BOR53201020 Body Repairs

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Body Repairs
Bora 1999
Bora Variant 1999
Golf 1998
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Service Department. Technical Information
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Edition 06.2010
Service
Repair Group overview for Body Repairs
Repair Group
00 - Technical data
50 - Body - front
51 - Body - centre
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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.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright 2010 Volkswagen AG, Wolfsburg
BOR53201020
Bora 1999 , Bora Variant 1999 , Golf 1998

Body Repairs - Edition 06.2010
Contents
olkswagen AG
en AG. V
00 - Technical data . . . . . . . . V.o.lks.w.ag. . . . . . . . . . . . .do. e.s n.o.t g. . . . . . . . . . . . . . . . . . . . . . .

ua
. . . . . . . . . . . . . . . . . . . . . . .ra.n.te. . . . . . . . . . . . .
e
. . . . . . . . . . . . . . . . . . . . . . . . . . o.r a. . . . . . . . . . .
c
Vehicle
..........
Vehicle
..........
Identification plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vehicle data plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body foam insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Galvanized body parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Strengthened steel body panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Laser welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body panel gaps/shut lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body - front (Golf) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body - rear (Golf) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body - front (Bora) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body - rear (Bora) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body - rear (estate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body - rear (Golf) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body - rear (Bora) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body - rear (estate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Floor group - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Floor group - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Floor group - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alignment jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview, Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview, Bora, Bora estate, Golf estate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview, Golf 4MOTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview, Bora 4MOTION, Bora estate 4MOTION, Golf estate 4MOTION . . . . . . . . . . . .
Portal gauge (2-door) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Portal gauge (4-door) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1
1.1
1.2
1.3
2
3
4
5
6
6.1
6.2
6.3
6.4
6.5
7
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
8
8.1
8.2
8.3
8.4
8.5
8.6
by
ed
identification
ris data . .
o
th
identification
number
au
ss
1
1
1
1
1
2
3
4
5
6
6
8
10
12
14
16
16
20
27
30
33
36
37
38
39
39
50
53
58
63
64
50 - Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
1
1.1
2
2.1
3
3.1
4
4.1
5
5.1
6
6.1
7
7.1
8
8.1
9
Renewing engine bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Right engine console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing intermediate piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing wing connecting plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing upper wheel housing longitudinal member . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing front wheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing front wheel housing - partial renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing front longitudinal member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing front longitudinal member - partial renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing front section of longitudinal member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents
65
65
67
67
69
69
71
71
73
73
75
75
77
77
79
79
81

9.1
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
82
51 - Body - centre . . . . . . . . . . . . . . . . . . . . . . . . .lk.sw.a.ge.n.AG. ..V.olk.s.wa.g.en. A.G.do. e.s n. . . . . . . . . . 85

ot
Vo
Renewing roof (Golf) . . . . . . . . . . . . . . . . e. d.b.y . . . . . . . . . . . . . . . . . . . . . . . . . g. u.ar.a. . . . . . .

n
is
Removing . . . . . . . . . . . . . . . . . . . . . u.th.or. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . t.ee.o. . . .
ra
a
Renewing roof (Bora) . . . . . . . . . . .ss. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .c . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing roof (estate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions for roof railing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing front roof cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing roof reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing rear roof cross member (Golf) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing rear roof cross member (Bora) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing rear roof cross member (estate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing A-pillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing inner A-pillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing B-pillar (4-door), renewing B-pillar (Bora) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing inner B-pillar (2-door) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing inner B-pillar (Golf 4-door), renewing inner B-pillar (Bora) . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing outer side member (2-door) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing outer side member (Golf 4-door), renewing outer side member (Bora) . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing side member reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Includes: Web plate part section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing floor panel - partial renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
85
86
89
90
92
92
98
99
99
101
101
103
103
105
105
107
107
109
109
113
113
116
117
119
119
122
122
126
126
129
130
132
132
135
135
rrectness of i
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spec
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1
1.1
2
2.1
3
3.1
3.2
4
4.1
5
5.1
6
6.1
7
7.1
8
8.1
9
9.1
10
10.1
11
11.1
12
12.1
13
13.1
14
14.1
15
15.1
16
16.1
17
17.1
53 - Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

1
1.1
2
2.1
2.2
3
3.1
3.2
3.3
3.4
3.5
3.6
ii
Contents
Renewing rear cross panel (Golf) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing outer rear cross panel (estate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing complete rear cross panel (estate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Welding in lock carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Welding in inner side panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Welding in lower D-pillar reinforcing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D-pillar reinforcing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
138
138
140
140
141
144
144
144
146
146
147
148

Welding in inner D-pillar reinforcing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Welding in tail light cluster mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Welding cross member to inner rear cross panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing rear cross panel (4MOTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing complete rear cross panel (4MOTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing centre piece of rear cross
wagen AG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G. Volks(Bora)
Apanel
do
agen
Removing . . . . . . . . . . . .V.ol.ks. w. . . . . . . . . . . . . . . . . . e.s.no. t .g. . . . . . . . . . . . . . . . . . . . . . . . .
y
ua
db
r
Renewing rear roof cross
ise panel (Bora) . . . . . . . . . . . . . . . . . a.n.te . . . . . . . . . . . . . . . . . . . . .
r
o
e
h
Removing . . . . s.a.ut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o.r a.c . . . . . . . . . . . . . . . . . .
s
Renewing tail light mounting (Golf) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing cross member carrier (Golf) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing cross member carrier (Bora) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing towing eye (4MOTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing C-pillar reinforcement (estate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing cover plate (Bora) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing longitudinal member - partial renewal (Golf) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing longitudinal member - partial renewal (4MOTION) . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing rear longitudinal member (Bora) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing longitudinal member - partial renewal (Bora) . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing side panel - partial renewal (2-door) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing side panel - partial renewal (Golf 4-door) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing side panel - partial renewal (Bora) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing side panel - partial renewal (estate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing outer wheel housing liner - partial renewal (Golf) . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing outer wheel housing liner - partial renewal (Bora) . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing outer wheel housing liner - partial renewal (estate) . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing spare wheel well (Golf) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing spare wheel well - partial renewal (Golf) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing spare wheel well (4MOTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
do
c
um
en
ht
rig
py
Co
t.
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te o
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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
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ot
com
pe
rm
itte
d
un
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an
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agen
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by
AG.
Prote
cted
by
c
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C
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3.7
3.8
3.9
4
4.1
5
5.1
6
6.1
7
7.1
8
8.1
9
9.1
10
10.1
11
11.1
12
12.1
13
13.1
14
14.1
15
15.1
16
16.1
17
17.1
18
18.1
19
19.1
20
20.1
21
21.1
22
22.1
23
23.1
24
24.1
25
25.1
26
26.1
27
27.1
Contents
149
150
150
151
151
153
153
157
157
160
160
162
162
165
165
167
167
169
169
172
172
174
174
176
176
178
179
181
181
183
183
185
186
189
190
193
193
197
197
202
202
204
204
207
207
210
210
212
212
214
214
iii

28
28.1
Renewing spare wheel well (Bora) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
ht
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Co
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AG.
Prote
cted
by
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C
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Contents
do
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iv
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nform
spec
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h re
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es, in part or in w
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AG. Volkswagen AG d
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ara
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Body
Repairs
Edition
06.2010
eo
h
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a
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s
s
Technical data
Vehicle identification data
1.1
Vehicle identification number
rrectness of i
t to the co
nform
spec
a
t
i
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wit
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l purpos
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00
Identification plate
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1.3
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Co
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The identification plate is located on the left suspension turret be

low the cover support.
do
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1.2
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The vehicle identification number (chassis number) is stamped

on the rear cross panel of engine compartment. It can be seen
through a window in the plenum chamber cover.
Vehicle data plate
The vehicle data sticker is located in the spare wheel well at the
rear of the vehicle.
1. Vehicle identification data

Body foam insulation
On this vehicle various bodywork cavities are foam treated.

The location of the foam treatments is described in the individual
repair instructions.
Treating with foam reduces the transfer of noises to the
ageinterior
es n
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when driving.
yV
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ris parts (parts des

Treatment is via pre-formed synthetic material
ho
ut
ignation: insulation).
a
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In the parts catalogue the insulation is shown on figure 864-00.
or
ac
rrectness of i
t to the co
nf
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m
spec
atio
h re
n in
wit
The pre-formed parts are fitted during body shell construction and
they increase their volume in the paint shop drying oven at ap
prox.180 C, after priming.
As these temperatures cannot be achieved under normal work
shop conditions, proceed as follows:
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.
Remove foam material remains on vehicle.
Repair any damage to body paint.
Renewing insulation
Install insulation on vehicle.
Rep. gr.00 - Technical data
AG.
Carry out cavity protection to repair area after painting vehicle.
agen
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Prote
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Do not SG weld 15 mm either side of insulation.
ht
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Co
t.
Attach new part (e.g. A-pillar) and locate new part by pressing
gently in area of insulation and weld in.
thi
sd
o
cu
m
en
Apply sealing cord AKD 497 010 04 R10 around circumfer

ence of insulation.

Galvanized body parts
The vehicle consists completely of body panels galvanized on

both sides!
Before carrying out body repairs, refer to the following informa
tion: General notes; Body repairs, General body repairs; Work
procedures; Galvanized body parts.
rrectness of i
t to the co
nform
spec
at
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h re
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3. Galvanized body parts
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Prote
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es n
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ir se
tee
o
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or
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ac
a
ss
Prote
cted
by
Various front parts of chassis (hatched items)

Plenum chamber (hatched items)
B-pillar, roof reinforcement (hatched items)
Rear reinforcements (hatched items)
AG.
Reinforced body sheet-metal is used in following body areas:
agen
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Workshop manual general information, chapter: Repair pro

cedures
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Strengthened steel body panels
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Laser welding
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On this vehicle the roof below the roof strip is welded
by
laser.
d
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ise
r
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With laser welding, a high-energy beam of alight
is directed over
ut
ra
c
s
s optical fibre.
the seam to be welded by optical lenses or
ht
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Co
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For repairs the laser weld seam is replaced by a SG plug weld

seam.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
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cial p
is n
mer
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During the welding process, the upper panel is melted onto the
partially molten lower panel, creating a welded joint without the
need of additional material.
5. Laser welding
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Body panel gaps/shut lines
6.1
Body - front (Golf)
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
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Note
Gaps are always given in millimetres.
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To adjust or check gaps, use special tool 3371.
AG. Volkswagen AG d
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6. Body panel gaps/shut lines
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Prote
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6.2
Body - rear (Golf)
AG.
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Co
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Note
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at
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6.3
Body - front (Bora)
Prote
cted
by
AG.
10
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Co
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Note
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at
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es, in part or in w
l purpos
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11
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Body - rear (Bora)
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6.5
Body - rear (estate)
AG.
14
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Co
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Note
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nf
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7.1
Body - front
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Distance between front longitudinal members
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Distance between suspension strut mountings
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Body dimensions
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Dimension between top of wheel housings (bonnet hinges)

Distance between wheel housing front upper corners
7. Body dimensions
17
AG. Volkswagen AG d
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18
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Distance between bonnet hinge mounting and wheel housing

front upper corner
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Diagonal distance between bonnet hinge mounting and wheel

housing front upper corner
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form
spec
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Diagonal dimension for windscreen aperture
Note
The front and centre sections of the Bora body are identical to
the Golf
Dimensions only given for checking purposes. Correct dimen
sions are defined by alignment bracket set.
rrectness of i
t to the co
nf
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wit
Dimension plenum chamber flange - centre of roof flange
thi
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7. Body dimensions
19
ht
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olksw
AG.
The front and centre sections of the Bora body are identical to the
Golf
Door aperture width (2-door)
20
agen
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Prote
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Note
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Body - centre
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Bora
1999
,
Bora
Variant
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Body
Repairs
- Edition 06.2010
ss
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Front door aperture (4-door)

Note
The height of the front door aperture on 2-door and 4-door vehi
cles is the same.
7. Body dimensions
21
r
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22
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Rear door aperture
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Distance between A-pillars
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7. Body dimensions
23
AG. Volkswagen AG d
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24
ht
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Co
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Dimension between B-pillars (2-door)
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form
spec
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AG. Volkswagen AG d
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Dimension between B-pillars (4-door)
thi
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7. Body dimensions
25
ht
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do
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26
rrectness of i
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nform
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at
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es, in part or in w
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Dimension between C-pillars (4-door)
7.3
Body - rear (Golf)
rrectness of i
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nf
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wit
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Distance between rear wheel housings
Distance between mountings for tail light cluster
thi
sd
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ht
rig
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Co
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7. Body dimensions
27
AG.
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AG. Volkswagen AG d
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AG.
28
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.
C
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Distance between rear longitudinal members
ht
rig
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Co
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Width of rear lid aperture
do
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spec
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com
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, Bora Variant 1999 , Golf 1998

rrectness of i
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nf
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spec
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wit
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AG. Volkswagen AG d
Bora 1999
agen
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Distance between cross panel flange and roof flange at centre of

vehicle
Note

7. Body dimensions
29

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Distance between top of rear lid aperture and middle of roof flange
AG.
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30
c
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Diagonal distance of rear window aperture
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form
spec
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Body - rear (Bora)
ht
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Co
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7.4

rrectness of i
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nf
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spec
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wit
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l purpos
hole
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Height of rear lid aperture

Distance between side panel corners above tail light cluster
7. Body dimensions
31
AG. Volkswagen AG d
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The front and centre sections of the Bora body are identical to
the Golf
32
AG.
Note
agen
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ht
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Co
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Distance between mountings for tail light cluster
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7.5
Body - rear (estate)
rrectness of i
t to the co
nf
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spec
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n in
wit
es, in part or in w
l purpos
hole
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Width of rear lid aperture
7. Body dimensions
33
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,auBora Variant 1999 , Golf 1998
ac
ss
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.
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ht
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Co
t.
34
thi
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Height of rear lid aperture
rrectness of i
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nf
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spec
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wit
es, in part or in w
l purpos
hole
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, is n
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m
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t
a
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nl
f
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Bora 1999
rrectness of i
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7. Body dimensions
35
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7.6
Floor group - front
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Note

7. Body dimensions
37

7.8
Floor group - rear
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Alignment jig
8.1
Overview, Golf
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Note
The article number in the figures are identical to the final digits
on the alignment bracket (AB).
The necessary basic set for the alignment bracket is given.
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-VAS 5090- or
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AB = Alignment bracket
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-VAS 5020- (Audi A3) and -VAS 5020/2- (supplementary

AG.
alignment bracket set for Golf 98 )
The right side of the vehicle is shown in the following figures.
8. Alignment jig
39

6 - MZ 142
8 - MZ 260
10 - MZ 200
14 - MZ 601
16 - Centring piece, left and
right identical
42 - MZ 200 and TV 400
44 - On AB -4218 - MZ 140
20 - Mounting without MZ
22 - On mounting -2026 - MZ 140
28 - MZ 080
30 - MZ 080
31 - Mounting plate on AB
-3032 - MZ 602
34 - MZ 200
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40
rrectness of i
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Overview of front alignment bracket positions

42 - AB for front longitudinal
member
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44 - AB for wheel housing cor

ner
8. Alignment jig
41
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77 - Connecting rod between

alignment bracket and longitu
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This combination of alignment brackets are used for adjusting
the wheel housing corner and/or the front section of the lon
gitudinal member.
The complete set must always be used.

Mountings -46-, -47- and the pins -T044-- are secured to the
longitudinal members by screw clamps -1-.
Vehicle must be fitted on an alignment jig if the structural dam
age is large.
42
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Note
AG.
46 - Mounting for -42- and-44-
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8. Alignment jig
43
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8- - AB for engine mounting
9- - AB for gearbox mounting
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06.2010
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8. Alignment jig
45

member
10 - AB for subframe mounting
14 - AB and centring piece
-16- for suspension strut
mounting
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Overview of central alignment brackets
8. Alignment jig
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18 - AB for subframe mounting
20 - Mounting for AB -2222 - AB for production mount
ing
Front left and right are
identical.
Can be pressed up
wards.
Must not be used as a
reference point (vehicle
0 position).
26 - AB for drilling in floor panel
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48
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Overview of rear alignment bracket positions
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28 - AB for drilling in
nal member
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8. Alignment jig
49
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30 - AB for rear axle mounting
Set body on alignment
jig before adjusting
bracket.
31 - Distance piece, left and
right identical
Use only with rear axle
removed
32 - AB for suspension strut
mounting
34 - AB for drilling in longitudi
nal member
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es, in part or in w
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Assembly possibilities: -VAS 5020- AUDI A3, -VAS 5020/2- sup

plementary set Golf 4, -VAS 5020/3- supplementary set Bora/
Bora Variant/Golf Variant or -VAS 5090- Golf 4, -VAS 5020/3supplementary set Bora/Bora Variant/Golf Variant
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96 - MZ 200 and TV 400
8. Alignment jig
51
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olkswagen AG
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96 - AB for drilling in rear lon
gitudinal member
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-VAS 5020/5- supplementary set to alignment bracket set Golf

1998 page 39 .
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Overview, Golf 4MOTION
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AG.
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78 - MZ 140
80 - MZ 080
82 - MZ 260 and TV 400
84 - MZ 260
86 - MZ 200
88 - MZ 140
90 - MZ 200
91 - MZ 200
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54
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Overview of alignment bracket
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Overview of alignment bracket positions
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8. Alignment jig
55
AG.

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1999 , Golf 1998
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Body
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78 - AB for propshaft centre
bearing mounting
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-VAS 5020/5- supplementary set to alignment bracket set Golf

1998 page 39 .
58
AG.
Overview, Bora 4MOTION, Bora estate

4MOTION, Golf estate 4MOTION
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78 - MZ 140
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8. Alignment jig
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8. Alignment jig
61
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8.5
Portal gauge (2-door)
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Note
The portal gauge is a alignment bracket for the hinges and
striker plates on A, B or C-pillars.
Basic set -VAS 5007- .
estate.
do
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Portal gauge -VAS 5007/5- for Golf 1998 , Bora 1999 and
The illustration shows a portal gauge fitted to a 2-door vehicle.
8. Alignment jig
63
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8.6
Portal gauge (4-door)
64
AG.
The shows a portal gauge fitted to a 4-door vehicle.
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striker plates on A, B or C-pillars.
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The portal gauge is a alignment bracket for the hinges and
thi
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Note
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Body - front
RO: 50 40 55 50
Renewing engine bracket
WARNING
Observe safety notes!
General Information; Body Repairs, General Body Repairs ;

Chapter 1 - Safety notes
Right engine console
do
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1.1
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Cutting locations
Separate engine console.

Separate original joint.
Remove front part section.
1. Renewing engine bracket
65

Drill out weld points -a-, 7 mm.
Remove remaining material.
1.1.2
Replacement part
Engine bracket
Preparing new part
Drill 7 mm holes for SG plug weld seam.
Welding in
Fix new part using alignment bracket.
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l purpos
hole
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Weld console in, SG plug weld seam.
Weld in weld points -a- from outside, SG plug weld seam.
rrectness of i
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nform
spec
at
i
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Rep. gr.50 - Body - front
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RO: 50 52 55 50
Renewing intermediate piece
WARNING

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Removing
2.1.1
Cutting locations
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2. Renewing intermediate piece
67

Note
Offset parting cut 50 mm to wing connecting plate and intermedi

ate piece.
Partial renewal
If the extent of damage permits, a vertical parting cut can be

made.
Butt weld parting cut, SG continuous weld seam.
2.1.2
Replacement part
Connecting plate
2.1.3
Welding in
Secure new part and check gaps with attached parts.

Spot weld intermediate piece, RP
spot weld seam.
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AG
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68
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Weld in wing connecting
olks plate page 70 .
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RO: 50 53 55 50
Renewing wing connecting plate
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Cutting locations
r
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3.1.1
Removing
ht
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3.1
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s
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WARNING
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Cut out connecting plate.

3. Renewing wing connecting plate
69

Note
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Offset parting cut 50 mm to wing connecting plate and
gen AG
does
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Partial renewal
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A part section repair is possible using parting cut -1- shown.
rrectness of i
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nform
spec
a
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wit
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hole
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com
Replacement part
Connecting plate
Transfer parting cut to new part and cut out.
Prote
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by
Weld new part in, RP spot weld seam.

Weld in longitudinal member for wheel housing page 72 .
70
AG.
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Welding in
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Preparing new part
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3.1.2
or
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RO: 50 72 55 50
Renewing upper wheel housing lon

gitudinal member
WARNING

Removing
4.1.1
Cutting locations
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4.1
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Cut out upper wheel housing longitudinal member according

to degree of damage.
4. Renewing upper wheel housing longitudinal member
71

Note
If the damage is beyond the prescribed separating lines -1-, then

the inner A-pillar must be renewed as well.
Partial renewal
A partial renewal, depending on damage, is possible using the

parting cuts -a- shown.
es, in part or in w
l purpos
hole
ercia
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Replacement part
Upper wheel housing longitudinal member

Preparing new part
4.1.3
Welding in
Adapt new part to fit and hold in position.

Spot weld upper wheel housing longitudinal member, RP spot
weld seam.
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Co
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72

RO: 50 74 55 00
Renewing front wheel housing
WARNING

Longitudinal member for upper wheel housing already cut out.
Wing connecting plate already cut out.
Intermediate piece already cut out.
5.1.1
Cutting locations
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Removing
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5.1
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5. Renewing front wheel housing
73

5.1.2
Replacement part
AG. Volkswagen AG d
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for
SG plug weld seam.
c
s
s
Front wheel housing

Preparing new part
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rrectness of i
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nform
spec
a
t
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wit
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5.1.3
es, in part or in w
l purpos
hole
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, is n
m
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com
pe
rm
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d
un
le
Drill 7 mm holes
Welding in
Secure wheel housing on alignment bracket.

Spot weld wheel housing to lower longitudinal member, RP
spot weld.
Weld in intermediate piece page 68 .
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Co
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74
do
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r
te o
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Weld in remaining joint, SG plug weld seam.

RO: 50 75 55 50
Renewing front wheel housing - par

tial renewal
WARNING

Longitudinal member for upper wheel housing already cut out.
Wing connecting plate already cut out.
Intermediate piece already cut out.
6.1
Removing
6.1.1
Cutting locations
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
m
ot p
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erm
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t
a
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6. Renewing front wheel housing - partial renewal
75
AG.
Prote
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by
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.
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Cut out wheel housing in front of suspension strut mounting.
6.1.2
Replacement part
Wheel housing
Preparing new part
Transfer parting cut to new part plus 10 mm for overlap. Cut
off hatched area.
Make joddle joints on body side.
6.1.3
Welding in

Spot weld wheel housing, RP spot weld seam.
Apply overlapping weld to both sides of lower parting cut,
staggered SG continuous weld seam. gen AG. Volkswagen AG d
a
lksw
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Weld in intermediate piece page
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thi
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76
rrectness of i
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nf
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spec
atio
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wit
es, in part or in w
l purpos
hole
ercia
, is n
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or
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t
a
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o
nl
f
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ris
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au

RO: 50 79 55 00
Renewing front longitudinal member
WARNING

7.1.1
Cutting locations
AG. Volkswagen AG d
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atio
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Removing
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7.1
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AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Cut out longitudinal member.

7. Renewing front longitudinal member
77

7.1.2
Replacement parts
Longitudinal member
Front section of longitudinal member
Preparing new part
ility
ab
y li
an
pt
ce
7.1.3
Welding in
Adapt new part and secure on alignment bracket.
c
o
p
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gh
t
.
C
op
yi
Spot weld remaining joint in, RP spot weld seam.

Weld in longitudinal member, SG plug weld seam.
ht
rig
py
Co
t.
r
fo
ng
Weld parting cut, SG continuous weld seam.
agen
lksw
Vo
by
Prote
cted
by
Weld in front section of longitudinal member page 83 .
AG.
78
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
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
un
le
es n
wage
s
k
l
Transfer parting cutVto
ot g
o new part and cut out.
y
ua
b
ran
ed
s
i
tee
r
Drill 7 mm hholes
for SG plug weld seam.
o
t
or
u
ac
a
ss

RO: 50 79 55 02
Renewing front longitudinal member

- partial renewal
WARNING

Removing
8.1.1
Cutting locations
es n
wage
s
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l
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b
d
ran
ir se
tee
o
h
t
or
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ac
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ss
do
c
um
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ht
rig
py
Co
t.
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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
pt
ce
un
le
8.1
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Locate parting cut according to degree of damage.
8. Renewing front longitudinal member - partial renewal
79

Note
Separating cut must be straight.
8.1.2
Replacement parts
Longitudinal member
Preparing new part
Transfer parting cut to new part and remove hatched area.
8.1.3
Welding in
Secure section of longitudinal member on alignment bracket.

Depending on damage, butt weld parting cut, SG continuous
seam.
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
Note
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
thi
sd
o
cu
m
en
80
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
The weld points must run parallel with one another if the repairs
to longitudinal member and covering plate are carried out as in
dividual parts. The prescribed distances must be adhered to.
ht
rig
py
Co
t.
Weld in front section of longitudinal member
AG. Volkswagen AG d
agen
oes
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not
l
o
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b
ara
d83 .
page
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s

RO: 50 80 55 00
Renewing front section of longitudi

nal member
WARNING

Note
The towing eye must be removed before the front section of the
right-hand longitudinal member can be renewed.
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
ab
y li
an
pt
ce
AG. Volkswagen AG d
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oes
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not
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is
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h
ut
ra
a
c
s
s
do
c
um
en
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
9. Renewing front section of longitudinal member
81

Cutting locations
AG.
Prote
cted
by
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
82
thi
sd
o
cu
m
en
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
9.1.1
ht
rig
py
Co
t.
Removing
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
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not
l
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ise
r
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ra
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c
s
s
9.1
es n
wage
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b
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ran
ir se
tee
o
h
t
or
u
ac
a
ss
9.1.3
Prote
cted
by
AG.
Towing eye (only right side)
agen
lksw
Vo
by
Replacement parts
c
o
p
yri
gh
t
.
C
op
yi
9.1.2
ht
rig
py
Co
t.
r
fo
ng
Make separating cut in front of 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
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

Welding in
Adapt new part and secure on alignment bracket.
9. Renewing front section of longitudinal member
83

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
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
do
c
um
en
84
agen
lksw
Vo
by
Dimension a = 70 mm
ht
rig
py
Co
t.
Weld in towing eye, SG continuous seam.
ility
ab
y li
an
pt
ce
Weld in front section of longitudinal member, SG

weld seam.
AG. Volkswagen AG d
agen
oes
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not
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b
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is
r
o
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h
continuous
ut
ra
a
c
s
s
AG. Volkswagen AG d
agen
oes
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not
l
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V
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ara
d
e
nte
is
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h
ut
ra
Bora 1999 , oBora
a
c
s
s
Body - centre
RO: 51 03 55 00
Renewing roof (Golf)
WARNING

1 - Bonded section
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
51
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
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
Variant 1999 , Golf 1998

1. Renewing roof (Golf)
85
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
un
le
Cutting locations
r
fo
ng
1.1.1
AG.
Prote
cted
by
Note
A special hose with reduced jet diameter is required for the
shielding gas welding unit to repair the roof.
-VAS 5023- Hose set

-VAS 5023/2- - Jet set
Remove sealant from sealing channel.
86
Rep. gr.51 - Body - centre
agen
lksw
Vo
by
c
o
p
yri
gh
t
.
C
op
yi
Roughly cut roof out.
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
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
Removing
ht
rig
py
Co
t.
1.1
ility
ab
y li
an
pt
ce
es n
wage
s
k
l
ot g
o , Golf 1998
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss

Grind laser weld seam down, bend remaining material up with
a chisel and lever off.
Note
Grind down only laser weld seam. Do not grind through roof.
If roof frame is damaged, it must be replaced as well.
Use flap discs only, do not use cutting disks or rough grinding
disks.
Remove adhesive remains completely and grind adhesive

surface back to bare metal.
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
Roof
Replacement parts
Butyl adhesive sealing cord AKL 450 005 05

Adhesive: DA 001 730 A1
Preparing new part
Notches -enlargement- must be cut in the horizontal roof

flange with a bench grinder or angled grinder for later SG plug
weld seam.
ht
rig
py
Co
t.
r
fo
ng
Spacing approx. 45 - 50 mm.
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
1.1.2
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
ility
ab
y li
an
pt
ce
un
le
Grind spot weld flange, from inside, to bright surface using ball
milling tool.
1. Renewing roof (Golf)
87
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi

1.1.3
Welding in
Before welding roof in, apply Butyl adhesive sealing cord to

roof reinforcement.
Apply adhesive before welding in.
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
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b
ara
d
e
nte
is
r
New part must be installed within 30 minutes, otherwise
adhesive
o
eo
th
u
ra
a
properties of adhesive will be impaired.
c
s
s
Note
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
Spot weld roof, RP spot weld seam.

Note
Check fit with windscreen and rear window. It is essential that

dimension -a- = 13.2 mm for the roof trim strip, be maintained.
Note
The seal must be even and thin. Irregularities will result in visible
waves in roof trim strip.
88
AG.
Seal roof channel (thin layer).
agen
lksw
Vo
by
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Grind SG-weld points down flush.
ht
rig
py
Co
t.
Braze remaining joint.
thi
sd
o
cu
m
en
Weld in roof, SG plug weld seam.

RO: 51 03 55 00
Renewing roof (Bora)
WARNING

1 - Bonded section
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
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not
l
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b
ara
d
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nte
is
r
o
eo
h
ut
ra
a
c
s
s
thi
sd
o
cu
m
en
2. Renewing roof (Bora)
89
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi

2.1
Removing
2.1.1
Cutting locations
1 - Note roof reinforcement.

Drill out original joint to
roof frame.
Remove roof.
Remove remaining ma
terial.
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
2.1.2
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
pt
ce
un
le
Replacement parts
Roof
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
ht
rig
py
Co
t.
90
do
c
um
en
r
te o
iva
r
rp
fo
g
n

2.1.3
Welding in
Before welding in roof, apply Butyl adhesive sealing cord to

roof reinforcement -1-.
Note
New part must be installed within 30 minutes, otherwise adhesive

Check fit with windscreen and rear window. It is essential that
dimension -a- = 13.2 mm for the roof trim strip, be maintained.
Areas -b- are only bonded and sealed.
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
ble waves in roof trim strip.
r
fo
ng
The seal must be even and thin. Irregularities will result in visi
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
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
Note
un
le
Spot weld roof, RP spot weld seam.
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
2. Renewing roof (Bora)
91

RO: 51 03 55 20
Renewing roof (estate)
WARNING
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
Tools
3.1.1
Special tools, workshop equipment,

testers, measuring instruments and aux
iliary items required
Note
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
3.1
Wire brush -VAS 5182-
ility
ab
y li
an
pt
ce
General Information; Body Repairs, General

AG. Volkswagen AG d
agen
oes
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not
l
o
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b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
Body
Repairs
;
c
s
s
A special hose set with reduced jet diameter is required for the
shielded gas welding unit to repair the roof: -VAS 5023- hose set
-VAS 5023/2- nozzle set.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
ht
rig
py
Co
t.
92
thi
sd
o
cu
m
en
-V.A.G 2005- Pneumatic glue gun

1 - Bonded section
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
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
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b
ara
d
e
nte
is
r
o
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h
ut
ra
a
c
s
s
do
c
um
en
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
3. Renewing roof (estate)
93
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi

3.1.2
Cutting locations
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
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
Prote
cted
by
Roughly cut roof out between C and D-pillars.

Remove roof.
94
AG.
The brazed seam must be ground down completely on the vehi

cle.
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi
Note
ht
rig
py
Co
t.
Grind out brazed seam.
thi
sd
o
cu
m
en
Drill out original joint to roof frame.
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
Remove sealant from sealing channel.

Grind laser weld seam down, bend remaining material up with
a chisel and lever off.
Note
ht
rig
py
Co
t.
r
fo
ng
Grind down only laser weld seam. Do not grind through roof. If
roof frame is damaged, it must be replaced as well.
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
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

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

agen
lksw
Vo
by
AG.
Remove residue and clean spot weld flange to bright surface

using a wire brush from inside vehicle.
95

AG. Volkswagen AG d
agen
oes
3.1.3
Roof
ksw
Replacement parts
Vol
by
ed
ris
o
h
t
au
un
le
Notches -enlargement- must be cut in the horizontal roof

flange with a bench grinder or angled grinder for later SG plug
weld seam (spacing approx. 45 - 50 mm).
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
Preparing new part
pe
rm
itte
d
ility
ab
y li
an
pt
ce
ss AKL 450 005 05

Butyl adhesive sealing cord
not
gu
ara
nte
eo
ra
c
Drill holes for roof railing, if required page 98 .
Welding in
Apply butyl adhesive sealing cord -1- to front and rear roof
reinforcements.
agen
lksw
Vo
by
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Note

AG.
96
ht
rig
py
Co
t.
Apply adhesive to roof frames before welding in.
do
c
um
en
r
te o
iva
r
rp
fo
g
n
3.1.4
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
do
c
um
en
ht
rig
py
Co
t.
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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Weld in roof, RP spot weld seam and SG plug weld seam.

Braze in remaining joint to rear roof frame or use SG stepped
seam.
Grind SG-weld points down flush.
Note
Check fit with windscreen. It is essential that dimension -a- =
13.2 mm for the roof trim strip, be maintained.
The seal must be even and thin. Irregularities will result in visi
ble waves in roof trim strip.
97

3.2
Dimensions for roof railing
a - 34 mm
b - 153 mm
c - 1155 mm
d - 29 mm
e - 523 mm
f - 26 mm
g - 146 mm
Note
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Measurements for right side are
a mirror image.
Reinstate cavity protection.
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Before drilling holes, fit roof rail by V
ara
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nte
ing and check position of all oris
eo
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holes.
ut
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RO: 51 07 55 50
Renewing front roof cross member
WARNING

4.1
Roof already removed.
Cutting locations
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Cut out cross member.

4. Renewing front roof cross member
99

4.1.2
Replacement part
Roof cross member
4.1.3
Welding in
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100
rrectne
s
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RO: 51 08 55 50
Renewing roof reinforcement
WARNING
un
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Roof already cut out
Cutting locations
r
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ng
5.1.1
ht
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Removing
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s
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5.1
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Observe safety
ua
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General Information; Body Repairs, General Body Repairs
agen
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Cut out roof reinforcement.

5. Renewing roof reinforcement
101

Note
The procedure Golf and Bora 1999 is identical.
5.1.2
Replacement part
Roof cross member

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Welding in
es, in part or in w
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5.1.3
rrectness of i
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nf
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spec
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wit
Note

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102

RO: 51 09 55 50
Renewing rear roof cross member

(Golf)
ility
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WARNING
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Cutting locations
do
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Prote
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by
6.1.1
AG.
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Removing
rrectness of i
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6.1
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Cut out cross member.

6. Renewing rear roof cross member (Golf)
103

6.1.2
Replacement part
Roof cross member
6.1.3
Welding in

ht
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104
rrectness of i
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nform
spec
at
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his
es, in part or in w
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hole
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RO: 51 09 55 50

(Bora)
WARNING
AG. Volkswagen AG d
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General Information;
Body
Repairs,
General
Body
Repairs
;
e
nte
is
r
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ho
Chapter 1 -utSafety
notes
ra
a
c
ss
Cutting locations
r
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ng
7.1.1
rrectne
s
s
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f
i
t to the co
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form
spec
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n
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Removing
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7.1
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Cut out roof cross member.

7. Renewing rear roof cross member (Bora)
105

7.1.2
Replacement part
Roof cross member
Welding in
AG.
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106
do
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7.1.3

RO: 51 09 55 70

(estate)
WARNING

8.1
Removing
8.1.1
Cutting locations
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
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Drill out roof cross member.

8. Renewing rear roof cross member (estate)
107

8.1.2
Replacement part
Rear roof cross member
Welding in
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For reasons of strength, use welding set -V.A.G 1713 B- to
agen
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spot weld roof cross member (3 panels each of different thick

ness in weld area).
AG.
If other welding sets are used, then the roof cross member
must be welded with SG plug weld seam.
108
ht
rig
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Co
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Note
r
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ng
Spot weld roof cross member in, RP spot weld seam.
rrectne
s
s
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f
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form
spec
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8.1.3

RO: 51 37 55 00
Renewing A-pillar
WARNING
Welding, parting using spark generating machines/tools or tin

ning in foam treated areas creates gases which are hazardous
to health and environment. Therefore, refrain from using these
processes.
Use 2K filler material to smooth out irregularities.
AG. Volkswagen AG d
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Removing
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9.1
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1 - Foam treated area
Scrape out as much foam remains as possible before starting

grinding work.
9. Renewing A-pillar
109
un
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Make parting cut -a- according to degree of damage.

Make parting cut -b- as shown. Do not damage internal rein
forcement.
Partial renewal
Due to internal reinforcements, parting cut -c- is permissible only

at this position!
The reinforcement can be felt through the oval opening.
110
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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um
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ole,
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is n
mer
m
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or
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v
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p
Cutting locations
ht
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9.1.1
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b
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r Variant 1999 , Golf 1998
Bora 1999 , Bora
o
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t
or
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ac
Body Repairs s-aEdition
06.2010
s

es, in part or in w
l purpos
hole
ercia
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m
m
ot p
o
c
erm
or
e
t
a
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iv
r
du
rp
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f
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Replacement part
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nf
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spec
atio
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n in
wit
9.1.2
ility
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A-pillar subpart with side member

Preparing new part

thi
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9.1.3
Welding in
Adapt new part with vehicle standing on its wheels or on align

ment fixtures and tack weld in position.
Weld in A-pillar, RP spot weld seam.
9. Renewing A-pillar
111

Butt weld parting cuts, SG continuous weld seam.
Weld in A-pillar, SG plug weld seam.
ht
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Prote
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by
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thi
sd
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112
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
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t
a
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du
rp
o
nl
f
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AG. Volkswagen AG d
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RO: 51 38 55 50
10
Renewing inner A-pillar
WARNING

processes.
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
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riv
du
p
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nl
f
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n
rrectness of i
t to the co
nform
spec
at
i
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do
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10.1
agen
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2 - Cutting line for partial re

newal
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AG. Volkswagen AG d
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Removing

grinding work.
10. Renewing inner A-pillar
113

AG. Volkswagen AG d
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114
AG.
Partial renewal
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a
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wit
thi
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es, in part or in w
l purpos
hole
ercia
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com
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rm
itte
d
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un
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Cutting locations
ht
rig
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Co
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10.1.1

Note
Only use body saw -V.A.G 1523- or compressed air driven ham
mer -V.A.G 1577- for parting cut!
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
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erm
o
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t
a
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riv
du
p
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nl
f
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n
rrectness of i
t to the co
nform
spec
at
i
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his
10.1.2
ility
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c
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Replacement parts
Inner A-pillar
Insulation
Preparing new part
do
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10.1.3
Foam insulation
Note repair instructions page 2 .
10.1.4
Welding in

Check gaps and shut lines to bolt-on parts.
Weld in inner A-pillar, RP spot weld seam.
10. Renewing inner A-pillar
115

RO: 51 41 55 62, 51 41 55 52
11
Renewing B-pillar (4-door), renewing

B-pillar (Bora)
WARNING

1 - Bonded section
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Prote
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thi
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116
rrectness of i
t to the co
nf
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m
spec
atio
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n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
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or
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t
a
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iv
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du
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nl
f
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ility
ab
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AG. Volkswagen AG d
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Removing
11.1.1
Cutting locations
AG. Volkswagen AG d
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Position parting cut according to degree of damage and cut

out.
Grind through outer edge of wheel arch.
Note
Keep the cutting of the replacement part in mind!

ht
rig
py
Co
t.
r
fo
ng
Do not damage reinforcing in area of parting cut.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
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i
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p
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11.1
agen
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11. Renewing B-pillar (4-door), renewing B-pillar (Bora)
117
Prote
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by c
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C
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AG. Volkswagen AG d
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11.1.2
Replacement part
un
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pe
rm
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d
rrectness of i
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spec
a
t
i
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wit
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Preparing new part
es, in part or in w
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Side panel frame subpart
by
ed
ris
o
th
au

Apply adhesive to area of flange. 2 beads each of 3.5 mm

diameter.
Welding in
Place backing plate behind parting cuts.

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

Reform wheel housing flange.
Remove excessive adhesive and seal.
118
AG.
11.1.3
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Note
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Clean flange area, to ensure free of dust and grease.

RO: 51 42 55 50
12

Side panel and side member already removed.
Cutting locations
do
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12.1.1
ht
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Removing
rrectness of i
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at
i
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12.1
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AG. Volkswagen AG d
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safetys aunotes!
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Observe
Renewing inner B-pillar (2-door)
Prote
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by c
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C
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12. Renewing inner B-pillar (2-door)
119

Note
Make side panel parting cut -B- 100 mm below edge of roof.
Make B-pillar parting cut -A- 47 mm above upper seat belt se
curing point.
12.1.2
Replacement part
Inner B-pillar
Preparing new part
AG. Volkswagen AG d
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Make holes in new part.
AG.
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C
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120
ht
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Co
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fo
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rrectne
s
s
o
f
i
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form
spec
atio
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n
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thi
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p
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12.1.3

12.1.4
Welding in
Align B-pillar and side panel with portal gauge ( page 63 ).

Tack weld B-pillar to body.
Remove portal gauge and side panel.
Weld in B-pillar, RP spot weld seam, SG plug weld seam.

Weld in B-pillar, RP spot weld seam, SG continuous seam.
Note
The remaining spot welds in the upper area will be welded when
welding side panel in.
Weld in inner B-pillar, SG continuous weld seam, 4 x 25 mm.

Weld in side panel (for 2-door vehicle) page 187 .
Weld in side member page 131 .
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
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12. Renewing inner B-pillar (2-door)
121
Prote
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by
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RO: 51 42 55 60, 51 42 55 50
13
Renewing inner B-pillar (Golf 4-door),

renewing inner B-pillar (Bora)
WARNING
Cutting locations
1 - Bonded section
Cut out B-pillar -2-.
Grind through outer

edge of wheel housing
-1-.
Cut out sill panel -3-.
un
le
AG.
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122
do
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13.1.1
es, in part or in w
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Removing
rrectness of i
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spec
a
t
i
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13.1
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General Information; Body Repairs, General Body

AG. Volkswagen AG d
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Repairs
;
c
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Co
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Note
Only complete replacement possible.
The procedure Golf and Bora 1999 is identical.
Drill out inner roof frame -1- without damaging it.
Drill out material remains -1-.
es, in part or in w
l purpos
hole
ercia
, is n
m
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Grind out shielded arc weld seam.
rrectness of i
t to the co
nform
spec
at
i
h re
o
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wit
in t
his
Drill out material remains.
do
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13. Renewing inner B-pillar (Golf 4-door), renewing inner B-pillar (Bora)
123
AG.
Prote
cted
by c
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C
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es, in part or in w
l purpos
hole
ercia
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m
m
ot p
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or
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t
a
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iv
r
du
rp
o
nl
f
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ng
Replacement parts
Inner B-pillar
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Outer B-pillar
Preparing new parts
Prote
cted
by
Welding in
Fit inner and outer B-pillars on alignment bracket with portal

gauge ( page 64 ) and tack weld in position.
Remove outer B-pillar from body.
124
AG.
13.1.4
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Make holes in new parts.
thi
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Transfer parting cut to web plate and cut out.
ht
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13.1.3
ility
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13.1.2
AG. Volkswagen AG d
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agen AG
. VolkswBody
Repairs
- Edition 06.2010
gen AG
d
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rrectness of i
t to the co
nform
spec
at
i
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o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
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a
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wa
olks
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b
d plug weld
Weld in inner B-pillar, RP spot weld seams,iseSG
seams and SG continuous weld seam. uthor
a
ss
Weld in inner B-pillar, SG continuous weld seam, 4 x 25 mm.
do
c
um
en
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rig
py
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c
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Weld in B-pillar in roof area, RP spot weld seam and SG plug

weld seam.
Prote
cted
by
Adapt panels -1- and -2- to fit and tack weld in position.
Weld in panels, SG plug weld seam.

Weld in panels with SG plug weld seam and SG continuous
weld seam.
Weld in outer B-pillar page 118 .
Note
The SG plug welds may only be placed a maximum of 15 mm
apart.
The remaining spot welds will be welded when welding outer
B-pillar in.
13. Renewing inner B-pillar (Golf 4-door), renewing inner B-pillar (Bora)
125

RO: 51 45 55 00
14
Renewing outer side member (2door)
WARNING

14.1
Removing
14.1.1
Cutting locations
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Prote
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126
thi
sd
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cu
m
en
Locate side member parting cut according to degree of dam

age.
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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erm
or
e
t
a
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iv
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rp
o
nl
f
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ility
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AG. Volkswagen AG d
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Drill out original joint to A-pillar.
Note
14.1.2
Replacement part
Side member subpart

Preparing new part
ole,
cial p
is n
mer
m
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or
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t
a
itte
v
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Welding in

ht
rig
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Co
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fo
ng
Weld in side member, RP spot weld seam.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
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n
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thi
sd
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14.1.3
AG. Volkswagen AG d
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AG.
14. Renewing outer side member (2-door)
127
Prote
cted
by c
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p
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t.
C
op
yi
es, in part or in w
l purpos
hole
ercia
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Weld in side member, SG plug weld seam.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
agen
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Prote
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do
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128
ht
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Co
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Butt
AG. Volkswagen AG d
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weld parting cuts, SG continuous
weld seam.

RO: 51 45 55 10, 51 45 55 00
15
Renewing outer side member (Golf 4door), renewing outer side member
(Bora)
WARNING

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Prote
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c
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.
C
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15. Renewing outer side member (Golf 4-door), renewing outer side member (Bora)
do
c
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r
te o
iva
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rp
fo
g
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rrectness of i
t to the co
nform
spec
a
t
i
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wit
thi
s
es, in part or in w
l purpos
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1 - Bonded section
129

Removing
15.1.1
Cutting locations
AG. Volkswagen AG d
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Prote
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Note
130
ht
rig
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Co
t.
Locate side member parting cut according to degree of dam

age.
do
c
um
en
r
te o
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r
rp
fo
g
n
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
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s
es, in part or in w
l purpos
hole
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com
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rm
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15.1

15.1.2
Replacement parts
Side member subpart

Preparing new part
ility
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diameter.
un
le
Note

15.1.3
Welding in

Weld in side member, RP spot weld seam.
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
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thi
sd
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mer
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a
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AG. Volkswagen AG d
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Clean flange area, to ensure free of dust and
isegrease.
r
o
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h
t
u
ra
a each of 3.5 mm
Apply adhesive to area of flange. 2 beads
c
s
s
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Prote
cted
by
c
o
p
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gh
t.
C
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yi
15. Renewing outer side member (Golf 4-door), renewing outer side member (Bora)
131

RO: 51 49 55 50
16
Renewing side member reinforce

ment
16.1
Includes: Web plate part section

WARNING

olksw
AG. V
agen
Outer side member already removed Volksw

by
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Cutting locations
ho
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AG.
132
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Prote
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.
C
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With rear parting cut, cut a strip out of the side member rein
forcement first then separate the web plate.
do
c
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r
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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
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16.1.1
agen AG
does
not
gu
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c
ht
rig
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Co
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16.1.2
Replacement parts
Side member reinforcement

Web plate for side member
Preparing new parts
ility
ab
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an
pt
ce
rrectness of i
t to the co
nform
spec
at
i
h re
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n
wit
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his
16.1.3
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
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o
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t
a
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Transfer parting
AG. Volkswagen AG d
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and cut out.
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Welding in

ment fixtures and tack weld.
do
c
um
en
ht
rig
py
Co
t.
Prote
cted
by c
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p
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gh
t.
C
op
yi
Weld side member reinforcement to side member web plate,

RP spot weld seam.
agen
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16. Renewing side member reinforcement
133
AG.

Weld web plate in, RP spot weld seam.
AG. Volkswagen AG d
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Secure removed section and weld in, SG continuous seam.
agen
lksw
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by
AG.
Prote
cted
by c
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p
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gh
t.
C
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ht
rig
py
Co
t.
134
do
c
um
en
r
te o
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r
rp
fo
g
n
Weld in side member page 131 .
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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un
le
Weld parting cut, SG continuous weld seam.
un
le
Renewing floor panel - partial renew

al
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
WARNING
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
17
ility
ab
y li
an
pt
ce
RO: 51 73 55 50
wagen Variant
olk,sBora
AG do
Bora
1999 , Golf 1998
n AG. V
age1999
es n
ksw
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o
V
Body
Repairs
y
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b
ran
ed
tee
ris
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t
or
u
ac
a
ss

17.1.1
Cutting locations
Cut out floor panel.
Remove remaining ma
terial.
AG.
Locate parting cut ac

cording to degree of
damage.
agen
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Prote
cted
by c
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C
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2 - Cutting line partial repair
do
c
um
en
1 - Cutting line complete re

placement
r
te o
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r
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fo
g
n
Removing
ht
rig
py
Co
t.
17.1
17. Renewing floor panel - partial renewal
135

Part section repair
At parting cut -2-, carry out offset overlap weld to both sides,
staggered SG continuous weld seam.
Note
Do not make parting cuts in area of centre tunnel.

Seat cross member and guide rail may only be replaced com
plete.
17.1.3
Replacement parts
Floor panel
Seat cross member
Guide rail
c
o
p
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t
.
C
op
yi
Do not forget to add approx. 10 mm for overlap.

AG.
Prote
cted
by
agen
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136
ht
rig
py
Co
t.
r
fo
ng
Preparing new parts
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
ole,
cial p
is n
mer
m
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or
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17.1.2

17.1.4
Welding in
At parting cut, carry out offset overlap weld to both sides, stag
gered SG continuous weld seam.
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gen AG
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ris
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ss
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spec
a
t
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s
es, in part or in w
l purpos
hole
ercia
, is n
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Align seat cross member, hold in place
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Weld in floor plate, RP spot weld.

Weld in seat cross member, RP spot weld seam.
Weld in seat guide rail, SG continuous seam.
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Weld in seat guide rail, RP spot weld seam.
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137
AG.
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53
Body - rear
RO: 53 05 55 50
Renewing rear cross panel (Golf)
WARNING
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Cutting locations
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1.1.1
Rep. gr.53 - Body - rear
AG.
138
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Cut out rear cross panel.
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1.1.2
Replacement part
Rear cross panel
1.1.3
Welding in

Check closing/locking of rear lid.
Spot weld rear cross panel, RP spot weld seam.
Weld in cross panel carrier page 166 .
rrectness of i
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1. Renewing rear cross panel (Golf)
139
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RO: 53 05 55 20
Renewing outer rear cross panel (es

tate)
WARNING

2.1.1
Special tools, workshop equipment,

testers, measuring instruments and aux
iliary items required
r
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Tools
AG.
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2.2
Removing
2.2.1
Cutting locations
rrectness of i
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spec
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Remove residue and clean weld area to bright surface using
a wire brush -VAS 5182- , from inside of vehicle.
2.2.2
Replacement parts
Outer rear cross panel

2. Renewing outer rear cross panel (estate)
141

Preparing new part
2.2.3
Welding in
Apply butyl adhesive sealing cord -1- to longitudinal members.
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do
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142
rrectness of i
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Braze remaining joint to tail light cluster mounting.
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Weld in cross panel, RP spot weld seam and SG plug weld

seam.
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2. Renewing outer rear cross panel (estate)
143
Prote
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RO: 53 05 55 23
Renewing complete rear cross panel

(estate)
WARNING

3.1
Tools
3.1.1
Required special tools, workshop equip

ment, test and measuring devices and
auxiliary items
Outer cross panel
es, in part or in w
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hole
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144
Cutting locations
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3.2.1
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AG. Volkswagen AG d
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and sideorpanel
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Removing
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3.2

Drill out cross member to inner rear cross panel.
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Drill out tail light cluster mounting.
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3. Renewing complete rear cross panel (estate)
145

Cut out rear cross panel and part of D-pillars.
RO: 53 09 55 70
3.3
Welding in lock carrier
3.3.1
Lock
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Replacement parts
Make a joddle joint in area of spot weld seam -a- on new part.
Apply adhesive in area of spot weld seam -a-.
Note

Weld in new part, RP spot weld seam and SG continuous weld
seam.
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3.4
Welding in inner side panel
3.4.1
Replacement parts
Side part, inner

146
ht
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Co
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RO: 53 61 55 70
rrectness of i
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nf
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spec
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wit
Transfer parting cut to new part plus 20 mm for overlap in area

if spot weld seam -a- and remove hatched area.
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Preparing new part
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Preparing new part
Transfer parting cuts to new part plus 20 mm for overlap in
area if spot weld seams -a- and remove hatched area.
Make a joddle joint in area of spot weld seam -a- on new part.
Apply adhesive in area of spot weld seam -a-.
Note

properties of adhesive will be
impaired.
. Volkswag
RO: 53 13 55 70
3.5
Welding in lower D-pillar reinforcing
3.5.1
Replacement part
Lower D-pillar reinforcing
do
c
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Preparing new part
rrectness of i
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Weld remaining joint in, SG continuous seam.
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Weld inrisinner side panel, RP spot weld seam and
ee stepped
o
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weld
ut seam.
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147
ht
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Drill holes for SG plug weld seam.
AG. Volkswagen AG d
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D-pillar reinforcing
Preparing new part
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Replacement part
AG.
148
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D-pillar reinforcing
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3.6
rrectness of i
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nform
spec
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wit
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RO: 53 30 55 70
es, in part or in w
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hole
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Weld in D-pillar reinforcing, RP spot weld and SG plug weld.
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Clean area of spot weld seam with a wire brush, access

through oval hole -1-.

Weld in new part, RP spot weld seam and SG stepped weld
seam.
Weld remaining joint, SG plug weld seam.
3.7
Welding in inner D-pillar reinforcing
3.7.1
Replacement part
Inner D-pillar reinforcing

Preparing new part
rrectness of i
t to the co
nform
spec
at
i
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wit
in t
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RO: 53 17 55 70
do
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es, in part or in w
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Weld in reinforcement, RP spot weld.
149

RO: 53 10 55 70
AG. Volkswagen AG d
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3.8.1
Replacement part
3.9.1
Replacement part
Cross member to inner rear cross panel

Weld in outer rear cross panel page 142 .
Weld in side panel page 200 .
150
AG.
Welding cross member to inner rear

cross panel
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3.9
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Welding in tail light cluster mounting
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3.8

RO: 53 05 55 04
Renewing rear cross panel (4MO

TION)
WARNING
un
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Cutting locations
do
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4.1.1
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Removing
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Body
Repairs,
General
Body
Repairs
; or
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Chapter 1 - Safety
notes
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4. Renewing rear cross panel (4MOTION)
151
Replacement part
152
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Welding in
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Rear cross panel
4.1.3
rrectness of i
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spec
at
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4.1.2
es, in part or in w
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Renewing complete rear cross panel

(4MOTION)
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RO: 53 05 55 00
AG. Volkswagen AG d
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BodyranRepairs
- Edition 06.2010
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WARNING

5.1.1
Cutting locations
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Removing
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5. Renewing complete rear cross panel (4MOTION)
153

5.1.2
Left inner
Drill out original joint with spot weld breaker.
5.1.3
Right inner
Separate joint to wheel housing.

Make separating cut with sabre saw -V.A.G 1523- .
es, in part or in w
l purpos
hole
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nf
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wit

Replacement parts
Rear cross panel
AG.
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154
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Cross panel
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Left and right tail light cluster mountings
thi
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5.1.4

Preparing new parts
Make holes in outer joint surface of new part.
Weld new parts in, RP spot weld seam.
5.1.5
Welding in
Adapt new part and hold in position.

Weld in cross panel, RP plug weld seam.
. Volkswagen AG
en AG
Weld in remaining joint, SG plug weld
agseam.
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5.1.6
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Left inner
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Right inner
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5.1.7
5. Renewing complete rear cross panel (4MOTION)
155

At parting cut, perform overlap weld, staggered SG continuous
weld seam.
Adapt rear cross panel to fit and fix in place.
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a
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156
rrectne
s
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un
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Weld in cross panel carrier paged b166
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RO: 53 05 55 20
Renewing centre piece of rear cross

panel (Bora)
WARNING
Cutting locations
rrectness of i
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nf
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spec
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wit
AG.
6.1.1
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158
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Rear cross panel
6.1.3
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Adapt rear cross panel to rear lid and fix in place.
6.1.4
Welding in

Align side panel end pieces to rear cross panel and weld in,
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6. Renewing centre piece of rear cross panel (Bora)
159
c
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RO: 53 05 55 23
Renewing rear roof cross panel

(Bora)
WARNING

7.1.1
Cutting locations
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7.1

Open out side panel end pieces -arrows- -hatched-.
7.1.2
Replacement parts
Tail light mounting
7.1.3
Welding in
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Rear cross member carrier
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161
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RO: 53 10 55 50
Renewing tail light mounting (Golf)
WARNING

8.1
Rear cross panel already cut out.
Cutting locations
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8.1.2
Left inner
Drill out original joint with spot weld breaker.
8.1.3
Right inner
Separate joint to wheel housing.
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8. Renewing tail light mounting (Golf)
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163

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Weld new parts in, RP spot weld seam.
8.1.5
Welding in

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164

RO: 53 16 55 00
WARNING
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Renewing cross member carrier

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rrectness of i
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165
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9.1.2
Replacement part
Cross panel
9.1.3
Welding in

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166
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10
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10. Renewing cross member carrier (Bora)
167

10.1.2
Replacement part
Cross panel
10.1.3
Welding in
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RO: 53 22 55 50
11
Renewing towing eye (4MOTION)
WARNING

11.1
Cross panel already cut out.
Cutting locations
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Removing
11. Renewing towing eye (4MOTION)
169
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Note
The original joint must be separated from below.
11.1.2
Replacement part
Towing eye
Preparing new part
Make 7 mm holes in joint surface to longitudinal member.
Welding in
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170
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Weld in area to spare wheel well, RP spot weld.
Weld in remaining joint, staggered SG continuous weld seam.
rrectness of i
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171
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RO: 53 29 55 70
12
Renewing C-pillar reinforcement (es

tate)
WARNING
c
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C
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172
thi
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Drill out C-pillar reinforcement.
Prote
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Cutting locations
rrectness of i
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nf
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12.1.1
AG.
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12.1
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Welding in
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Weld in side panel (estate) page 200 .
12. Renewing C-pillar reinforcement (estate)
173

RO: 53 36 55 50
13
Renewing cover plate (Bora)
WARNING

Removing
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174
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13.1.2
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Cut out cover plate.
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13.1.3
Welding in
Weld in cover plate, RP spot weld.
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at
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13. Renewing cover plate (Bora)
175
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RO: 53 47 55 52
AG. Volkswagen AG d
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14
WARNING
rrectness of i
t to the co
nf
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spec
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n in
wit

14.1
Cross panel and tail light mounting already cut out.
Cutting locations
Prote
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by
176
AG.
c
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14.1.2
Replacement part
Rear longitudinal member

Preparing new part
Welding in
rrectness of i
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at
i
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Spot weld rear longitudinal member, RP spot weld seam.
do
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14. Renewing longitudinal member - partial renewal (Golf)
177
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RO: 53 47 55 80
15
Renewing longitudinal member - par

tial renewal (4MOTION)
WARNING

processes.
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178
ht
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grinding work.
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a
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v
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p
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Removing
. Volkswagen AG
AG
genrear
Cross panel, tail light mounting and spare wheel well
waat
olks
V
already cut out.
by
Cutting locations
ility
ab
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ed
ris
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au
rrectness of i
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in t
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es, in part or in w
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ercia
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o
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t
a
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nl
f
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n
15.1.1
does
not
gu
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ra
c
do
c
um
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ht
rig
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Co
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15.1
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi

Grind open area to wheel housing using straight grinder.
15.1.2
Replacement part
Longitudinal member
Insulation
Butyl sealing cord
15. Renewing longitudinal member - partial renewal (4MOTION)
179

Preparing new part
15.1.3
Welding in
Secure longitudinal member on alignment bracket.

pe
rm
itte
d
es, in part or in w
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hole
ercia
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com
Foam insulation
rrectness of i
t to the co
nform
spec
a
t
i
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o
n in
wit
thi
s
15.1.4
AG. Volkswagen AG d
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ility
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ce
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le
Weld longitudinal member to wheel housing, staggered SG

continuous weld seam.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
ht
rig
py
Co
t.
180
do
c
um
en
r
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iva
r
rp
fo
g
n

RO: 53 48 55 50
16
Renewing rear longitudinal member

(Bora)
WARNING

16.1
Cross panel and tail light mountings already cut out.
Cutting locations
AG. Volkswagen AG d
agen
oes
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not
l
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V
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te o
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fo
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rrectness of i
t to the co
nform
spec
a
t
i
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wit
thi
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es, in part or in w
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com
pe
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16.1.1
ht
rig
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Co
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Removing
agen
lksw
Vo
by
AG.
Prote
cted
by c
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gh
t.
C
op
yi

16. Renewing rear longitudinal member (Bora)
181

16.1.2
Replacement part
16.1.3
Welding in

Weld in longitudinal member, RP spot weld seam.
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
thi
sd
o
cu
m
en
182
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
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is
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ra
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c
s
s

RO: 53 47 55 52
17
Renewing longitudinal member - par

tial renewal (Bora)
WARNING

17.1
Cross panel and tail light mountings already cut out.
AG. Volkswagen AG d
agen
oes
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not
l
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V
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by
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Cutting locations
do
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um
en
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te o
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rp
fo
g
n
rrectness of i
t to the co
nform
spec
a
t
i
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o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
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com
pe
rm
itte
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ility
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pt
ce
un
le
17.1.1
ht
rig
py
Co
t.
Removing
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi

17. Renewing longitudinal member - partial renewal (Bora)
183

17.1.2
Replacement part
Longitudinal member
Insulation
Preparing new part
Transfer parting cut to longitudinal member and cut out.
17.1.3
Welding in
Fit longitudinal member along with attached components, se

cure and tack weld in position.
Butt weld longitudinal member, SG continuous seam.
Wrap butyl adhesive sealing cord around insulation -1- and
press into longitudinal member.
Spot weld rear longitudinal member page 182 .
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
do
c
um
en
184
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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pt
ce
es n
wage
s
k
l
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ua
b
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ran
ir se
tee
o
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t
or
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ac
a
ss
18
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
RO: 53 55 55 00
ility
ab
y li
an
pt
ce
es n
wage
s
k
l
ot g 1999 , Golf 1998
o
Bora 1999 , Bora Variant
yV
ua
b
d
ran - Edition 06.2010
Body Repairs
ir se
tee
o
h
t
or
u
ac
a
ss
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Renewing side panel - partial renewal

(2-door)
WARNING

1 - Bonded section
2 - Cutting line for partial re

newal
do
c
um
en
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
18. Renewing side panel - partial renewal (2-door)
185
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi

Removing
18.1.1
Cutting locations
AG. Volkswagen AG d
agen
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V
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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
ility
ab
y li
an
pt
ce
un
le
18.1
AP No.: 53 64 .. ..
186
AG.
agen
lksw
Vo
by
Partial renewal
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
ht
rig
py
Co
t.
Roughly cut side panel out.
do
c
um
en
r
te o
iva
r
rp
fo
g
n
Make parting cut on B and C-pillar according to degree of

damage.

Make parting cut above wheel housing with body saw V.A.G 1523- .
18.1.2
Replacement parts
Side panel frame subpart

Preparing new part
. Volkswage
ot g
ua
ran
tee
or
ac

diameter.
Note

18.1.3
Welding in
ht
rig
py
Co
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r
fo
ng

agen
lksw
Vo
by
c
o
p
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gh
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.
C
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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
ole,
cial p
is n
mer
m
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o
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erm
or
e
t
a
itte
v
i
r
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p
by
ed
ris
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th
au
ss
Vol
ility
ab
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an
pt
ce
un
le
gen AG
Drill 7 mm holes for SG
weld seam.n AG does n
aplug
ksw
18. Renewing side panel - partial renewal (2-door)
187
AG.
Prote
cted
by

Weld in side panel, RP spot weld seam.
es n
wage
s
k
l
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ua
b
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ran
ir se
tee
o
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t
or
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ac
a
ss
r
fo
ng
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
ht
rig
py
Co
t.
188
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
ole,
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is n
mer
m
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o
c
erm
or
e
t
a
itte
v
i
r
d
p
ility
ab
y li
an
pt
ce
un
le

RO: 53 55 55 10
19

(Golf 4-door)
WARNING

. Volkswagen AG
does
to health and environment. Therefore, refrain from using these kswagen AG
not
l
Vo
processes.
gu
by
a
pe
rm
itte
d
un
le
ran
tee
or
ac
ility
ab
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an
pt
ce
ed
ris
ho
t
au
ss
r
te o
iva
r
rp
fo
g
n
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
19. Renewing side panel - partial renewal (Golf 4-door)
do
c
um
en
ht
rig
py
Co
t.
2 - Bonded section
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

189

19.1
Removing

grinding work.
19.1.1
Cutting locations
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Make parting cut on C-pillar according to degree of damage.

Make lower parting cut above side member.
agen
lksw
Vo
by
c
o
p
yri
gh
t.
C
op
yi

Prote
cted
by
Only use body saw -V.A.G 1523- or compressed air driven
190
AG.
hammer -V.A.G 1577- for parting cut!
ht
rig
py
Co
t.
Note
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
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
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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

19.1.2
Replacement parts
Side panel subpart

Insulation
Preparing new part
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
Foam insulation
AG. Volkswagen AG d
agen
oes
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not
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V
gu
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b
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ise
r
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t
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ra
a
c
s
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ility
ab
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an
pt
ce
19.1.3
un
le

diameter.
Note
19.1.4
Welding in
c
o
p
yri
gh
t.
C
op
yi
agen
lksw
Vo
by
AG.
Prote
cted
by
ht
rig
py
Co
t.

do
c
um
en
r
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iva
r
rp
fo
g
n

19. Renewing side panel - partial renewal (Golf 4-door)
191

. Volkswagen AG
gen AG
does
not
gu
ara
nte
eo
ra
c
r
fo
ng
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
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
192
ht
rig
py
Co
t.
by
ed
ris
o
th
au
ss
ility
ab
y li
an
pt
ce
un
le
a
Remove excessive adhesiveVoand
lksw seal.

RO: 53 55 55 00
20

(Bora)
WARNING

processes.
olkswagen AG
does
not
gu
ara
nte
eo
ra
c
.V
General Information; Body Repairs, General Body
Repairs
gen AG ;
a
ksw
l
o
V
by
20.1.1
Cutting locations
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
Removing
ility
ab
y li
an
pt
ce
20.1
ed
ris
o
h
t
au
ss
1 - Reinforcement
Located directly behind
marked upper parting
cut.
2 - Insulation
Joins reinforcement -1to side panel.
thi
sd
o
cu
m
en
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
4 - Bonded section
ht
rig
py
Co
t.
20. Renewing side panel - partial renewal (Bora)
193

Note

20.1.2
Replacement parts
Side panel subpart

Insulation
194
AG.
agen
lksw
Vo
by
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
ht
rig
py
Co
t.
do
c
um
en
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
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
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not
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is
r
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Butyl
AG. Volkswagen ABora

G do 1999 , Bora Variant 1999 , Golf 1998
agen
es n
ksw
l
ot g
o
V
y
ua
b
d
ran
e
is
t
r
e
eo
tho
adhesiveausealing
cord AKL 450 005 05
ra
c
s
s
Preparing new part

Apply butyl adhesive sealing cord -1- to striker pin reinforce
ment.
agen
lksw
Vo
by
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Foam insulation
ht
rig
py
Co
t.
20.1.3
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
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
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
AKD 476 KD5 05
Apply butyl adhesive sealing cord to both sides of insulation

-1- and press forcefully onto C-pillar reinforcing.
AG.
Apply adhesive to area of flange -2-. 2 beads each of 3.5 mm

diameter.
Note
New part must be installed within 30 minutes, otherwise ad
hesive properties of adhesive will be impaired.
20.1.4
Welding in

Butt weld parting cuts, SG stepped weld seam.
Note
Right side panel, apply butyl sealing cord -1- to area of fuel filler
neck before welding side panel in.
20. Renewing side panel - partial renewal (Bora)
195

AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
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
ility
ab
y li
an
pt
ce
un
le
Reform wheel housing flange -1-.
Weld in side panel, RP spot weld seam and SG plug weld

seam.
Note
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
ht
rig
py
Co
t.
196
do
c
um
en
r
te o
iva
r
rp
fo
g
n
Before starting welding on the right-hand side panel, seal off area
of the fuel filler neck with AKD 476 KD5 05.

RO: 53 55 55 20
21

(estate)
WARNING

processes.
AG. Volkswagen AG d
agen
o
Cutting locations
ss
ility
ab
y li
an
pt
ce
21.1.1
Removing
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
21.1
es n
ot g
ua
ran
tee
or
ac
ksw
Vol
by
d
e
ris
ho
t
au
2 - Bonded section
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
1 - Reinforcement
Located directly behind
cut -a- = max. 270 mm.
Seats directly behind
cut.
thi
sd
o
cu
m
en
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
21. Renewing side panel - partial renewal (estate)
197
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi

Note
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s

21.1.2
Replacement parts
Side panel subpart

198
AG.
agen
lksw
Vo
by
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
ht
rig
py
Co
t.
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
y li
an
pt
ce
un
le

Polyurethane adhesive compound AKD 476 KD5 05
21.1.3
Preparing new part
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
o
gu
yV
b
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

Apply butyl adhesive sealing cord -1- to striker pin reinforce
ment.
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199
AG.

21.1.4
Welding in

Apply adhesive to area of flange -2-. 2 beads each of 3.5 mm
diameter.
Note
Right side panel, apply butyl sealing cord -1- to wheel housing
around the opening of the fuel filler neck before welding side
panel in.
ility
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Reform wheel housing flange -1-.
AG.
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ht
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spec
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Butt weld parting
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cuts, SG
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weld
seam.
h
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s

Weld in side panel, RP spot weld seam and SG plug weld
seam.
Weld parting cut, SG stepped weld seam.
Braze joint to D-pillar.

Note
Before starting welding on the right-hand side panel, seal off area
of the fuel filler neck with AKD 476 KD5 05.
rrectness of i
t to the co
nform
spec
at
i
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Prote
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201
c
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RO: 53 69 55 50
22
Renewing outer wheel housing liner partial renewal (Golf)
WARNING

Removing
Side panel
Cutting locations
rrectness of i
t to the co
nf
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m
spec
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n in
wit
es, in part or in w
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hole
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Make separating cut so that edges can be stepped for joddle

joint on body side.
202
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22.1

22.1.2
Replacement part
Wheel housing liner

Preparing new part
ility
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rrectness of i
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spec
a
t
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22.1.3
es, in part or in w
l purpos
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Transfer parting cut to new part and remove
by hatched area.
ara
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Do not forget to add approx. 10 mm
ut for overlap.
ra
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s
Welding in
Adapt wheel housing liner to fit, with side panel fitted and ve
hicle stress free, check gaps/shut lines.
Spot weld wheel housing liner, RP spot weld seam.
Weld in side panel (2-door) page 187 .
do
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Weld in side panel (4-door) page 191 .
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22. Renewing outer wheel housing liner - partial renewal (Golf)
203

RO: 53 69 55 50
23
Renewing outer wheel housing liner partial renewal (Bora)
WARNING

23.1
Cutting locations
AG. Volkswagen AG d
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204
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Make separating cut so that edges can be stepped for joddle

joint on body side.
do
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te o
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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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hole
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23.1.1
ht
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Co
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Removing

23.1.2
Replacement part
Wheel housing liner
23.1.3
Preparing new part
es, in part or in w
l purpos
hole
ercia
, is n
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ot p
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erm
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t
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rrectness of i
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Transfer parting cut to new part and cut out, remember 10 mm

for overlap.
do
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23. Renewing outer wheel housing liner - partial renewal (Bora)
205

Welding in
AG. Volkswagen AG d
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206
ht
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Weld in side panel (Bora) page 195 .
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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23.1.4
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Renewing outer wheel housing liner partial renewal (estate)
WARNING

24.1
Cross panel and C-pillar reinforcing already cut out.
Cutting locations
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24.1.1
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Removing
do
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24
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RO: 53 69 55 50
AG. Volkswagen AG d
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s no Variant 1999 , Golf 1998
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Bora 1999 o, eBora
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d
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Drill corner bracket -1- for luggage compartment out from

wheel housing.
Drill out web plate -2- and separate from wheel housing.
24. Renewing outer wheel housing liner - partial renewal (estate)
207

Grind open brazed seam
Make separating cut so
joint on body side.
Replacement parts
Outer wheel housing liner

rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Preparing new part
Transfer parting cut to new part plus 20 mm for overlap for area
of spot weld seam and cut off hatched area.
Welding in
AG.
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208
ht
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24.1.3
thi
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hole
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24.1.2
AG. Volkswagen AG d
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that edges
b can be stepped for joddle
ara
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r
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h
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Align corner plate -1- for luggage compartment floor and weld
to wheel housing, SG plug weld seam.
Adapt web plate -2- to fit to wheel housing and weld to wheel
housing, SG plug weld seam.
Braze joint to inner wheel housing.
Weld in C-pillar reinforcement page 173 .
Weld in side panel (estate) page 200 .
Note
AG. Volkswagen AG d
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wit
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es, in part or in w
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un
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C
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24. Renewing outer wheel housing liner - partial renewal (estate)
209

RO: 53 80 55 50
25
Renewing spare wheel well (Golf)
WARNING

25.1
Removing
25.1.1
Cutting locations
AG.
210
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Co
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Cut out spare wheel well.
do
c
um
en
Drill out front original joint to floor plate.
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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AG. Volkswagen AG d
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b
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h
ut
ra
a
c
s
s

25.1.2
Replacement part
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
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f
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ng
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AG. Volkswagen AG d
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gu
Spare wheel well, parts designation: floor
y
b
ara
d
nte
ise
r
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Preparing new parts
h
t
u
ra
a
c
s
s of new part.
Make holes in outer joint surface
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
25.1.3
Welding in

Weld additionally along forward joint area to floor, staggered
SG continuous weld seam.
ht
rig
py
Co
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Weld in tail light mounting page 164 .
thi
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Weld in spare wheel well, SG plug weld seam.
agen
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25. Renewing spare wheel well (Golf)
211
AG.
Prote
cted
by

RO: 53 80 55 52
26
Renewing spare wheel well - partial

renewal (Golf)
WARNING

26.1
Removing
Cross panel already cut out.
26.1.1
Cutting locations
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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rp
o
nl
f
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an
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AG. Volkswagen AG d
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c
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s
AG.
Prote
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by
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212
ht
rig
py
Co
t.
thi
sd
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cu
m
en
Locate parting cut according to degree of damage.

Note
Make separating cut so that edges can be stepped for joddle joint
on body side.
26.1.2
Replacement part
Spare wheel well, parts designation: floor panel

Preparing new part
Hole spacing approx. 20 mm.
26.1.3
AG. Volkswagen AG d
Welding
genin
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Vol
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d bpart with vehicle standing on its wheels
Adapt new
ran or on align
ise
tee
r
ment tfixtures
and tack weld in position.
ho
o
au
un
le
pe
rm
itte
d
Weld in new part, SG plug weld seam.
do
c
um
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ht
rig
py
Co
t.
r
te o
iva
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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
ra
c
ility
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an
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ss
Check
gaps and shut lines to bolt-on parts.
26. Renewing spare wheel well - partial renewal (Golf)
213
agen
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Vo
by
AG.
Prote
cted
by
c
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C
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yi

RO: 53 80 55 50
Renewing spare wheel well (4MO

TION)
pe
rm
itte
d
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
WARNING
ility
ab
y li
an
pt
ce
un
le
27
AG. Volkswagen AG d
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not
l
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is
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h
ut
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r
te o
iva
r
rp
fo
g
n
214
AG.
agen
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by
Prote
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by c
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Removing
do
c
um
en
27.1
ht
rig
py
Co
t.
1 - Bonded areas

AG. Volkswagen AG d
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h
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s
r
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iva
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rp
fo
g
n

Replacement part
AG.
27.1.2
agen
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by
Prote
cted
by c
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p
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gh
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C
op
yi
do
c
um
en
Cut out spare wheel well.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Drill out original joint.
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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ce
un
le
Cutting locations
ht
rig
py
Co
t.
27.1.1

27. Renewing spare wheel well (4MOTION)
215
AG. Volkswagen AG d
agen
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not
l
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b
ara
d Variant 1999 , Golf 1998
Bora 1999 , Bora
e
nte
is
r
o
eo
h- Edition 06.2010
Body Repairs
ut
ra
a
c
s
s
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
Preparing new parts
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

Apply adhesive.
The adhesive must be applied to the underside in area -1-.

Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
AG.
27.1.3
agen
lksw
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ht
rig
py
Co
t.
Welding in

Weld in spare wheel well, SG plug weld seam.

216
thi
sd
o
cu
m
en
Note

RO: 53 80 55 50
28
Renewing spare wheel well (Bora)
WARNING

AG. Volkswagen AG d
agen
oes
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not
l
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yV
General eInformation;
Body Repairs, GeneralguBody
Repairs
ara
db
nte
ris - Safety notes
Chapterho1
e
t
or
ac
au
ss
un
le
pe
rm
itte
d
Cutting locations
do
c
um
en
r
te o
iva
r
rp
fo
g
n
28.1.1
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
ht
rig
py
Co
t.
Removing
ility
ab
y li
an
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ce
28.1
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
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gh
t.
C
op
yi
Drill out spare wheel well.

28. Renewing spare wheel well (Bora)
217

Note
Reinforcing -1- and -2- in longitudinal member, when cutting
out note that the reinforcing lies directly under the spare wheel
well.
For reasons of safety, we recommend that the weld points
should be released with spot weld breaker -V.A.G 1731- if

possible.
28.1.2
Replacement parts

Towing eye
Insulation
Preparing new parts
ility
ab
y li
an
pt
ce
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Spot welding towing eye to spare wheel well.

Drill additional holes for SG plug weld seam.
Note
The SG plug welds may only be placed a maximum of 15 mm
apart. This ensures that the strength of the original joint is re

instated.
All SG plugs welds should be performed from the outside, for
AG.
Prote
cted
by
agen
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Vo
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.
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218
ht
rig
py
Co
t.
optical reasons, if possible.
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
rp
o
nl
f
e
ng
Make holes in outer
es n
wage
s
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l
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b
ran
ed
s
i
tee
r
joint surface
of
new
part.
o
h
t
or
u
ac
a
ss

Wrap butyl adhesive sealing cord around insulation -1- and
press into longitudinal member.
Apply adhesive -2-.
Note

28.1.3
Welding in
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
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Adapt new part to fit with vehicle standing on its wheels or on

alignment bracket set and tack weld in position.
Weld in spare wheel well, RP spot weld seam and SG plug
weld seam.
28. Renewing spare wheel well (Bora)
219

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Drill holes, from outside, in areas -1-, -2- and -3- for SG plug weld
seam.

BOR53201020 Body Repairs

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BOR53201020 Body Repairs

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Service

Service Department. Technical Information

Bora 1999 , Bora Variant 1999 , Golf 1998

00 - Technical data . . . . . . . . V.o.lks.w.ag. . . . . . . . . . . . .do. e.s n.o.t g. . . . . . . . . . . . . . . . . . . . . . .

Renewing engine bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bora 1999 , Bora Variant 1999 , Golf 1998

51 - Body - centre . . . . . . . . . . . . . . . . . . . . . . . . .lk.sw.a.ge.n.AG. ..V.olk.s.wa.g.en. A.G.do. e.s n. . . . . . . . . . 85

Renewing roof (Golf) . . . . . . . . . . . . . . . . e. d.b.y . . . . . . . . . . . . . . . . . . . . . . . . . g. u.ar.a. . . . . . .

53 - Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Renewing rear cross panel (Golf) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bora 1999 , Bora Variant 1999 , Golf 1998

Bora 1999 , Bora Variant 1999 , Golf 1998

Renewing spare wheel well (Bora) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

Vehicle identification data

Vehicle identification number

The identification plate is located on the left suspension turret be

The vehicle identification number (chassis number) is stamped

Vehicle data plate

1. Vehicle identification data

Bora 1999 , Bora Variant 1999 , Golf 1998

Body foam insulation

On this vehicle various bodywork cavities are foam treated.

ris parts (parts des

In the parts catalogue the insulation is shown on figure 864-00.

Install insulation on vehicle.

Rep. gr.00 - Technical data

Carry out cavity protection to repair area after painting vehicle.

Do not SG weld 15 mm either side of insulation.

Apply sealing cord AKD 497 010 04 R10 around circumfer

Bora 1999 , Bora Variant 1999 , Golf 1998

Galvanized body parts

The vehicle consists completely of body panels galvanized on

3. Galvanized body parts

Bora 1999 , Bora Variant 1999 , Golf 1998

Various front parts of chassis (hatched items)

Rep. gr.00 - Technical data

Reinforced body sheet-metal is used in following body areas:

Workshop manual general information, chapter: Repair pro

Strengthened steel body panels

Bora 1999 , Bora Variant 1999 , Golf 1998

For repairs the laser weld seam is replaced by a SG plug weld

Bora 1999 , Bora Variant 1999 , Golf 1998

Body panel gaps/shut lines

Body - front (Golf)

Gaps are always given in millimetres.

Rep. gr.00 - Technical data

To adjust or check gaps, use special tool 3371.

Bora 1999 , Bora Variant 1999 , Golf 1998

6. Body panel gaps/shut lines

Bora 1999 , Bora Variant 1999 , Golf 1998

Body - rear (Golf)

Rep. gr.00 - Technical data

Gaps are always given in millimetres.

To adjust or check gaps, use special tool 3371.

Bora 1999 , Bora Variant 1999 , Golf 1998

6. Body panel gaps/shut lines

Bora 1999 , Bora Variant 1999 , Golf 1998

Body - front (Bora)

Rep. gr.00 - Technical data

Gaps are always given in millimetres.

To adjust or check gaps, use special tool 3371.

Bora 1999 , Bora Variant 1999 , Golf 1998

6. Body panel gaps/shut lines

Bora 1999 , Bora Variant 1999 , Golf 1998