. 9: Body Dimensions - Floor Group, Rear
  • Fig. 10: Body Dimensions - Body, Front (1 Of 2)
  • Fig. 11: Body Dimensions - Body, Front (2 Of 2)
  • Fig. 12: Body Dimensions - Body, Center
  • Fig. 13: Body Dimensions - Body, Rear (1 Of 2)
  • Fig. 14: Body Dimensions - Body, Rear (2 Of 2)
  • Fig. 15: Bonded Joints
  • Fig. 16: Spot-Welded Bonded Joints
  • Fig. 17: Identifying Repair Methods For Bonded Joints (Body, Front - A, B , C, D, E, F, X)
  • Fig. 18: Identifying Repair Methods For Bonded Joints (Body, Front - A, B ,C, D, E, F, X)
  • Fig. 19: Identifying Repair Methods For Bonded Joints (Body, Front - G, H)
  • Fig. 20: Identifying Repair Methods For Bonded Joints (Body, Front - J, K, M)
  • Fig. 21: Identifying Repair Methods For Bonded Joints (Body, Center - A, B)
  • Fig. 22: Identifying Repair Methods For Bonded Joints (Body, Center - C, D)
  • Fig. 23: Identifying Repair Methods For Bonded Joints (Body, Rear - A, B, C)
  • Fig. 24: Straightening Jig (1 Of 10)
  • Fig. 25: Straightening Jig (2 Of 10)
  • Fig. 26: Straightening Jig (3 Of 10)
  • Fig. 27: Straightening Jig (4 Of 10)
  • Fig. 28: Straightening Jig (5 Of 10)
  • Fig. 29: Straightening Jig (6 Of 10)
  • Fig. 30: Straightening Jig (7 Of 10)
  • Fig. 31: Straightening Jig (8 Of 10)
  • Fig. 32: Straightening Jig (9 Of 10)
  • Fig. 33: Straightening Jig (10 Of 10)
  • Fig. 34: Supplement For Quattro Versions (1 Of 3)
  • Fig. 35: Supplement For Quattro Versions (2 Of 3)
  • Fig. 36: Supplement For Quattro Versions (3 Of 3)
  • Fig. 37: Portal Gauge (1 Of 3)
  • Fig. 38: Portal Gauge (2 Of 3)
  • Fig. 39: Portal Gauge (3 Of 3)
  • Fig. 40: Intermediate Piece, Partial Replacement - Cutting Locations
  • Fig. 41: Intermediate Piece, Partial Replacement - Replacement Parts
  • Fig. 42: Intermediate Piece, Partial Replacement - Welding In
  • Fig. 43: Longitudinal Member For Upper Wheel Housing, Replacement - Cutting Locations
  • Fig. 44: Longitudinal Member For Upper Wheel Housing, Replacement - Replacement Part
  • Fig. 45: Longitudinal Member For Upper Wheel Housing, Replacement - Welding In
  • Fig. 46: Front Longitudinal Member, Partial Replacement - Cutting Locations
  • Fig. 47: Front Longitudinal Member, Partial Replacement - Replacement Part
  • Fig. 48: Front Longitudinal Member, Partial Replacement - Welding In
  • Fig. 49: Front Longitudinal Member, Replacement - Cutting Locations (1 Of 2)
  • Fig. 50: Front Longitudinal Member, Replacement - Cutting Locations (2 Of 2)
  • Fig. 51: Front Longitudinal Member, Replacement - Replacement Parts
  • Fig. 52: Front Longitudinal Member, Replacement - Welding In
  • Fig. 53: Outer Roof Frame, Replacement - Cutting Locations
  • Fig. 54: Outer Roof Frame, Replacement - Replacement Part
  • Fig. 55: Outer Roof Frame, Replacement - Welding In
  • Fig. 56: Side Frame, Replacement - Cutting Locations
  • Fig. 57: Side Frame, Replacement - Replacement Part
  • Fig. 58: Side Frame, Replacement - Welding In
  • Fig. 59: Replacing A-Pillar - Cutting Locations
  • Fig. 60: Replacing A-Pillar - Replacement Parts
  • Fig. 61: Replacing A-Pillar - Welding In (1 Of 3)
  • Fig. 62: Replacing A-Pillar - Welding In (2 Of 3)
  • Fig. 63: Replacing A-Pillar - Welding In (3 Of 3)
  • Fig. 64: Reinforcement Tube, Replacement - Cutting Locations
  • Fig. 65: Reinforcement Tube, Replacement - Welding In
  • Fig. 66: Outer Side Member, Replacement - Cutting Locations
  • Fig. 67: Outer Side Member, Replacement - Replacement Part
  • Fig. 68: Outer Side Member, Replacement - Welding In (1 Of 2)
  • Fig. 69: Outer Side Member, Replacement - Welding In (2 Of 2)
  • Fig. 70: Floor Plate, Partial Replacement - Cutting Locations
  • Fig. 71: Floor Panel, Partial Replacement - Replacement Part
  • Fig. 72: Floor Panel, Partial Replacement - Welding In
  • Fig. 73: Rear Cross Panel, Upper Section, Replacement - Cutting Locations
  • Fig. 74: Rear Cross Panel (Upper Section), Replacement - Replacement Part
  • Fig. 75: Rear Cross Panel (Upper Section), Replacement - Welding In
  • Fig. 76: Rear Cross Panel, Inner Section, Replacement - Cutting Locations
  • Fig. 77: Rear Cross Panel, Inner Section, Replacement - Welding In
  • Fig. 78: Rear Cross Panel, Replacement - Cutting Locations
  • Fig. 79: Rear Cross Panel (Inner Section), Replacement - Replacement part
  • Fig. 80: Rear Cross Panel (Inner Section), Replacement - Welding In
  • Fig. 81: Tail Light Mounting, Replacement - Cutting Locations
  • Fig. 82: Tail Light Mounting, Replacement - Replacement Part
  • Fig. 83: Tail Light Mounting, Replacement - Welding In
  • Fig. 84: Replacing Side Panel - Cutting Locations
  • Fig. 85: Replacing Side Panel - Replacement Parts
  • Fig. 86: Replacing Side Panel - Welding In
  • Fig. 87: Rear Wheel Housing, Replacement - Cutting Locations
  • Fig. 88: Rear Wheel Housing, Replacement - Welding In
• TABLES

ACCESSORIES & EQUIPMENT

Body Collision Repair - Cabriolet

00 - General, Technical Data, Materials

Vehicle identification data

The type plate and vehicle identification number (VIN)

Fig. 1: Locating Type Plate And Vehicle Identification Number
Courtesy of VOLKSWAGEN UNITED STATES, INC.

The identification plate is located on the left suspension turret below the cover support.

Vehicle data plate

Fig. 2: Identifying Vehicle Data Sticker
Courtesy of VOLKSWAGEN UNITED STATES, INC.

The vehicle data sticker is located under the rear seat.

Welding, definitions and symbols

Definitions

RP = spot welding

SG = Shielded arc welding

Symbols

Fig. 3: Symbols For Welding Operations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

RP Spot welded seam (single row)

Body panel gaps/mating lines

Body, front

Fig. 4: Body Panel Gaps/Mating Lines - Body, Front
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Use special tool 3371 for checking or adjusting.

N - 0.0 mm

A - 1.0 mm

D - 2.0 mm

F - 3.0 mm

G - 3.5 mm

J - 4.5 mm

K - 5.0 mm

O - 8.5 mm

Body, center

Fig. 5: Body Panel Gaps/Mating Lines - Body, Center
Courtesy of VOLKSWAGEN UNITED STATES, INC.

N - 0.0 mm

G - 3.5 mm + 1

H - 4.0 mm + 1

K - 5.0 mm

Body, rear

Fig. 6: Body Panel Gaps/Mating Lines - Body, rear
Courtesy of VOLKSWAGEN UNITED STATES, INC.

N - 0.0 mm

D - 2.0 mm

E - 2.5 mm

F - 3.0 mm

G - 3.5 mm

J - 4.5 mm

K - 5.0 mm

Body dimensions

Floor group, front

Fig. 7: Body dimensions - Floor Group, Front
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Distance between front attachment points of front suspension

a - 840 2mm

Distance between rear attachment points of front suspension

b - 620 2mm

Diagonal distance between attachment points of front suspension

c - 1005 2mm

CAUTION:

These dimensions only serve as a check. Correct dimensions are defined by alignment bracket set.

Floor group, center

Fig. 8: Body Dimensions - Floor Group, Center
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Distance between rear attachment points of front suspension and rear axle mounting

d - 1510 2mm

Diagonal distance between rear attachment points of front suspension and rear axle mounting

e - 1742 2mm

CAUTION:

These dimensions only serve as a check. Correct dimensions are defined by alignment bracket set.

Floor group, rear

Fig. 9: Body Dimensions - Floor Group, Rear
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Distance between axle mountings

f - 1090 2mm

Diagonal distance between axle mounting and longitudinal member

g - 1235 2mm

Distance between rear longitudinal members

h - 995 2mm

CAUTION:

These dimensions only serve as a check. Correct dimensions are defined by alignment bracket set.

Body, front

Fig. 10: Body Dimensions - Body, Front (1 Of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Dimension between front side members

a - 820 2mm

CAUTION:

These dimensions only serve as a check. Correct dimensions are defined by alignment bracket set.

Distance between front hinge mountings

Fig. 11: Body Dimensions - Body, Front (2 Of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

b - 1405 2mm

Distance between fender panel mountings

c - 1287 2mm

Diagonal distance between hinge mountings and fender panel mountings

d - 1576 2mm

Distance between outer attachment points of suspension strut mountings

e - 1036 2mm

CAUTION:

These dimensions only serve as a check. Correct dimensions are defined by alignment bracket set.

Body, center

Fig. 12: Body Dimensions - Body, Center
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Dimension between A-pillars

a - 1395 2mm

Distance between A-pillar and B-pillar

b - 1250 2mm

Dimension between B-pillars

c - 1388 2mm

CAUTION:

These dimensions only serve as a check. Correct dimensions are defined by alignment bracket set.

Body, rear

Fig. 13: Body Dimensions - Body, Rear (1 Of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Distance between rear longitudinal members

a - 1069 2mm

Distance between flange on cross member for soft top box and flange on rear cross panel

b - 514 2mm

Distance between flange on cross member for soft top box and flange on rear section of back panel (behind rear backrest)

c - 120 2mm

Distance between side panels (top)

Fig. 14: Body Dimensions - Body, Rear (2 Of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

d - 1141 2mm

Distance between side panels (bottom)

e - 1108 2mm

Distance between side panels (bottom)

f - 1528 2mm

Bonded joints

Bonded joints

The body of the Audi A4 features bonded and spot-welded bonded joints in order to increase the rigidity and strength.

Fig. 15: Bonded Joints
Courtesy of VOLKSWAGEN UNITED STATES, INC.

In the case of the bonded joints, the joint between the sheet metal parts is formed only by the adhesive.

Spot-welded bonded joints

Fig. 16: Spot-Welded Bonded Joints
Courtesy of VOLKSWAGEN UNITED STATES, INC.

In spot welded bonded joints an electrically conductive adhesive is used between the panels, which allows good root penetration for spot welding.

Inspecting and repairing bonded joints

Particular attention should be given to these joints when diagnosing accident damage and performing body repairs.

Note the following points:

Do not use a chisel to test the strength of a joint or relieve stresses by hammering as this will damage or destroy the bonded joint.

These joints should be inspected particularly closely when diagnosing accident damage and after performing straightening work on the body.

If the joint is not accessible with pop rivets, it must be repaired with an arc-welded seam (SG). In this case the entire area of the joint must be re-welded, as the heat produced by welding destroys the adhesive in the bonded joint. The SG seams should be welded working from the thin to the thick panel. A fume extractor must be used.

Repair methods for replacing body parts

When making repairs, welded joints can be used in place of all spot-welded bonded joints and certain bonded joints if no suitable body adhesive is available.

Do not make the repair with only the same spot welds or seams as originally used in production as these alone are not adequate.

The repair methods are presented in detail on the article which follow.

NOTE:

If the instructions call for additional spot welds, these should be applied in a single operation. Do not place new spot welds in between the original spot welds. SG plug welding should not be performed until after spot welding. This avoids any increased shunt current when spot welding. Ensure good root penetration at all joints. Seal off repaired joint flanges and apply cavity sealing where necessary.

Repair methods for bonded joints

Fig. 17: Identifying Repair Methods For Bonded Joints (Body, Front - A, B , C, D, E, F, X)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Body, front

• A = Wheel housing to longitudinal member: also make 5 x SG plug weld seams in place of bonded joint
• B = Longitudinal member reinforcement to support: also make 2 x 15 mm SG seams on flange.
• C = Longitudinal member reinforcement to support: also make SG plug weld seams between spot welds.
• D = Longitudinal member to closure plate and rear section of wheel housing: also make SG plug weld seams between spot welds. Longitudinal member to closure plate: make double number of spot welds in place of bonded joint.

• E = Closure plate on longitudinal member to mounting for suspension strut cross member: also make 6 x SG plug weld seams in place of bonded joint.

Fig. 18: Identifying Repair Methods For Bonded Joints (Body, Front - A, B ,C, D, E, F, X)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• F = Inner section of side panel to outer section of side panel: also make 6 x SG plug weld seams in place of bonded joint.
• X Refer to Body, center.
• G = Front panel of plenum chamber to suspension strut mounting: also make SG plug weld seams between spot welds.

Fig. 19: Identifying Repair Methods For Bonded Joints (Body, Front - G, H)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• H = Cross member to longitudinal member: also make 15 mm SG seam at each of the 3 flanges.
• J = Cross member to plenum chamber: also make SG plug weld seams between spot welds.

Fig. 20: Identifying Repair Methods For Bonded Joints (Body, Front - J, K, M)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• K = Cross member to suspension strut mounting: also make 3 x 15 mm SG seams on flange.
• M = Plenum chamber to bulkhead: also make 15 mm SG seams every 30 mm.
• M = Stiffener for suspension strut cross member to connecting panel on longitudinal member (top): also make SG plug weld seams between spot welds.

Body, center

Fig. 21: Identifying Repair Methods For Bonded Joints (Body, Center - A, B)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• A = Side frame to bulkhead panel at B-pillar: also make 3 x 15 mm SG seams on flange.
• B = Outer side frame to fillet plate at A-pillar: make double number of RP spot welds
• C = Outer side panel to outer slot reinforcement: same as production version. Apply adhesive and bead over side panel. If adhesive joint is damaged, make good as follows.

Fig. 22: Identifying Repair Methods For Bonded Joints (Body, Center - C, D)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Brush area, paint, seal and apply cavity sealing. If adhesive bond is damaged over a length of more than 100 mm, make a 10 mm SG seam every 50 mm. Rework wheel housing liner if necessary.
• D = Outer side panel to inner side panel: same as production version. Apply adhesive and bead over side panel. If adhesive joint is damaged, make good as follows.
• Brush area, paint, seal and apply cavity sealing. If adhesive bond is damaged over a length of more than 100 mm, make a 10 mm SG seam every 50 mm. Rework wheel housing liner if necessary.

Body, rear

Fig. 23: Identifying Repair Methods For Bonded Joints (Body, Rear - A, B, C)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• A = As original joint: apply adhesive and bead over edge of wheel housing. If adhesive bond is damaged, rework as follows:
• Brush area, paint, seal and apply cavity sealing. If adhesive bond is damaged over a length of more than 100 mm, make a 10 mm SG seam every 50 mm. Rework wheel housing liner if necessary.
• B = Longitudinal member to inner wheel housing: make double number of SG plug welds
• C = Longitudinal member suspension mounting to fillet plate on longitudinal member: make double number of RP spot welds

Straightening jig

Straightening jig

NOTE:

The item numbers in the figure are identical with the end numbers on the alignment bracket mountings.

Fig. 24: Straightening Jig (1 Of 10)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

The item numbers of the alignment bracket mountings marked with a circle are for checking the body with mechanical units installed. The required basic size is given for the alignment bracket mountings. In the following figures the right side of the vehicle is shown (left side similar).

Alignment bracket set VAS 6050 (also suitable for quattro versions)

Overview and locations of MZ elements

Fig. 25: Straightening Jig (2 Of 10)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Overview of alignment brackets with MZ elements for vehicles with mechanical units installed

Fig. 26: Straightening Jig (3 Of 10)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Overview of front alignment brackets

Fig. 27: Straightening Jig (4 Of 10)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Overview of front alignment brackets

Fig. 28: Straightening Jig (5 Of 10)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fig. 29: Straightening Jig (6 Of 10)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Overview of central alignment brackets

Fig. 30: Straightening Jig (7 Of 10)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fig. 31: Straightening Jig (8 Of 10)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Overview of rear alignment brackets

Fig. 32: Straightening Jig (9 Of 10)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fig. 33: Straightening Jig (10 Of 10)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Supplement for quattro versions

Fig. 34: Supplement For Quattro Versions (1 Of 3)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Overview of alignment brackets for quattro versions

Fig. 35: Supplement For Quattro Versions (2 Of 3)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fig. 36: Supplement For Quattro Versions (3 Of 3)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Portal gauge

Portal gauge VAS 5007/12

Fig. 37: Portal Gauge (1 Of 3)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fig. 38: Portal Gauge (2 Of 3)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fig. 39: Portal Gauge (3 Of 3)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

50 - Body - Front

Intermediate piece, partial replacement

Cutting locations

Fig. 40: Intermediate Piece, Partial Replacement - Cutting Locations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Separate original joint.
• Remove remaining material
• Remove part.

Replacement parts

• Connecting plates

Preparing new part

Fig. 41: Intermediate Piece, Partial Replacement - Replacement Parts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Drill 7 mm holes for SG plug weld seam.

Welding in

Fig. 42: Intermediate Piece, Partial Replacement - Welding In
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Spot weld intermediate piece, RP spot weld seam.

Longitudinal member for upper wheel housing, replacement

Longitudinal member for upper wheel housing, replacement

• Intermediate piece already removed.

Longitudinal member for upper wheel housing, replacement

Cutting locations

Fig. 43: Longitudinal Member For Upper Wheel Housing, Replacement - Cutting Locations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Cut out as shown
• Separate original joint.
• Remove remaining material

Replacement part

• Upper wheel housing longitudinal member

Fig. 44: Longitudinal Member For Upper Wheel Housing, Replacement - Replacement Part
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Transfer separating cut to new part plus 10 mm for overlap. Separate shaded area.

Welding in

Fig. 45: Longitudinal Member For Upper Wheel Housing, Replacement - Welding In
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Spot weld upper wheel housing longitudinal member, RP spot weld seam.

Front longitudinal member, partial replacement

Front longitudinal member, partial replacement

Cutting locations

Fig. 46: Front Longitudinal Member, Partial Replacement - Cutting Locations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Dimension -a- = 95 mm
• Remove longitudinal member.

NOTE:

Separating cut must be a straight line.

Replacement part

Fig. 47: Front Longitudinal Member, Partial Replacement - Replacement Part
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Sub-part - longitudinal member

Welding in

• Dimension -b- = 240 mm

Fig. 48: Front Longitudinal Member, Partial Replacement - Welding In
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Adapt length on body side if necessary.

Front longitudinal member, replacement

Front longitudinal member, replacement

Cutting locations

Fig. 49: Front Longitudinal Member, Replacement - Cutting Locations (1 Of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Separate original joint between inner longitudinal member and reinforcement plates.
• Separate original joint between upper longitudinal member and support.
• Grind off weld seams on longitudinal member.
• Take out inner longitudinal member.

• Remove remaining material
• Drill off reinforcing plate - a - so that it can be re-used.

Fig. 50: Front Longitudinal Member, Replacement - Cutting Locations (2 Of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Make separating cut - b - at bottom as shown and bend panel out (see insert).
• Make separating cut in longitudinal member as shown. Do not damage internal reinforcement.
• Use a straight grinder to make separating cut.

CAUTION:

If the inner longitudinal member is damaged it must also be replaced.

• Separate original joint.

Replacement parts

• Inner longitudinal member
• Longitudinal member

Preparing new part

Fig. 51: Front Longitudinal Member, Replacement - Replacement Parts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Drill 7 mm holes for SG plug weld seam.

Welding in

• Adapt new part and secure on alignment bracket.

Fig. 52: Front Longitudinal Member, Replacement - Welding In
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Butt weld parting cut, SG continuous seam.

51 - Body - Center, Chassis, Roof

Outer roof frame, replacement

Cutting locations

Fig. 53: Outer Roof Frame, Replacement - Cutting Locations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Separate original joint.
• Pull out part from above

Replacement part

• Outer roof frame

Preparing new part

Fig. 54: Outer Roof Frame, Replacement - Replacement Part
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Drill 7 mm holes for SG plug weld seam.

Welding in

• Slide in new part between outer pillar and inner A-pillar.

Fig. 55: Outer Roof Frame, Replacement - Welding In
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Weld in roof frame, RP spot weld seam.

Side frame, replacement

Side frame, replacement

• Side panel already removed.

Side frame, replacement

Cutting locations

Fig. 56: Side Frame, Replacement - Cutting Locations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Rear wheel housing: open spot welds.
• Reinforcement tube: grind off weld seam from outside
• A-pillar: grind off continuous SG weld seam at top and bottom
• B-pillar: grind off continuous SG weld seam at top seat belt reinforcement

• Separate original joint.

Replacement part

• Side frame

Preparing new part

Fig. 57: Side Frame, Replacement - Replacement Part
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Drill 7 mm holes for SG plug weld seam.

Welding in

Fig. 58: Side Frame, Replacement - Welding In
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Apply adhesive DA 001 730 A1 in a 5 mm bead as shown.

Replacing A-pillar

Replacing A-Pillar

• Intermediate piece already cut out.

Replacing A-Pillar

Cutting locations

Fig. 59: Replacing A-Pillar - Cutting Locations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Do not damage inner reinforcement when making separating cut in sill.
• Separate original joint.
• Remove adhesive remains with knife and scraper.

NOTE:

A partial replacement is possible with the separating cuts illustrated. SG continuous butt weld in the separated areas.

Replacement parts

• Side frame
• Body adhesive DA 001 730 A1

Preparing new part

Fig. 60: Replacing A-Pillar - Replacement Parts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Transfer separating cut to new part and cut-out.

Welding in

• Apply adhesive DA 001 730 A1 in a 5 mm bead as shown.

Fig. 61: Replacing A-Pillar - Welding In (1 Of 3)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• A = 320 mm

• Place backing plate behind parting cut and tack weld in position.

Fig. 62: Replacing A-Pillar - Welding In (2 Of 3)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Weld in A-pillar, RP spot weld seam.

Fig. 63: Replacing A-Pillar - Welding In (3 Of 3)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Weld in A-pillar, RP spot weld seam.

Reinforcement tube, replacement

Reinforcement tube, replacement

• Side frame part section already removed

• Roof frame already removed.

Reinforcement tube, replacement

Cutting locations

Fig. 64: Reinforcement Tube, Replacement - Cutting Locations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Separate original joint.

Replacement part

• A-pillar reinforcement frame

Welding in

Fig. 65: Reinforcement Tube, Replacement - Welding In
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Weld in reinforcement, SG continuous seam (broken).

Outer side member, replacement

Outer side member, replacement

Cutting locations

Fig. 66: Outer Side Member, Replacement - Cutting Locations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Separate original joint.
• Make sill parting cut according to degree of damage.
• Remove remaining material

Replacement part

• Side member

Preparing new part

Fig. 67: Outer Side Member, Replacement - Replacement Part
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Transfer separating cut to new part and cut-out.

Welding in

• Apply adhesive DA 001 730 A1 in a 5 mm bead as shown.

Fig. 68: Outer Side Member, Replacement - Welding In (1 Of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• A = 320 mm

Fig. 69: Outer Side Member, Replacement - Welding In (2 Of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Weld in side member, RP spot weld seam.

Floor plate, partial replacement

Floor plate, partial replacement

Cutting locations

Fig. 70: Floor Plate, Partial Replacement - Cutting Locations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Separate original joint.
• Grind off MIG brazed seam and make SG continuous seam in its place.
• Make separating cut as shown. Do not damage internal reinforcement or longitudinal member.
• Remove remaining material

Replacement part

• Floor plate

Preparing new part

Fig. 71: Floor Panel, Partial Replacement - Replacement Part
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Transfer parting cut plus 15 mm for overlap to new part. Part shaded area.

Welding in

• Step separating cut (body side).

Fig. 72: Floor Panel, Partial Replacement - Welding In
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Weld new part in, SG plug weld seam.

53 - Body - Rear

Rear cross panel, upper section, replacement

Cutting locations

Fig. 73: Rear Cross Panel, Upper Section, Replacement - Cutting Locations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Separate original joint.
• Take off part.

Replacement part

Fig. 74: Rear Cross Panel (Upper Section), Replacement - Replacement Part
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Rear cross panel

Welding in

Fig. 75: Rear Cross Panel (Upper Section), Replacement - Welding In
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Spot weld rear cross panel, RP spot weld seam.

Rear cross panel, inner section, replacement

Rear cross panel, inner section, replacement

• Upper section of rear cross panel already removed

Rear cross panel, inner section, replacement

Cutting locations

Fig. 76: Rear Cross Panel, Inner Section, Replacement - Cutting Locations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Separate original joint.
• Remove part.

Replacement part

• Rear cross panel

Welding in

Fig. 77: Rear Cross Panel, Inner Section, Replacement - Welding In
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Spot weld rear cross panel, RP spot weld seam.

Rear cross panel, replacement

Rear cross panel, replacement

• Upper section of rear cross panel already removed

Rear cross panel, replacement

Cutting locations

Fig. 78: Rear Cross Panel, Replacement - Cutting Locations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Separate original joint.
• a - Drill through tail light mounting (two metal thicknesses).
• Take off part.

Replacement part

• Reinforcement for rear cross panel

Preparing new part

Fig. 79: Rear Cross Panel (Inner Section), Replacement - Replacement part
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Drill 7 mm holes for SG plug weld seam.

Welding in

Fig. 80: Rear Cross Panel (Inner Section), Replacement - Welding In
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Insert part from above between tail light mounting and bottom reinforcement.

Tail light mounting, replacement

Tail light mounting, replacement

• Upper section of rear cross panel already removed (part section)

Tail light mounting, replacement

Cutting locations

Fig. 81: Tail Light Mounting, Replacement - Cutting Locations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Separate original joint.
• Pull part downward to remove.

Replacement part

• Tail light mounting

Preparing new part

Fig. 82: Tail Light Mounting, Replacement - Replacement Part
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Drill 7 mm holes for SG plug weld seam.

Welding in

• The tail light mounting is now tilted into the installation position, pulled up and installed in place.
• Check gap to side panel and boot lid.

Fig. 83: Tail Light Mounting, Replacement - Welding In
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Spot weld tail light mounting, RP spot weld seam.

Replacing side panel

Replacing Side Panel

Cutting locations

Fig. 84: Replacing Side Panel - Cutting Locations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Grind through outer edge of wheel housing.
• Grind through outer edge at top part of side panel.
• Separate original joint.
• Take off part.

Replacement parts

• Side panel
• Body adhesive DA 001 730 A1

Preparing new part

• Drill 7 mm holes for SG plug weld seam.

Fig. 85: Replacing Side Panel - Replacement Parts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Apply adhesive before welding in.

Welding in

Fig. 86: Replacing Side Panel - Welding In
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Weld in side panel, RP spot weld seam.

Rear wheel housing, replacement

Rear wheel housing, replacement

• Side panel already removed.

Rear wheel housing, replacement

Cutting locations

Fig. 87: Rear Wheel Housing, Replacement - Cutting Locations
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Separate original joint.

Replacement part

• Wheel housing liner

Welding in

Fig. 88: Rear Wheel Housing, Replacement - Welding In
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Spot weld wheel housing, RP spot weld seam.

Didn't find what you were looking for? Try to find in:
- ElsaWin online
- Alldata Online (Beta)