VOLKSWAGEN
BODY REPAIR INFORMATION
FOX (1987—) Body Repair Information
FOX
VOLKSWAGEN OF AMERICA This publication contains the essential body repair procedures for the VW Fox
vehicles sold in the USA and Canada.
Information is grouped according to repair procedures, which are identified as to the
location of that part on the vehicle (front, center, or rear)
CAUTION
It is assumed that the reader is familiar with basic automotive body
repair procedures.
Special tools required in performing certain service operations ar
identified in this publication and recommended for use.
Use of tools or procedures other than those recommended in this
repair publication may be detrimental to the vehicle's sate operation
as well as the safety of the person servicing the vehict
Section parts listed in this publication are for reference only.
Always check with your authorized dealer to verify part numbers.
Service Literature No. W42-701-007-1
Printed 10/86
Manufactured in the United States of America
© 1986 Volkswagen United States, Serviceability and Repair Techniques, Troy, MI General
Basic Information 2
Basic Tools and Equipment 4
Vehicle Identification Number (V.IN.) 7
Lifting and Towing Points 9
Wheel Alignment Specifications WW
Body Assembly Materials 13
Vehicle Dimensions
Sedan, Coupe and Wagon 15
Covity Sealing 23
Repair Procedures and Cutting Lines
Front Group 50
Bumpers (Front and Rear) 50.2
Front Fender 50.5
Front Apron 50.6
Front Wheelhouse (Sectional Part) 50.8
Front Wheelhouse 50.12
Battery Carrier 50.16
Center Group 51
Front Hinge Pillar 51.2
Cow! Panel 51.5
Rocker Panel 517
Center (“B") Pillar (4 Dr) 51.11
Roof (2 Dr + 4 Or) 5113
Roof (Station Wagon) 51.16
Front Roof Crossmember 51.18
Front Windshield 51.21
Door (Front) 51.26
Door (Rear) 51.31
Rear Group 53
Side Panel (2 Dr) 53.2
Side Panel (4 Dr) 53.6
Side Panel (Station Wagon) 53.11
Side Panel (Front Sectional Part) (2 Dr) 53.14
Side Panel (Rear Sectional Part) (2 Dr) 53.16
Rear Wheelhouse 53.21
Rear Apron (2 Dr + 4 Or) 53.23
Rear Apron (Wagon) 53.25
Rear Floor 53.27
Rear Crossmember 53.29
Rear Extension Floor Plate (2 Dr + 4 Dr) 53.32
Rear Extension Floor Plate (Wagon) 53.34 General Basic Information
Replacement of body sectional parts and
parts sections
On the basis of detailed investigations
concerning damage frequency and the extent of
damage to sheet metal sections, Volkswagen of
‘America has included sectional parts in its
replacement parts program and approved the
use of “parts sections” in order to rationalize
the repairs to these areas.
A “sectional part” is a section of a complete
part (eg. section front and rear), which is,
supplied direct from the Parts Department,
already cut to size.
‘On the other hand, “parts sections” are cut
trom complete parts to me required size, by the
bodyshop doing the repair. In individual cases it
will be necessary to work exactly to the method
described and illustrated in the manual.
Because the use of “sectional andior parts
sections’ together with special tools and
‘equipment influence efficiency of the operation,
special note is made of the tools and equipment
in the description of repair.
Basic instructions for body repairs
Cutting lines/points: The cutting lines or points
illustrated in the description of the operations
are based on detailed examinations carried out
‘on accident vehicles.
In areas where cutting and subsequent joining
affect the rigidity of the body and also the
operational safety and serviceability of the
vehicle, the culling lines/points must be made in
accordance with the instructions in this manual
Straightening: Bodies and floor sections are
produced mainly from cold formed deep drawn,
sheet metal. For this reason the reshaping of
accident damaged areas should be carried out
in the same manner.
If the extent of damage does not permit
reforming, the damaged part should be cut after
the adjacent surfaces have heen straightened
Note:
The removal of parts alters the weight
distribution, making it necessary to secure the
vehicle to a hoist, bench or a suitable alternate
Diagnosis of accident vehicles
Damage to the running gear and assembly
mountings which could have very serious
effete later on, is sometimes not discovered
when accident vehicles are being repaired.
Where the accident damage indicates possible
damage to the running gear, special attention.
must be paid to the following components,
completely independent of the axle geometry
measurement which must be made in all cases:
Check to ensure that the steering gear and
linkage operate correctly over the complete
lock-to-lock range. Carry out a visual check for
bent or cracked parts.
‘heck the running gear and all running gear
components such as wishbones‘trailing arms,
suspension struts, steering knuckles, anti-roll
bars, sub-frames, axle beams and mountings for
bending, twisting or fractures.
Examine rims and tires for damage, run out and
imbalance. Examine tires for cuts/splits etc. in
treads and walls and check tire pressure.
Examine the engine/transmission/exhaust
system mountings for damage.
Finally, a thorough road test will give the
assurance that the vehicle is once again
completely roadworthy and can be handed back
to the customer without any doubt as to its
‘mechanical state.
Similar Repair Procedures
Since the cutting and welding lines for come
models are similar, we have incorporated them
all in one basic procedure. The manual will only
differentiate the dissimilar operation on these
models. The headings at the bottom of each
page will signify the applicable vehicles referred
to in that specific procedure.
Preserving (Undercoating) Repaired Panels
All panels that have been repaired or replaced
must have the exposed surfaces re-
undercoated to insure lasting durability. If
access to the panels Is unobtainable after
welding, paint the panels where necessary and
apply weld thru primer on the direct area to be
welded Basic Information
Welds Safety Factors
No specific number of spot or plug welds Disconnect the negative (~) battery cable
will be singled out. Make note of the before performing any work on the vehicle.
number when cutting out the damaged
Panels. All welded seams should be no
more than 25mm in length.
Protect yourselt by wearing goggles,
earplugs, respirators, gloves, safety shoes,
caps, etc. when working on a vehicle.
Safely support the vehicle before any work
is done. Block the front or rear wheels if
Prior to and during welding procedures, test the ete ere te cet ea or
weld(s) for quality and strength. You can best Cap or remove the fuel tank when working
accomplish this by using scraps of similar ‘on the rear section of the car.
metals, cut and clamped in a similar manner to
what you are welding. Check the test sample Insure proper ventilation of your working
for penetration and strength in order to make area. Some paints and sealants can
adjustments if needed, generate toxic gases when heated. Use
an ait chisel or Saw lo remove damaged
Test Welds
nels instead of a gas torch.
‘CAUTION par :
Observe all local and national safety
Always disconnect the battery prior to any raeiets ialanan petonae ere
MIG welding
Cover interior with heat-resistant cover to
insure safety when welding.
‘Too! or Welding Identification
‘Take care when using gas or cutting
The specific tool(s) or form of welding required torches so as not to burn body sealer or
within @ procedure will be specified following interior. Extinguish immediately if they
each step or illustration, should catch fire,
For example.
Corrosion Protection
Beginning with the 1985 model year, a
corrosion perforation warranty is in effect for all
Volkswagen vehicles. Therefore, when repairing
any Volkswagen vehicles it is imperative that all
repaired areas have cavity preservation material
properly applied to protect from corrosion.
Refer to service literature #W42-701-004-1
(Application Instructions—Cavity and Underbody
Preservation) for additional information on these
and all Volkswagen and Audi vehicles.
Air chisel, hammer. chisel Basic Tools And Equipment
Air Grinder
Dual Action Sander
Oxy-Acetylene Torches Basic Tools And Equipment Recommended Equipment
Bonch With Dedicated Fixtures
2 Post Hoist Vehicle Identification Number (V.I.N.)
VW/AUDI VIN BREAKDOWN Vehicle Identification (V.I.N.)
Vehicle Identification Number (VIN) location
~~
On top of cowl behind engine
Engine identification code
ee)
sees Co
saree a a
a
The vehicle date sticker is stuck onto the rear
apron, in the luggage compartment on the left
hand side. The sticker contains the following
data:
1. Chassis No.
‘On engine block near distributor 2. Type No,
3, Engine and gearbox code letters
4, Paint No. interior equipment code number.
5. Optional extras code numbers, Lifting and Towing Points
Lifting vehicle with hist/floor jack
WARNING.
When removing components such as rear axle,
fuel tank, spare wheel and rear lid, place
‘scctional weight on rear end of car or anchor
car to hoist to prevent tipping if center of gravity
changes.
Note
Lifting vehicle with floor jack
The same lifting points as illustrated for the
hoist also apply when using a floor jack. To
avoid damage to the underbody or chassis
frame, it is necessary to insert a rubber pad
between the floor jack and the lift points.
‘CAUTION
‘Betore driving onto lft, check for clearance
between lifting arms and tires to avoid cutting
‘soewall.
Extend arms and check to see if arms are long
‘enough to contact iting points.
Ltt only at points shown,
‘The front lift points are located on the under-
body. where the door hinge pillar is welded to
the chassis frame rail
CAUTION
Do not lift vehicle by engine, transmission, front
Or rear suspension. Doing so may result in
damage to components.
The rear lift points are located below the triangle
mark in front of the rear whee! wel
Take care to avoid damaging critical components.
which are close to the lift points. This applies
especially to the electric fuel pump. Lifting And Towing Points
CAUTION
‘* Whenever possible tow with front
wheels off ground.
+ Do not wrap safety chains around brake
lines
Front hook-up
‘attach Thooks to tie down loops
* position towbar against bumper
‘* double wrap chains on towbar
* attach safety chains to lower control arms.
‘* towing clearance: 4 inches between tires
and ground
WARNING
Always secure front wheels with an
external steering wheel lock when towing
with rear wheels off grouna.
Never use -ignition/steering lock to secure
front wheels.
Never allow passengers to ride in towed
vehicle.
Rear hook-up
* attach T-hooks to tie down loops
* position towbar against bumper
‘+ double wrap chains on towbar
‘* attach safety chains to axle beam
* towing clearance: 4 inches between tires
and ground
* towing speed/miles:
‘manual transmission - 50 mph/SOmi
10 Wheel Alignment Specifications
Wheel bolt torque - 110 Nm (81 ft Ib)
WHEELS - TIRE PRESSURES
Modo! Wheols Otfeot Tires Per teatieael
(steel) Half load Max load
Front___Rear_| Front___Rear
2 door 5x13 45 155 SR13_| 24 (1.7) 26 (1.8) | 24 (1.7) 92 (2.2)
‘4 door SJ x13 45 [175/70 sr 13| 24 (1.7) 26 (1.8) | 24 (17) 32 (2.2)
‘Wagon 5d x13 45 |i7si70 sR 13] 24 (1.7) 26 (1.8) | 24 (1.7) 34 (2.4)
Steel Wheel
WARNING
Do not exceed maximum pressure marked
on tire
11 Wheel Alignment Specifications
Wheel alignment data for front and rear axles.
When checking wheel alignment, following conditions are important:
* Alignment should not be checked until * Test surface level and horizontal
vehicle has run 1000-2000 miles and coil * Vehicle bounced properly.
springs have settled, * Steering gear correctly adjusted.
* Vehicle empty. '* Steering linkage free of play.
* Tire pressure correct.
Front axle 2-door/4-door Wagon
Total toe, wheels not pressed =20' to 0" =20' to 0”
Toe angle difference at 20° lock to left and right (not pressed)_| -1° 40’ to —40' | 1° 40’ to -40"
‘Camber, wheels in straight ahead position =50' to —10" =50' to —10°
Maximum permissible difference between sides 15° 15°
Caster without link rod (not adjustable) 1° 40° to 2° 20° | 1° 25' to 2° 5
Corresponds to camber difference or wheel on lock
from 20° left and 20° right
Maximum permissible difference between left and right 30" 30"
Rear axle (not adjustable)
‘Camber
Maximum permissible difference between left and right
Determining total toe/alignment of
rear wheels
1—If toe values have same signs (+/+ or ~/-). 2—If toe values have different signs (+/—) add
subtract smaller value from bigger value and both values and divide by 2
divide by 2
Exampl Example:
© toe value, left rear * toe value, right rear © toe value, left rear * toe value, right rear
wheel wheel wheel wheel
+18" +5" +15) -5
158 - 6 = 10° 15° + 6 = 20°
wr2= 5 20-2 = 10
* toe, actual deviation from driving * toe, actual deviation from driving
direction = 5° direction = 10°
12 Body assembly materials
Body Assembly Materials
Aghesives Application VW Replacement Part No.
Glass to metal adhesive Rear-view mirror base, D 000 702
vent window fitinas
Activator glass to metal adhesive D 000 701
‘Synthetic adhesive gluing leatherette D 001 101
reversal adhesive felt, fabric, rubber and D 001 200
carpet to painted metal
Prastic adhesive rubber, PU, EPDM D 001 300
‘Metal adhesive; roof supports, spare tire D 001 500
2K Epory adhesive well, Jack mounting
Profile rubber adhesive door seals D 002 100
Achesive sealant gluing windows D 009 100
‘Siicone rubber
reinforcement, braces and
rails to body
AMV 176 000 05 (black)
AMY 176 100 05 (white)
AMV 197 000 01 (transparent)
Two-sided tape (adhesive) protection sheet to door ‘AKL 440 025,
Achesive sealing kit windows 1 008 300
‘Achesive sealant windows (300 mi cartridge) 009 100
Geaning solution 1D 009 400 1
Paint primer 1 009 300
Liquid plastic removeable threaded connections Blue Loctite® No. 274
Sealants
YW Original plastic sealing gaps in bolts, cables 1D 001 400
sealant and wires to panels
Window sealant
windows
1D 001 003 0 mi
1D 001 007 320 mi
Prastic adhesive strip
between fenders and body
1D 001 900
10 mm sealing cord
taillamps
‘AKD 497 010 R 10 Gray
Sticone rubber
white roots
AMF 176 100 05
13 Vehicle Dimensions Dimensions
16 Dimensions
Se
@- 1028 mm - distance between the suspension ¢ - 1060 mm - distance between the front side
strut mountings. members,
b- 1336 mm - distance between front wheel
housings.
17 Dimensions
d- 1557 + 2 mm - diagonal distance from f-901 + 2mm- distance from cowl panel
‘cowl panel corner to hole center of front comer to hole center of front wheel housing.
wheel housing.
e- 693 + 2 mm- distance from center of
cowl panel to center lock carrier plate.
18 Dimensions
Where no tolerance is given all dimensions + 2 mm.
a= 1008 mm - distance between hinge and b+ 848 mm - distance between center pillar
center pillars. and rear side panel.
4Dr 19 Dimensions
¢ - 1293 mm - distance between center pillars.
(4 Dr)
20
f+ 1085 mm - distance between the hinge pillar
and center pillar (2 Dr). Dimensions
a= 1085 mm - distance between the hinge pillar © - 952 mm - distance between roof and rear
and center pillar. (2 Dr. and Wagon) apron. (Wagon)
d- 1331 mm - distance between rear side panels.
(Wagon)
b - 1293 mm - distance between center pillar
(2 Dr. and Wagon)
wagon 21 Cavity Sealing Cavity Sealing
1° 2*3* 4* 7* 1178"
1* 2*3* 4* 6*5* etii*
AY oS
AQ
1°) 23+ at 7 9* 10°
The cavities which have to be treated with cavity preservation material are indicated by the shaded araas on the body.
After the cavity preservation material has dried out, all water drain holes in doors and side members must be cleared and
the rubber valves should be cleaned and inserted in the holes provided.
*) All operations are explained with detailed diagrams and instructions.
24 Cavity Sealing
25 Cavity Sealing
Fig. 1: Front hood
Using reduced pressure, sprav through
openings provided
a 7 |
j Fe Yj
Fig. 5: Rear door (4 Dr)
Remove grommet, spray through existing
‘opening.
Fig. 3: Hinge pillar
Remove grommet, spray through existing
‘opening,
26 Cavity Sealing
Fig. 6: Center “B” Pillar (4 Dr)
Remove grommet, spray with reduced
pressure through opening,
Fig. 10: Rear lid (Wagon)
Remove rubber stops.
Spray with reduced pressure through
existing openings.
Fig. 11: Rear lid (2 Dr and 4 Dr)
Fig. 8: Side Panel (2 Dr and 4 Dr)
Spray with reduced pressure through
existing openings.
27 Cavity Sealing
Fig. 20: Rocker pane!
Remove grommet, spray through
existing opening.
28 Repair Procedures
And
Cutting Lines
Front
Group 50 50 Bumpers (Front and Rear)
‘Assembling
(4) Lefthand bracket
(fig. 1)
(x) Disassemble in numerical order.
Assemble in reverse order.
(2) Bumper
Reinforcement
7 \
Kk —
(6) Side guide
Le
Nc Bumper cover
50.2 Bumpers (Front and Rear) 50
Fig. 1: Bracket installation Remove bumpers from their side guides.
Install in reverse order of removal
Fix bracket with Fillister head bolts and hexagon
nuts (arrows).
Removing/Installing
Front Bumper Rear Bumper
Remove hexagon bolts (arrows) which fix bumper Remove hexagon bolts (arrows) which fix
bracket to front side members. bumper brackets to rear side member.
Remove bumper towards front side.
50.3 Fender, removing/installing
Work sequence
Removing
—Use a heat gun and razor knife to soften and cut through PVC body coating along A-pillar.
‘CAUTION
Heat PVC slightly and for a short time only.
Do not discolor PVC or blister.
Installation
CAUTION
Always install sealing tape and zinc foil
plates (VW Part #AKL 381 035 50) when
replacing bolt-on exterior body parts
(hoods, front fenders, lids). This preserves
metal surfaces from the formation of rust
and thus insures the corrosion protection
of the vehicle,
50.5 50 Front Apron
Replacing front apron
Cutting: Fig. 1 + 2
Aligning + Welding: Fig. 3
Note
Paint inside of new part before installation
Remove the following components to gain necessary access:
Disconnect battery
Front bumper assembly (complete)
Front grill assembly
Headlight assemblies and trim
Front fenders
Note
It not replacing the fenders, care should be taken not to bend or distort the fenders when removing.
Use a heat gun to carefully soften the caulking on the underside of the fender before removing.
Front wiring harness
Front hood locks
Front hood support
Note
Remove or support front hood, whichever is safer.
Air cleaner hose
Front engine support
Antenna (if necessary)
Radiator shroud
AIC condensor
50.6 Front Apron 50
Ss"
Fig. 1: Cutting out front apron
Air chisel.
Fig. 2: Front apron
Removing scrap metal
Grinder, pliers.
ee
Fig. 3: Aligning and welding in front apron
‘Areas: A - Spot weld
B - MIG (continuous)
Prime all repaired areas and seal.
Carry out cavity preservation in repaired
area.
50.7 50 Front inner Wheethouse (Sectional Part)
Replacing front wheel housing - sectional part Note
includes: Front apron and front side member. Paint inside of new parts before installing.
Cutting: Figs. 1-3
Preparing new parts: Figs. 4 - 5 Note
Aligning: Fig. 6 Coat all connecting areas inaccessible after
Welding: Figs. 7 - 10 welding with cold zinc paint.
Remove the following components to gain necessary access:
Disconnect battery
Front bumper assembly (complete)
Front grill assembly
Headlight assemblies and trim
Front fenders
Note
If not replacing the fenders, care should be taken not to bend or distort the fenders when removing.
Use a heat gun to carefully soften the caulking on the underside of the fender before removing.
Front wiring harness
Front hood locks
Front hood support
Note
Remove or support front hood, whichever is safer.
Front engine support
Antenna (if applicable)
Washer bottle (if necessary)
Radiator shroud and reservoir
Fuel injection assembly (if necessary)
‘AIC condensor
50.8 Front Inner Wheelhouse (Sectional Part) 50
Fig. 1: Cutting out front wheel housing and Fig. 3: Removing scrap metal
side member Removing scrap metal.
Grinder, pliers.
Air chisel.
Fig. 4: Front side member
Fig. 2: Cutting out front apron
Mark off cutting line allowing approx. 20
Air chisel mm for overlapping and cut off shaded
area.
Hacksaw
50.9 50 Front Inner Wheelhouse (Sectional Part)
KML”
IP
Fig. 5: Front wheethousing - sectional part
Mark off cutting line and cut off shaded
area,
Note:
The hook lock cable guide tube is not part of
spare part and must be ordered separately.
Fig. 6: Front wheelhousing and side member
Align in conjunction with fender, hood
and front apron. Mark off cutting line on
side member exactly and cut member as
required.
Coat all connecting areas which will not
be accessible after welding with cold
zine paint.
50.10
Fig. 7: Welding in front wheelhousing and
side member.
Areas: A - Spot weld
B - MIG (continuous)
Fig. 8: Welding in front wheelhousing
A- MIG (continuous)
B - Spot weld
C - Remove surplus material
MIG (continuous) Front Inner Wheelhouse (Sectional Part) 50
Fig. 9: Aligning and welding in front apron Fig. 10: Welding in cover plate
Areas: A - Spot Weld Areas: A - Spot Weld
B - MIG (Continuous) B - MIG (Continuous)
Clean all weld seams with wire brush.
Prime and seal all repaired areas.
Apply permanent underbody soaiant.
Carry out cavity preservation in
repaired area.
50.11 50 Front inner Wheelhouse
Replacing front wheelhouse
Includes: Front Apron, Side Member and Reinforcement.
Cutting: Figs. 1-5 Note:
Aligning: Fig. 6 inside of new parts before
Welding: Figs. 7-12 installation.
Note: CAUTION
Coat any welded areas inaccessible after welding with When welding, protect interior from fire
cold zine paint. and sparks.
Remove the following components to gain necessary accé
Disconnect or remove battery
Front bumper assembly ee
Headlight assemblies and trim Take care not to bend or break fuel or
Fi ; brake lines when removing. Clean up any
rill assembly and hood locks
Behe {uel or brake uid spills to eliminate re
hazards
Note:
If not replacing the fenders, take care not to bend or distort the fenders when removing. Use a heat gun to
carefully soften the caulking on the underside of the fender before removing.
Radiator, chroude, and reeervoir (if nececeary) Carpeting
Front wiring hamess Steering linkage
Front motor mount Fuel or brake lines (as necessary)
Fuel injection assembly (if necessary) Front door
W/asher bottle AVC condensor
50.12 Front Inner Wheelhouse 50
50.13 50 Front Inner Wheelhouse
Fig. 5: Cutting out front wheelhouse Fig. 7: Welding in front wheelhouse
Air chisel, hammer, chisel. Areas: F - MIG (Plug Weld)
G - MIG (Staggered)
H - Spot Weld.
J+ MIG (Continuous)
Note to G,H + J:
Alter welding, apply seam sealant.
Fig. 6: Aligning front wheelhouse
Clamps.
Note
Coat all areas not accessible after welding with
cold zine paint Fig. 8: Welding in front wheelhouse
Areas: K - Spot Wold
L- MIG (Continuous)
M - Spot Weld
50.14 Front Inner Wheelhouse 50
Fig. 9: Welding in front wheelhouse Fig. 11: Welding in front apron
Areas: N - Spot Weld - MIG (Staggered) Areas: A - Spot Weld
O - Spot Weld B - MIG (Continuous)
Fig. 10: Welding in front whee!house Fig. 12: Welding in front wheelhouse
Areas: R - MIG (Continuous) Wheethouse reinforcement
S- MIG (Plug Weld) ‘Areas: W - Spot Weld
Y - MIG (Staggered)
Clean all weld seams with wire brush
Prime and seal repaired areas.
Carry out cavity preservation in
repaired areas.
50.15 50 Battery Carrier
Replacing battery carrier
Cutting
Removing surplus metal
Preparing new parts
Note:
Apply cold zinc paint to areas inaccessible after welding.
Aligning
Welding
50.16 Repair Procedures And
Cutting Lines
Center
Group 51 51 Front Hinge Pillar
Replacing front hinge pillar
Includes: Inner hinge pillar Note:
Cutting out: Figs. 1-3 Vehicle must be completely free of stress
Preparing new parts: Figs. 4,5 when aligning and welding in new parts.
Welding: Figs. 6,7
Remove the following components to gain necessary access:
Disconnect battery
Front door and weatherstrip
Front fender
Note:
If not replacing fender, care should be taken not to bend or distort the fender when removing.
Use a heat gun to carefully soften the underside of the fender before removing.
Front windehiold and necessary headliner trim
Dash and associated trim pancie
Carpeting
‘Any wiring or vacuum lines
Front hood
‘Sil molding
51.2 Fig. 1: Cutting out hinge pillar
Air chisel, hacksaw, hammer, chisel,
grinder.
Fig. 2: Cutting out hinge pillar
Air chisel, hacksaw, hammer, chisel,
grinder.
Fig. 3:
Front Hinge Pillar 51
Cutting out hinge pillar
Drill out spot welds at area D on
reinforcement plate. Remove scrap
metal, straighten and grind connecting
surfaces clean.
Grinder, pliers, hammer, chisel, drill
Fig. 4:
Preparing outer hinge pillar (new part)
Transfer cutting lines onto new part and
remove surplus material (shaded area)
Hacksaw, grinder.
51.3 51
51
Front Hinge Pillar
|
Fig. 5: Preparing inner hinge pillar (new part)
Transfer cutting lines onto new part and
remove surplus material (shaded area)
Hacksaw, grinder.
Note
Align hinge pillar and tack in position with MIG.
Install door and check/adjust gap to adjacent
parts.
Ge]
Fig. 6: Welding in hinge pillar - part section
Areas: C - MIG (Staggered)
D - MIG (plug) (reinforcement
plate)
E - MIG (continuous)
F - MIG (continuous)
A
Fig. 7: Welding in hinge pillar - part section
Areas: G - Spot Weld
H - MIG (continuous)
(Also weld inside of hinge
pillar in Area H),
Finishing off operations:
Grind visible weld seams smooth, fill with 2-
‘component polyester filler and sand down.
Clean all other weld seams with wire brush.
Prime all repaired areas. Cowl Panel 51
Replacing cow! panel
Cutting
Removing surplus metal
Preparing new parts
Aligning
Welding
Remove the following components to gain necessary access:
Disconnect battery
Front windshield & associated trim
Front hood
Front fenders
Nott
If not replacing, take care when removing fenders not to bend or distort them. Use a heat gun to
carefully soften the caulking on the underside ot the fenders before removing them.
Front doors
Windshield wipers and linkage
Note:
Protect interior from welding or grinding sparks.
51.5 51 cow! Panel
Repair Stops Area: Tools and equipment
Cutting out:
Chisel 1-7 Air chisel
Removing surplus mi
Grind 1-7 Grinder
Tear off 1-7 Pliers,
Preparing new parts:
Grind (remove primer) 1-7 Grinder
Corrosion protection 14,7 Cold zine paint
Aligning:
Locate in position 147 Clamping pliers
Welding in:
Spot weld 14,7 ‘Spot welder
MIG (Staggered) 26 MIG welder
Braze 3,6 (comers) ‘Oxyacetylene torch
Finishing off operations:
Grind 1
Grinder
Clean all weld seams with wire brush.
Prime and seal all repaired areas.
Apply cavity protection in repaired areas.
51.6 Rocker Pane! 51
Replacing rocker panol
Includes: Inner rocker panel and gusset plate.
Cutting: Figs. 1 - 4 Note
Preparing new part: Fig. 5 Before welding new parts, relieve pressure on
igning: Figs. 6, 8, 9 vehicle to insure proper door alignment later on.
Welding: Figs. 6 - 9
Remove the following components to gain necessary access:
Disconnect battery
Doors)
Door weatherstrips
Rocker and sill moldings
Front and rear seats (as necessary)
Carpeting
Front fender
Note:
Hf not replacing fender, take care not to bend or distort fender when removing. Use a heat gun to
carefully soften the caulking on the underside of the tenders before removing,
CAUTION
Check location of brake and fuel lines
before cutting or welding. Loosen or
remove as necessary.
51.7 51 Rocker Panel
Fig. 1: Cutting out outer rocker panel Fig. 3: Cutting out inner rocker panel
Air chisel, hacksaw. Air chisel,
Fig. 4: Inner and outer rocker panel
Remove scrap metal, align and grind
connecting surfaces.
Fig. 2: Cutting out outer rocker pane!
Air chisel, hacksaw.
Form offset in area A.
Grinder, pliers, offset pliers.
51.8 Rocker Panel 51
Fig. 5: Inner and outer rocker panel
Transfer cutting lines and cut off shaded
area
Grind clean all connecting surfaces of
new part.
Hacksaw, grinder.
Apply cold zinc paint to areas which are
to be spot welded,
igning and welding in inner rocker
panel
Areas: A - Spot weld
B - MIG (Staggered)
Note
Before welding in the new parts, the vehicle
must be relieved of all stress to insure correct
alignment of doors later on.
Fig. 7: Welding in inner rocker panel
Area: A - Spot weld
Fig. 8: Aligning and welding in outer rocker
panel
‘Areas: A - Spot weld
B - MIG (spot weld)
CC - MIG (continuous)
51.9 51 Rocker Panel
Aligning and welding in gusset plate
Areas: A - Spot weld
B - MIG (Spot weld)
Clean all weld seams with wire brush,
prime and seal
Apply permanent underbody sealant in
repaired area
Carry out cavity preservation,
51.10 Center (“B”) Pillar (4 Dr) 51
Replacing center ““B” pil
Cutting: Fig. 1
Aligning: Fig. 2
Welding: Fig. 3
Remove the following components to gain necessary acc
Disconnect battery
Rear door
Front seat
Carpeting
Inner door weatherstrips
Seat belt and necessary trim
Rocker and sill moldings
Loosen wiring hamess (if necessary)
CAUTION
Check location of brake and fuel lines
before cutting or welding. Loosen or
remove as necessary.
51.11 51 center “B” Pillar (4 Dr)
Fig. 1: Cutting out reinforced center pillar Fig. 3: Welding in reinforced center pillar
Hacksaw, air chisel, hammer, chisel Areas: A - MIG (continuous)
a = 80 mm B - MIG (continuous)
(Reference point: rib below rain
channel)
Finishing off operation:
Grind visible weld seams smooth, fill with two
component polyester filler and sand down.
Clean all other weld seams with wire brush.
Prime and seal repaired areas.
Carry out cavity preservation.
Fig. 2: Aligning reinforced center pillar
Cut new part to form butt joint.
Coat all areas not accessible after
welding with cold zinc paint.
51.12 Root 51
Replacing roof:
Cutting: Figs. 1, 2 Note
Preparing new parts: Fig. 3
Aligning: Figs. 4, 5
Welding: Figs. 6, 7
Finishing: Fig. 8
Protect interior from grinding and welding sparks.
Remove the following components to gain necessary access:
Disconnect battery
Headliner and associated trim
Front windshield
Rear window
Drip rail moldings.
Electrical wiring
Inner door weatherstrips
ie 5113 Fig. 1: Cutting out roof
Air chisel, hammer, chisel.
Fig. 2: Cutting out root
Air chisel, hammer, chisel.
Fig. 3: Preparing roof - new part
Cut out cow pane! front area.
Hacksaw
Fig. 4: Roof
Remove excess scrap metal.
51.14 3s Roof 51
Fig. 5: Aligning root Fig. 7: Welding in root
Stick non-hardening sealing tape (A) to ‘Areas: E - Spot weld
the roof reinforcement and frame. F - Spot weld
Coat all areas not accessible after
welding with cold zinc paint.
:: Finishing off roof
Seal off area G with joint sealing
Fig. 6: Welding in root compound
Areas: a : eee cadena Clean all weld seams with wire brush.
cate) Prime and sea! al roparod ars,
Fig.
se 5115 51 Root
Replacing roof:
Cutting
CAUTION
Because of roof cross member, great care
must be taken when cutting in area 1. Note
shape of new part when cutting in areas
2 - 4. To prevent damaging roof frame, cut
approx. 15 mm above spot welding flange
in areas 5, 7
Removing scrap metal eaunon
Preparing new parts
Aligning Protect interior from grinding and welding
Welding sparks,
Remove the following components to gain necessary access:
Disconnect battery
Headliner and associated trim
Front windshield
Rear lid and weatherstrip
Quarter windows
Electrical wiring
Inner door weatherstrips
SA AG acon Repair stages Areas Tools
Cutting out:
Chiseling 1,5, 7,10 Cold and air chisels
Sawing 2-49 Hacksaw
Removing scrap metal:
Grinding 1-10 Grinder
Tearing off 1-10 Pliers
Preparing new parts:
Grinding 1-10 Grinder
Anti-corrosion protection 1,5, 7,10 Cold zinc paint
Aligning:
Positioning 1,5, 7, 10 Clamps
Welding in:
Spot weld 4,5, 7, 10 Spot welder
MIG (continuous) 24,68 MIG welder
Braze 3.9 Oxy-acetylene torch
Finishing off operations:
Grinding 2-4,
Filing 2-4,
9 Grinder
Two component filler
Grind visible weld seams smootn, till with two component polyester filer and sand down.
Clean all other weld seams with wire brush,
Prime and seal all repaired areas.
Apply permanent underbody sealant in repaired areas.
Carry out cavity preservations in repaired area,
Wagon
51.17 51 Front Roof Crossmember
Replacing front roof crossmember
Associated operation
pues
Aligning: Fig. 3
Welding: Figs. 4, 5
51.18 Front Roof Crossmember 51
Air chisel.
51.19 51 Front Roof Crossmember
Fig. 4: Welding in front roof crossmember
Spot weld
Fig. 5: Welding in front roof crossmember
‘Areas: A - 4 x Spot welds
B - 2 x Spot welds
Clean welded areas with wire brush and
prime.
51.20 Bonded windshield replacement,
General information
The following tools and materials are required
when installing and removing windshield.
© Cutting tool tor glass VW 1351
Front Windshield 51
Repair kit, Replacement Part no. 431 898 099 A,
consisting of:
* adhesive cartridge 300 mi
© nozzle for cartridge
* bottle for primer
* application head for primer bottle
* felt pad for applicator head
* glass primer 20 mi
* cleaning solvent
* four adjustment wedges
Note
Before applying compound, warm up in water at
40° - 60°C (104° - 140°F) for approx. 30
minutes. Cartridges are available separately
under Spare Part Na D 009 100,
WARNING
Always wear protective goggles and leather
loves when removing and installing
windshield,
CAUTION
Part numbers are for reference only. Always
check with your Parts Department for latest
parts information.
'* Double suction pad holder used to hold glass
‘+ Caulking gun for applying bonding/sealing
‘compound
Commercial Tools
Carpet knife
Pliors
Cutting wire 0.5 mm (0.20 - 0.24) piano wire
51.21 51 Front Windshield
Bonded windshield,
removingjinstalling
WARNING
Protective goggles and leather gloves
must be worn when removing and
installing glass. Also, read warnings
supplied with installation kit.
Work sequence
Removing
—read through entire work sequence before
starting repair
—remove inside rear view mirror
—remove push-on trim molding from inside
windshield flange, starting at top center
—pull out rubber lip 3 from trim frame 2
around outside of windshield 1
—with aid of helper, push wire (about
360-400 mm oF 14-16 in. long) through
adhesive sealant at lower center of
windshield and grab wire on outside with
long-nose pliers
x—__
attach ends of wire to tool VW 135! (or use
2 needle nose vise grips) so part X is inside
and part Y outside of car. Thread wire
through in direction of arrows and secure
ends at screws A and B
Note:
Attach masking tape to body around entire
windshield perimeter to protect paint.
51.22 Front Windshield 51
Installing
—using carpet knife, cut remaining adhesive
material on glass flange smooth
CAUTION
Do not remove adhesive completely. It is
used as a base for new adhesive material.
If body parts in area of glass flange are
being worked on or replaced, flange must be
recleaned and primed after painting (use
paint primer, Part No. D 009 300).
—push point of tool X (or inside vise grip) into
adhesive approx. 152 mm (6 iin) from point
where wire was originally passed through
—heat windshield with hot air gun in area to be
cut to soften adhesive
—pull tool ¥ (outside vise grip) evenly in
direction B until it roaches anchor point Z
—repeat process and cut window free all around,
Note
Care must be taken that cutting wire does not
cut into trim frame when cutting around comers.
I necessary, use a screwdriver to guide wire
underneath trim frame.
‘stall trim frame 2 to windshield glass 1
stall rubber lip 3 into trim frame
Note
Ceramic black-out band around windshield is
not primer.
Before applying adhesive sealing compound,
this area must be primed.
51.23 51 Front Windshi
ield
—cut applicator head for required primer width
a= 19mm
—apply primer evenly all around edge of
windshield and trim frame in one continuous
operation. Make sure applicator head is
always completely saturated.
Note
If an undamaged windshield is to be reused, cut
the remaining adhesive on the glass and trim
frame smooth. Do not remove adhesive
completely.
Keep surfaces free from dirt and grease.
—install push-on molding to glass flange
i= 126)
1 Glace
4 Adhesive sealing compound
5 Push-on molding
—apply adhesive sealing compound 4 around
entire flange
51.24
1 10
8
— bonding sealing compound should be applied
in shape shown (in mm) which is determined
by nozzle opening and rate of application
— using double suction pad holders, hold glass
and center into windshield opening
— position glass using two spacers (made from
rubber wedges)
Hardening of adhesive sealing compound
— allow bonding/sealing compound 3 hours to
harden before driving car. Material hardens
quickest when kept wet and at room
temperature 20°C (68°F)
Removing of surplus adh
compound
ive sealing
— excess adhesive sealing compound can be
removed using a solvent such as kerosene or
Prep-Sol”
+ do not use cleaners which contain alcoho!
— to clean plastic trim, let adhesive sealing
compound harden 2-3 hours, then scrape off
execss CAUTION
Avoid putting pressure on glass from inside
‘car when cleaning around glass while
bonding/sealing compound is hardening
Sealing leaks
—water test window area
—
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