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Service
Body Repairs
Amarok 2011 ➤
Edition 10.2010
Service Department. Technical Information
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Repair Group overview for Body Repairs
Re pa ir G ro up
00 - Technical data
50 - Body - front
51 - Body - centre
53 - Body - rear
Service
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 D3E8027D416
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Key vehicle data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Identification plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Moulded foam elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 Galvanized body parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5 Body panel gaps/shut lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.1 Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.2 Body - centre, vehicles with double cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.3 Body - centre, vehicles with single cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.4 Body - rear, vehicles with double cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.5 Body - rear, vehicles with single cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.6 Body add-on parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6 Body dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.1 Double cab frame dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.2 Single cab frame dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.3 Double cab box dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.4 Single cab box dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.5 Double cab load surface dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.6 Single cab load surface dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7 Alignment jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.2 Alignment bracket fixture overview of complete vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.3 Alignment bracket fixture overview of vehicle chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.4 Alignment bracket fixture overview of vehicle cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.5 Alignment bracket fixture overview of vehicle cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
50 - Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1 Renewing cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2 Renewing deformation element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3 Renewing headlight mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4 Renewing wing connecting plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5 Renewing connection piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6 Renewing upper wheel housing longitudinal member . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Contents i
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
6.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7 Renewing front wheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
7.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
7.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8 Renewing front part of longitudinal member - part section 1- . . . . . . . . . . . . . . . . . . . . . . . . 75
8.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
8.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
9 Renewing longitudinal member - part section 2- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
9.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
9.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
10 Renewing longitudinal member complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
10.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
10.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
51 - Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1 Renewing roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
1.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
2 Renewing front cross member for roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
3 Renewing roof reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
3.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
3.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4 Renewing rear roof cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
4.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
4.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
5 Renewing rear window frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
5.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
5.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
6 Renewing cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
6.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
6.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
7 Renewing hinge pillar (A-pillar) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
7.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
7.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
7.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
8 Renewing hinge pillar (A-pillar) reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
8.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
8.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
8.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
9 Renewing centre pillar (B-pillar) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
9.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
9.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
9.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
10 Renewing centre pillar (B-pillar) reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
10.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
10.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
10.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
11 Renewing lock pillar (C-pillar) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
11.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
ii Contents
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
11.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
11.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
12 Renewing mounting bracket for front seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
12.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
12.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
53 - Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
1 Renewing rear cross panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
1.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
2 Renewing rear longitudinal member - part section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
2.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
2.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
3 Renewing rear side panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
3.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
3.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Contents iii
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
iv Contents
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
00 – Technical data
1 Key vehicle data
1.1 Vehicle identification number
Note
If components into which the vehicle ID number (chassis number) is stamped are renewed in the event of
damage, a surveyor must be involved prior to repair.
Vehicle identification number (chassis number) on the body:
The vehicle identification number (chassis number) is visibly
stamped into the lower left windscreen flange -arrow A-.
1. Key vehicle data 1
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
Vehicle identification number (chassis number) on the vehicle
frame:
The vehicle identification number (chassis number) is visibly
stamped into the right vehicle frame longitudinal member
-arrow B-.
Note
♦
♦
According to the legislation in Brazil, Argentina and Mexico, a „shortened vehicle ID number (chassis num‐
ber)“ is located at 3 further points within the vehicle.
The additional identification consists of an identification plate which cannot be removed without destroying
it.
Additional, shortened vehicle identification number (chassis num‐
ber) for Brazil, Argentina and Mexico:
♦ The vehicle identification number (chassis number) is stuck on
to the right wheel housing in the engine compartment
-arrow A-.
♦ The vehicle identification number (chassis number) is stuck on
to the right front passenger seat -arrow C-.
2 Rep. gr.00 - Technical data
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♦ The vehicle identification number (chassis number) is stuck on
to the right B-pillar -arrow B-.
1.2 Identification plate
The identification plate -arrow- is stuck on the left B-pillar.
1.3 Vehicle data sticker
– The vehicle data sticker -arrow- is located in the footwell on
the driver's side.
Body Repairs - Edition 10.2010
Amarok 2011 ➤
1. Key vehicle data 3
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
2 Safety instructions
WARNING
Before beginning any cutting, alignment or dent removal, refer
to safety notes in the binder General information, body repairs
and general body repairs.
4 Rep. gr.00 - Technical data
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3 Moulded foam elements
Note
♦
Various body cavities in the Amarok 2010 ► have been fitted
with moulded foam elements.
♦
The moulded foam elements reduce the amount of driving
noise that is transmitted into the interior.
♦
The moulded elements are fitted during body shell construc‐
tion and increase their volume in the paint shop drying oven
at approx.180°C, after priming.
♦
The exact locations of these moulded foam elements are ad‐
ditionally shown at the beginning of the respective repair de‐
scriptions.
1 - Upper A-pillar
❑ Moulded foam element
between A-pillar outer
skin and A-pillar rein‐
forcement.
❑ Moulded foam element
between A-pillar rein‐
forcement and inner
panel.
2 - Lower C-pillar
❑ Moulded foam element
between C-pillar outer
skin and C-pillar rein‐
forcement.
❑ Moulded foam element
between C-pillar rein‐
forcement and inner
panel.
3 - Lower B-pillar
❑ Moulded foam element
between B-pillar outer
skin and B-pillar rein‐
forcement.
❑ Moulded foam element
between B-pillar rein‐
forcement and inner
panel.
4 - Lower A-pillar
❑ Moulded foam element
between A-pillar outer
skin and A-pillar rein‐
forcement.
❑ Moulded foam element
between A-pillar rein‐
forcement and inner
panel.
Amarok 2011 ➤
Body Repairs - Edition 10.2010
As these temperatures cannot be achieved under normal work‐
shop conditions, proceed as follows:
– Remove foam material remains on vehicle.
3. Moulded foam elements 5
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.
Amarok 2011 ➤
Body Repairs - Edition 10.2010
– Restore the paint work structure. If necessary, apply two coats
(wet in wet) of glass/paint primer -D 009 200 02- (apply the
second coat in the opposite direction) - flash-off time of about
10 minutes.
Prerequisites
– Before continuing with this procedure, ensure that the part for
replacement is correctly prepared e.g. cut and adapt to fit,
corrosion protection measures.
Renewing moulded foam element
– Wrap moulded foam element with sealing cord -AKD 497 010
04 R10- all round.
– Fix moulded foam element to vehicle.
– Secure new part (e.g. A-pillar) in position. Apply gentle pres‐
sure to contact new part in area of moulded foam element and
weld in.
– Do not do perform shielded arc welding within 15 mm on either
side of moulded foam element.
– Carry out cavity preservation on repair area after painting ve‐
hicle.
6 Rep. gr.00 - Technical data
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4 Galvanized body parts
The vehicle consists partly of body panels galvanized on one or
both sides!
Before carrying out body repairs observe the following information
⇒ General Information; Body Repairs, General Body Repairs .
Amarok 2011 ➤
Body Repairs - Edition 10.2010
4. Galvanized body parts 7
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
5 Body panel gaps/shut lines
Note
Use setting gauge -3371- to set or check shut lines.
5.1 Body - front
A - 2.5 mm + 1.5 mm
B - 3.0 mm + 0.5 mm
C - 5.0 mm ± 0.5 mm
D - 2.0 mm ± 1.0 mm
E - 10.5 mm + 1.0 mm
F - 4.0 mm + 1.0 mm
G - 8.7 mm + 2.0 mm
8 Rep. gr.00 - Technical data
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5.2 Body - centre, vehicles with double cab
H - 0.5 mm ± 0.3 mm
I - 4.2 mm ± 0.5 mm
J - 5.0 mm ± 0.75 mm
K - 7.0 mm ± 1.0 mm
L - 34.5 mm ± 1.5 mm
Amarok 2011 ➤
Body Repairs - Edition 10.2010
5. Body panel gaps/shut lines 9
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
5.3 Body - centre, vehicles with single cab
J - 5.0 mm ± 0.75 mm
K - 7.0 mm ± 1.0 mm
M - 2.5 mm ± 0.3 mm
Q - 3.0 mm ± 0.3 mm
R - 35.0 mm ± 5.0 mm
10 Rep. gr.00 - Technical data
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5.4 Body - rear, vehicles with double cab
B - 3.0 mm + 0.5 mm
M - 2.5 mm ± 0.3 mm
N - 20.0 mm ± 5.0 mm
O - 6.0 mm ± 1.0 mm
P - 2.0 mm ± 0.5 mm
R - 35.0 mm ± 5.0 mm
V - 1.0 mm ± 0.3 mm
Amarok 2011 ➤
Body Repairs - Edition 10.2010
5. Body panel gaps/shut lines 11
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
5.5 Body - rear, vehicles with single cab
B - 3.0 mm + 0.5 mm
O - 6.0 mm ± 1.0 mm
P - 2.0 mm ± 0.5 mm
12 Rep. gr.00 - Technical data
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5.6 Body add-on parts
S - 1.0 mm + 0.5 mm / - 1.0 mm
❑ Shut line between wheel
cover and body part.
T - 3.0 mm ± 1.0 mm
❑ Height difference be‐
tween wheel cover and
drop sides.
Amarok 2011 ➤
Body Repairs - Edition 10.2010
5. Body panel gaps/shut lines 13
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
U - 10.5 mm ± 3.0 mm
❑ Shut line between rear
bumper and drop sides.
14 Rep. gr.00 - Technical data
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6 Body dimensions
Note
♦
Dimensions only given for checking purposes. The alignment
bracket set is definitive. Bolts, screws, plugs, trim and attached
components must be removed before starting the measuring
process.
♦
Use Telescopic gauge -VAS 5159- or Telescopic gauge -VAS
5160- to determine body dimensions.
6.1 Double cab frame dimensions
6.1.1 Front frame dimensions
Frame dimensions between front frame longitudinal members
Maß a - 1,320 mm ± 4.0 mm
❑ Dimension between cab
mounting 2
Maß b - 1,015 mm ± 3.0 mm
❑ Dimension between
suspension strut mount‐
ings
Maß c - 660 mm ± 3.0 mm
❑ Dimension diagonally
between assembly
mountings
Maß d - 645 mm ± 3.0 mm
❑ Dimension between as‐
sembly mountings
Maß e - 1,040 mm ± 4.0 mm
❑ Dimension between cab
Maß f - 800 mm ± 3.0 mm
❑ Inner dimension be‐
mounting 1
tween frame longitudi‐
nal members
Front lower frame dimensions
Amarok 2011 ➤
Body Repairs - Edition 10.2010
6. Body dimensions 15
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
Maß a - 800 mm ± 3.0 mm
❑ Inner dimension be‐
tween frame longitudi‐
nal members
Maß b - 815 mm ± 2.0 mm
❑ Dimension between an‐
ti-roll bar bolting points
Maß c - 840 mm ± 2.0 mm
❑ Dimension between
front axle mountings
16 Rep. gr.00 - Technical data
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6.1.2 Centre frame dimensions
Lower centre frame dimensions
Maß a - 780 mm ± 2.0 mm
❑ Dimension between
front axle rear mount‐
ings
Maß b - 810 mm ± 3.0 mm
❑ Dimension between
gearbox mountings
Maß c - 490 mm ± 2.5 mm
❑ Dimension between re‐
bound strap bolting
points
Upper centre frame dimensions
Amarok 2011 ➤
Body Repairs - Edition 10.2010
6. Body dimensions 17
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
Maß a - 1,340 mm ± 4.0 mm
❑ Dimension between cab
mounting 3
Maß b - 1,100 mm ± 4.0 mm
❑ Dimension between
load surface bolting
point 1
Maß c - 1,100 mm ± 4.0 mm
❑ Dimension between
load surface bolting
point 2
Maß d - 1,100 mm ± 4.0 mm
❑ Dimension between
load surface bolting
point 3
Maß e - 910 mm ± 3.0 mm
❑ Inner dimension be‐
tween frame rear longi‐
tudinal members
18 Rep. gr.00 - Technical data
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6.1.3 Rear frame dimensions
Upper centre frame dimensions
Maß a - 1,340 mm ± 4.0 mm
❑ Dimension between cab
mounting 3
Maß b - 1,100 mm ± 4.0 mm
❑ Dimension between
load surface bolting
point 1
Maß c - 1,100 mm ± 4.0 mm
❑ Dimension between
load surface bolting
point 2
Maß d - 1,100 mm ± 4.0 mm
❑ Dimension between
load surface bolting
point 3
Maß e - 910 mm ± 3.0 mm
❑ Inner dimension be‐
tween frame rear longi‐
tudinal members
Rear diagonal frame dimensions
Amarok 2011 ➤
Body Repairs - Edition 10.2010
6. Body dimensions 19
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
Maß a - 1,345 mm ± 4.0 mm
❑ Dimension diagonally
between load surface
bolting point 1 on left
and load surface bolting
point 2 on right
Maß b - 1,658 mm ± 4.0 mm
❑ Dimension diagonally
between load surface
bolting point 1 on right
and load surface bolting
point 3 on left
Maß c - 1,195 mm ± 4.0 mm
❑ Dimension diagonally
between load surface
bolting point 2 on left
and load surface bolting
point 3 on right
Maß d - 1,488 mm ± 2.5 mm
❑ Dimension between
front leaf spring mount‐
ing and rear leaf spring
mounting
20 Rep. gr.00 - Technical data
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6.2 Single cab frame dimensions
6.2.1 Front frame dimensions
Frame dimensions between front frame longitudinal members
Maß a - 1,320 mm ± 4.0 mm
❑ Dimension between cab
mounting 2
Maß b - 1,015 mm ± 3.0 mm
❑ Dimension between
suspension strut mount‐
ings
Maß c - 660 mm ± 3.0 mm
❑ Dimension diagonally
between assembly
mountings
Maß d - 645 mm ± 3.0 mm
❑ Dimension between as‐
sembly mountings
Maß e - 1,040 mm ± 4.0 mm
❑ Dimension between cab
mounting 1
Maß f - 800 mm ± 3.0 mm
❑ Inner dimension be‐
tween frame longitudi‐
nal members
Amarok 2011 ➤
Body Repairs - Edition 10.2010
Front lower frame dimensions
6. Body dimensions 21
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
Maß a - 800 mm ± 3.0 mm
❑ Inner dimension be‐
tween frame longitudi‐
nal members
Maß b - 815 mm ± 2.0 mm
❑ Dimension between an‐
ti-roll bar bolting points
Maß c - 840 mm ± 2.0 mm
❑ Dimension between
front axle mountings
6.2.2 Centre frame dimensions
Note
Centre frame dimensions were not yet available at time of going
to print!
6.2.3 Rear frame dimensions
Note
Rear frame dimensions were not yet available at time of going to
print!
22 Rep. gr.00 - Technical data
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6.3 Double cab box dimensions
6.3.1 Front box dimensions
Front engine compartment box dimensions
Maß - 956 mm ± 1.0 mm
❑ Dimension between
lock carrier bolting
points
Maß - 1,412 mm ± 2.0 mm
❑ Dimension between
lamp carriers
Maß - 982 mm ± 2.0 mm
❑ Dimension between
wheel housings
Maß - 758 mm ± 2.0 mm
❑ Dimension wing mount‐
ing flange
Maß - 1,742 mm ± 2.0 mm
❑ Dimension diagonally
between left wing
mounting flange at rear
and right wing mounting
flange at front
Amarok 2011 ➤
Body Repairs - Edition 10.2010
Front box dimensions
6. Body dimensions 23
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
Maß - 1,500 mm ± 2.0 mm
❑ Dimension between
lower part of front lamp
carriers
Maß - 943 mm ± 2.0 mm
❑ Dimension between
middle of lamp carriers
Maß - 935 mm ± 1.0 mm
❑ Dimension between up‐
per part of lamp carriers
Maß - 217 mm ± 2.0 mm
❑ Dimension cross mem‐
ber to lamp carrier
Maß - 270 mm ± 2.0 mm
❑ Dimension cross mem‐
ber to lamp carrier
Front end box dimensions
24 Rep. gr.00 - Technical data
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Maß - 950 mm ± 3.0 mm
❑ Dimension between A-
pillar and front end
Maß - 1,067 mm ± 2.0 mm
❑ Dimension between A-
pillar and front end
Body Repairs - Edition 10.2010
Amarok 2011 ➤
6. Body dimensions 25
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
6.3.2 Centre box dimensions
Centre box dimensions
Maß - 1,870 mm ± 3.0 mm
❑ Dimension between A-
pillars
Maß - 1,870 mm ± 3.0 mm
❑ Dimension between B-
pillars
Maß - 420 mm ± 2.0 mm: Di‐
mension
❑ Upper door hinge to low‐
er door hinge on A-pillar
Maß - 445 mm ± 2.0 mm
❑ Upper door hinge to low‐
er door hinge on B-pillar
26 Rep. gr.00 - Technical data
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6.3.3 Rear box dimensions
Rear box dimensions
Maß - 1,195 mm ± 2.0 mm
❑ Dimension between
roof side members
Maß - 1,465 mm ± 2.0 mm
❑ Dimension rear panel
aperture
Maß - 340 mm ± 2.0 mm
❑ Dimension rear window
aperture
Maß - 1,524 mm ± 3.0 mm
❑ Dimension between
side members
Amarok 2011 ➤
Body Repairs - Edition 10.2010
6. Body dimensions 27
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
6.4 Single cab box dimensions
6.4.1 Front box dimensions
Front engine compartment box dimensions
Maß - 956 mm ± 1.0 mm
❑ Dimension between
lock carrier bolting
points
Maß - 1,412 mm ± 2.0 mm
❑ Dimension between
lamp carriers
Maß - 982 mm ± 2.0 mm
❑ Dimension between
wheel housings
Maß - 758 mm ± 2.0 mm
❑ Dimension wing mount‐
ing flange
Maß - 1,742 mm ± 2.0 mm
❑ Dimension diagonally
between left wing
mounting flange at rear
and right wing mounting
flange at front
Front box dimensions
28 Rep. gr.00 - Technical data
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Maß - 1,500 mm ± 2.0 mm
❑ Dimension between
lower part of front lamp
carriers
Maß - 943 mm ± 2.0 mm
❑ Dimension between
middle of lamp carriers
Maß - 935 mm ± 1.0 mm
❑ Dimension between up‐
per part of lamp carriers
Maß - 217 mm ± 2.0 mm
❑ Dimension cross mem‐
ber to lamp carrier
Maß - 270 mm ± 2.0 mm
❑ Dimension cross mem‐
ber to lamp carrier
Front end box dimensions
Amarok 2011 ➤
Body Repairs - Edition 10.2010
6. Body dimensions 29
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
Maß - 950 mm ± 3.0 mm
❑ Dimension between A-
pillar and front end
Maß - 1,067 mm ± 2.0 mm
❑ Dimension between A-
pillar and front end
Note
Note
6.4.2 Centre box dimensions
Centre box dimensions were not yet available at time of going to
print!
6.4.3 Rear box dimensions
Rear box dimensions were not yet available at time of going to
print!
30 Rep. gr.00 - Technical data
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6.5 Double cab load surface dimensions
6.5.1 Upper load surface dimensions
Outer/inner load surface dimensions
Amarok 2011 ➤
Body Repairs - Edition 10.2010
Maß - 1,547 mm ± 2.0 mm
❑ Dimension inner side of
load area side panel
Maß - 1,810 mm ± 2.0 mm
❑ Dimension outer side of
load area side panel
Maß - 2,122 mm ± 2.0 mm
❑ Diagonal dimension for
load surface
Lashing eye deviations
6. Body dimensions 31
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
Maß - 1,574 mm ± 2.0 mm
❑ Dimension between
lashing eyes
Maß - 1,656 mm ± 2.0 mm
❑ Diagonal dimension be‐
tween lashing eyes
32 Rep. gr.00 - Technical data
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6.5.2 Lower load surface dimensions
Lower load surface deviations
Maß - 1,663 mm ± 2.0 mm
❑ Dimension between
front part of wheel hous‐
ings
Maß - 1,653 mm ± 2.0 mm
❑ Dimension between
rear part of wheel hous‐
ings
Maß - 1,420 mm ± 2.0 mm
❑ Dimension lower part of
tailboard aperture
Amarok 2011 ➤
Body Repairs - Edition 10.2010
6. Body dimensions 33
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.
Amarok 2011 ➤
Body Repairs - Edition 10.2010
6.5.3 Rear load surface dimensions
Rear load surface deviations
Maß - 1,421 mm ± 2.0 mm
❑ Dimension lower part of
tailboard aperture
Maß - 1,362 mm ± 2.0 mm
❑ Dimension between D-
pillars
Maß - 1,421 mm ± 2.0 mm
❑ Dimension upper part of
tailboard aperture
Maß - 381mm ± 1.0 mm
❑ Dimension tail light
aperture
6.6 Single cab load surface dimensions
6.6.1 Upper load surface dimensions
Note
Upper load surface dimensions were not yet available at time of
going to print!
6.6.2 Lower load surface dimensions
Note
Lower load surface dimensions were not yet available at time of
going to print!
34 Rep. gr.00 - Technical data
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6.6.3 Rear load surface dimensions
Rear load surface deviations
Maß - 1,421 mm ± 2.0 mm
❑ Dimension lower part of
tailboard aperture
Maß - 1,362 mm ± 2.0 mm
❑ Dimension between D-
pillars
Maß - 1,421 mm ± 2.0 mm
❑ Dimension upper part of
tailboard aperture
Maß - 381mm ± 1.0 mm
❑ Dimension tail light
aperture
Amarok 2011 ➤
Body Repairs - Edition 10.2010
6. Body dimensions 35
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
7 Alignment jig
7.1 Tools
Special tools and workshop equipment required
♦ Alignment jig -V.A.G 1920/1-
♦ Measurement and alignment system -VAS 6526-Basis-
♦ Measurement and alignment system -VAS 6527-Profi-
♦ Measurement and alignment system -VAS 6527-Profi-Plus-
♦ Alignment bracket set Amarok -VAS 6637-
♦ Portal gauge supplement, Amarok -VAS 5007/48-
7.2 Alignment bracket fixture overview of complete vehicle
Alignment bracket fixture overview of complete vehicle with align‐
ment bracket set Amarok -VAS 6637-
36 Rep. gr.00 - Technical data
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
Note
Detailed information on setting up the alignment bracket set can be found in the installation plans enclosed with
the alignment bracket set.
7.3 Alignment bracket fixture overview of vehicle chassis
Alignment bracket fixture overview of vehicle chassis with align‐
ment bracket set Amarok -VAS 6637-
Note
Detailed information on setting up the alignment bracket set can be found in the installation plans enclosed with
the alignment bracket set.
7. Alignment jig 37
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
7.4 Alignment bracket fixture overview of vehicle cab
Alignment bracket fixture overview of vehicle cab with alignment
bracket set Amarok -VAS 6637-
Note
Detailed information on setting up the alignment bracket set can be found in the installation plans enclosed with
the alignment bracket set.
38 Rep. gr.00 - Technical data
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Body Repairs - Edition 10.2010
7.5 Alignment bracket fixture overview of vehicle cab
Alignment bracket fixture overview of front of vehicle cab with
alignment bracket set Amarok -VAS 5007/48-
Amarok 2011 ➤
Alignment bracket fixture overview of rear of vehicle cab with
alignment bracket set Amarok -VAS 5007/48-
7. Alignment jig 39
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
Note
Detailed information on setting up the portal gauge supplementary set can be found in the installation plans
enclosed with the portal gauge set.
40 Rep. gr.00 - Technical data
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.
50 – Body - front
RO: 50 34 55 00
1 Renewing cross member
WARNING
Observe safety notes!
Safety notes ⇒ General Information; Body Repairs, General Body
Repairs ; Safety notes
Amarok 2011 ➤
Body Repairs - Edition 10.2010
1. Renewing cross member 41
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.
Amarok 2011 ➤
Body Repairs - Edition 10.2010
1.1 Removing
Carry out the following work:
Note
♦
The bolt for the cross member support -1- was discontinued in production as of July 2010 ▶. Instead the
front cross member support was welded to the frame longitudinal member -2- in production.
♦
If a cross member with bolted support requires replacement, the support must be welded to the new cross
member when installing the cross member. The bolting point in the frame longitudinal member must be
closed with weld and the support is then welded in position.
– Models ◀July 2010; undo bolt -1- of cross member support.
– Models July 2010 ▶: separate original joint of cross member
support.
– Separate original joint of cross member from front.
– Remove cross member from frame.
42 Rep. gr.50 - Body - front
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.
Amarok 2011 ➤
Body Repairs - Edition 10.2010
– Remove remaining material -1- on frame longitudinal mem‐
bers.
– Grind welding surfaces and welding edges down to bare met‐
al.
1.2 Installing
1.2.1 Preparing new part
Replacement part
♦ Cross member
Carry out the following work:
1. Renewing cross member 43
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
– Grind welding edges back to bare metal from inside.
– Grind support down to bare metal.
44 Rep. gr.50 - Body - front
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.
Amarok 2011 ➤
Body Repairs - Edition 10.2010
1.2.2 Welding in
Carry out the following work:
Note
♦
It is no longer permissible to bolt the cross member support to the frame longitudinal member.
♦
If a cross member with bolted support was installed in the vehicle, the threaded connection in the frame
longitudinal member must be closed with weld before installing the new cross member.
♦
Then the support must be welded to the frame longitudinal member, SG continuous weld seam.
– Adapt new part using alignment bracket set and fix in place.
– Weld in cross member, SG continuous weld seam.
– Weld in support, SG continuous weld seam.
1. Renewing cross member 45
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
RO: 50 34 55 10
2 Renewing deformation element
WARNING
Observe safety notes!
Safety notes ⇒ General Information; Body Repairs, General Body
Repairs ; Safety notes
2.1 Tools
Special tools and workshop equipment required
♦ Resistance spot welder -VAS 6239 A-
♦ Resistance spot welder -VAS 6535-
♦ Accessory pack -VAS 6535 /1-
2.2 Removing
Carry out the following work:
46 Rep. gr.50 - Body - front
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.
– Separate original joint.
– Remove deformation element from body.
– Remove remaining material.
– Grind welding edges back to bare metal.
2.3 Installing
Note
The use of different types and different thicknesses of steel re‐
quires that one of the welding units (inverter) listed under Tools
must be used for proper spot welding ⇒ „2.1 Tools“, page 46 .
2.3.1 Preparing replacement part
Replacement part
♦ Deformation element
Carry out the following work:
– Grind welding surfaces on both sides back to bare metal.
Amarok 2011 ➤
Body Repairs - Edition 10.2010
2. Renewing deformation element 47
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.
Amarok 2011 ➤
Body Repairs - Edition 10.2010
2.3.2 Welding in
Carry out the following work:
– Adapt new part on both sides according to -dimension a- and
fix in place.
Dimension a = 270 mm
48 Rep. gr.50 - Body - front
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– Weld in deformation element, RP spot weld seam.
Amarok 2011 ➤
Body Repairs - Edition 10.2010
2. Renewing deformation element 49
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.
Amarok 2011 ➤
Body Repairs - Edition 10.2010
RO: 50 60 55 00
3 Renewing headlight mounting
WARNING
Observe safety notes!
Safety notes ⇒ General Information; Body Repairs, General Body
Repairs ; Safety notes
3.1 Tools
Special tools and workshop equipment required
♦ Resistance spot welder -VAS 6239 A-
♦ Resistance spot welder -VAS 6535-
♦ Accessory pack -VAS 6535 /1-
3.2 Removing
• Deformation element already removed
⇒ „2 Renewing deformation element“, page 46 .
Carry out the following work:
50 Rep. gr.50 - Body - front
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
– Separate original joint.
3. Renewing headlight mounting 51
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
– Unscrew bolt -1- for cab mounting.
– Separate original joint.
– Heat bonding surface -1- with hot air blower -V.A.G 1416- .
– Remove headlight mounting -2- from body.
52 Rep. gr.50 - Body - front
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– Remove remaining material.
– Grind bonding surface and welding surfaces on both sides
back to bare metal.
Amarok 2011 ➤
Body Repairs - Edition 10.2010
3.3 Installing
Note
The use of different types and different thicknesses of steel re‐
quires that one of the welding units (inverter) listed under Tools
must be used for proper spot welding ⇒ „3.1 Tools“, page 50 .
3.3.1 Preparing replacement part
Replacement parts
♦ Headlight mounting
♦ Body adhesive 2K adhesive -D 180 KD3 A2-
Carry out the following work:
3. Renewing headlight mounting 53
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
– Drill specified holes in new part, ∅ 7.0 mm.
– Grind welding surfaces on both sides back to bare metal.
54 Rep. gr.50 - Body - front
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3.3.2 Welding in
Carry out the following work:
– Apply body adhesive 2K adhesive -D 180 KD3 A2- to bonding
surface.
Note
♦
Apply adhesive bead sufficiently thickly so that optimal bond‐
ing with the body is guaranteed.
♦
New part must be welded in within 90 minutes or adhesion of
adhesive will be impaired.
Amarok 2011 ➤
Body Repairs - Edition 10.2010
3. Renewing headlight mounting 55
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
– Adapt new part with vehicle standing on its wheels or on align‐
ment bracket set and hold in position.
– Check fit with all add-on parts.
– Weld in headlight mounting, RP spot weld seam and SG plug
weld seam.
– Install bolt -1- for cab mounting.
– Weld in headlight mounting, SG plug weld seam.
– Install deformation element ⇒ „2.3 Installing“, page 47 .
56 Rep. gr.50 - Body - front
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RO: 50 53 55 00
4 Renewing wing connecting plate
WARNING
Observe safety notes!
Safety notes ⇒ General Information; Body Repairs, General Body
Repairs ; Safety notes
1 - Bonded areas
2 - Cutting point
❑ The parting cut is per‐
mitted for other forms of
damage.
4.1 Tools
Amarok 2011 ➤
Body Repairs - Edition 10.2010
Special tools and workshop equipment required
♦ Resistance spot welder -VAS 6239 A-
♦ Resistance spot welder -VAS 6535-
♦ Accessory pack -VAS 6535 /1-
4. Renewing wing connecting plate 57
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
4.2 Removing
Carry out the following work:
– Bend up metal tab -1-.
– Separate original joint.
– Heat bonded areas with hot air blower -V.A.G 1416- .
– Remove wing connecting plate from body.
58 Rep. gr.50 - Body - front
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.
Body Repairs - Edition 10.2010
Amarok 2011 ➤
– Remove remaining material.
– Grind bonding surfaces and welding surfaces on both sides
back to bare metal.
4.3 Installing
Note
The use of different types and different thicknesses of steel re‐
quires that one of the welding units (inverter) listed under Tools
must be used for proper spot welding ⇒ „4.1 Tools“, page 57 .
4.3.1 Preparing replacement part
Replacement parts
♦ Wing connecting plate
♦ Body adhesive 2K adhesive -D 180 KD3 A2-
4. Renewing wing connecting plate 59
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
Carry out the following work:
– Drill specified holes in new part, ∅ 7.0 mm.
– Grind welding surfaces on both sides back to bare metal.
4.3.2 Welding in
Carry out the following work:
– Apply body adhesive 2K adhesive -D 180 KD3 A2- to bonding
surface.
60 Rep. gr.50 - Body - front
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
Note
♦
Apply adhesive bead sufficiently thickly so that optimal bonding with the body is guaranteed.
♦
New part must be welded in within 90 minutes or adhesion of adhesive will be impaired.
– Adapt new part with vehicle standing on its wheels or on align‐
ment bracket set and fix in position.
– Check fit with all add-on parts.
– Weld in wing connecting plate, RP spot weld seam and SG
plug weld seam.
– Bend metal tab -1- back.
4. Renewing wing connecting plate 61
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.
Amarok 2011 ➤
Body Repairs - Edition 10.2010
RO: 50 53 55 10
5 Renewing connection piece
WARNING
Observe safety notes!
Safety notes ⇒ General Information; Body Repairs, General Body
Repairs ; Safety notes
5.1 Tools
Special tools and workshop equipment required
♦ Resistance spot welder -VAS 6239 A-
♦ Resistance spot welder -VAS 6535-
♦ Accessory pack -VAS 6535 /1-
5.2 Removing
Note
Make parting cuts with pneumatic jig-saw -V.A.G 1523- only. Do not damage inner reinforcements.
62 Rep. gr.50 - Body - front
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Carry out the following work:
Body Repairs - Edition 10.2010
Amarok 2011 ➤
– Make parting cut.
– Separate original joint.
– Heat bonding surface -1- with hot air blower -V.A.G 1416- .
– Remove connection piece from body.
– Remove remaining material.
– Grind bonding surfaces and welding surfaces on both sides
back to bare metal.
5. Renewing connection piece 63
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
5.3 Installing
Note
The use of different types and different thicknesses of steel re‐
quires that one of the welding units (inverter) listed under Tools
must be used for proper spot welding ⇒ „5.1 Tools“, page 62 .
5.3.1 Preparing replacement part
Replacement parts
♦ A-pillar reinforcement
♦ Body adhesive 2K adhesive -D 180 KD3 A2-
Carry out the following work:
– Transfer dimension for parting cut from body and carry out.
– Drill out connection piece from A-pillar reinforcement.
– Punch specified holes in new part, ∅ 7.0 mm.
– Grind bonding surface back to bare metal.
– Grind welding surfaces on both sides back to bare metal.
5.3.2 Welding in
Carry out the following work:
– Apply body adhesive 2K adhesive -D 180 KD3 A2- to bonding
surface.
Note
♦
Apply adhesive bead sufficiently thickly so that optimal bond‐
ing with the body is guaranteed.
♦
New part must be welded in within 90 minutes or adhesion of
adhesive will be impaired.
64 Rep. gr.50 - Body - front
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– Adapt new part with vehicle standing on its wheels or on align‐
ment bracket set and fix in position.
– Check fit with bolt-on parts.
– Weld in connection piece, RP spot weld seam, SG plug weld
seam and SG continuous weld seam.
– Seal cavity after welding work.
Amarok 2011 ➤
Body Repairs - Edition 10.2010
5. Renewing connection piece 65
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
RO: 50 72 55 70
6 Renewing upper wheel housing lon‐
gitudinal member
WARNING
Observe safety notes!
Safety notes ⇒ General Information; Body Repairs, General Body
Repairs ; Safety notes
6.1 Tools
Special tools and workshop equipment required
♦ Resistance spot welder -VAS 6239 A-
♦ Resistance spot welder -VAS 6535-
♦ Accessory pack -VAS 6535 /1-
6.2 Removing
• Deformation element already removed
⇒ „2 Renewing deformation element“, page 46
• Headlight mounting already removed
⇒ „3 Renewing headlight mounting“, page 50
• Wing connecting plate already removed
⇒ „4 Renewing wing connecting plate“, page 57
• Connection piece already removed
⇒ „5 Renewing connection piece“, page 62
Carry out the following work:
66 Rep. gr.50 - Body - front
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– Separate original joint.
– Remove upper longitudinal member for wheel housing from
body.
Amarok 2011 ➤
Body Repairs - Edition 10.2010
6. Renewing upper wheel housing longitudinal member 67
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
– Remove remaining material.
– Grind welding surfaces on both sides back to bare metal.
6.3 Installing
Note
The use of different types and different thicknesses of steel re‐
quires that one of the welding units (inverter) listed under Tools
must be used for proper spot welding ⇒ „6.1 Tools“, page 66 .
6.3.1 Preparing replacement part
Replacement part
♦ Upper longitudinal member for wheel housing
68 Rep. gr.50 - Body - front
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Carry out the following work:
– Grind welding surfaces on both sides back to bare metal.
6.3.2 Welding in
Carry out the following work:
Amarok 2011 ➤
Body Repairs - Edition 10.2010
– Adapt new part with vehicle standing on its wheels or on align‐
ment bracket set and fix in position.
– Check fit with bolt-on parts.
– Weld in upper longitudinal member for wheel housing, RP spot
weld seam and SG plug weld seam.
6. Renewing upper wheel housing longitudinal member 69
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
• Install wing connecting plate ⇒ „4.3 Installing“, page 59 .
• Install connection piece ⇒ „5.3 Installing“, page 64 .
• Install headlight mounting ⇒ „3.3 Installing“, page 53 .
• Install deformation element ⇒ „2.3 Installing“, page 47 .
70 Rep. gr.50 - Body - front
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RO: 50 74 55 00
7 Renewing front wheel housing
Observe safety notes!
Safety notes ⇒ General Information; Body Repairs, General Body
Repairs ; Safety notes
7.1 Removing
• Deformation element already removed
• Headlight mounting already removed
• Wing connecting plate already removed
• Connection piece already removed
• Upper longitudinal member for wheel housing already re‐
WARNING
⇒ „2 Renewing deformation element“, page 46
⇒ „3 Renewing headlight mounting“, page 50
⇒ „4 Renewing wing connecting plate“, page 57
⇒ „5 Renewing connection piece“, page 62
moved
⇒ „6 Renewing upper wheel housing longitudinal member“,
page 66 .
Carry out the following work:
Amarok 2011 ➤
Body Repairs - Edition 10.2010
7. Renewing front wheel housing 71
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
– Separate original joint.
– Remove front wheel housing from body.
– Remove remaining material.
– Grind welding surface on both sides back to bare metal.
7.2 Installing
7.2.1 Preparing replacement part
Replacement part
♦ Front wheel housing
72 Rep. gr.50 - Body - front
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Carry out the following work:
– Punch holes in new part, ∅ 7.0 mm.
– Grind welding surface on both sides back to bare metal.
7.2.2 Welding in
Carry out the following work:
Amarok 2011 ➤
Body Repairs - Edition 10.2010
– Adapt new part with vehicle standing on its wheels or on align‐
ment bracket set and fix in position.
– Check fit with bolt-on parts.
– Weld in front wheel housing, SG plug weld seam.
7. Renewing front wheel housing 73
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
• Install upper longitudinal member for wheel housing
⇒ „6.3 Installing“, page 68 .
• Install wing connecting plate ⇒ „4.3 Installing“, page 59 .
• Install connection piece ⇒ „5.3 Installing“, page 64 .
• Install headlight mounting ⇒ „3.3 Installing“, page 53 .
• Install deformation element ⇒ „2.3 Installing“, page 47 .
74 Rep. gr.50 - Body - front
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RO: 50 80 55 00
8 Renewing front part of longitudinal
member - part section 1-
WARNING
Observe safety notes!
Safety notes ⇒ General Information; Body Repairs, General Body
Repairs ; Safety notes
8.1 Removing
• Cross member already removed
⇒ „1 Renewing cross member“, page 41 .
Note
Parting cut must be straight.
Amarok 2011 ➤
Body Repairs - Edition 10.2010
Carry out the following work:
8. Renewing front part of longitudinal member - part section 1- 75
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
– Carry out parting cut -1- as per -dimension a-.
Dimension a = 60 mm from mounting bracket
– Remove front section of longitudinal member.
76 Rep. gr.50 - Body - front
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
– Remove remaining material.
– Grind welding surface back to bare metal.
8.2 Installing
8.2.1 Preparing replacement part
Replacement part
♦ Front longitudinal member complete
Carry out the following work:
8. Renewing front part of longitudinal member - part section 1- 77
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
– Transfer parting cut -1- from body to new part.
– Make parting cut -1-.
– Grind welding surface back to bare metal.
78 Rep. gr.50 - Body - front
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8.2.2 Welding in
Carry out the following work:
– Adapt new part to vehicle standing on alignment bracket set
and fix in place.
– Check fit with adjacent parts.
– Weld parting cut all round in front section of longitudinal mem‐
ber -1- adhering to -air gap dimension a-, SG continuous weld
seam.
Dimension a = 3.5 mm + 0.5 mm
Note
Amarok 2011 ➤
Body Repairs - Edition 10.2010
♦
Adherence to -air gap dimension a- is vital to guarantee proper through-welding.
♦
Before welding longitudinal member, check welder settings; weld several „test seams“ and check roots of
„test weld seams“ (correct welding parameters if necessary).
♦
SG continuous weld seam must not be reworked (ground or smoothed)!
– Carry out cavity preservation on front longitudinal member.
8. Renewing front part of longitudinal member - part section 1- 79
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
– Install front cross member ⇒ „1.2 Installing“, page 43 .
80 Rep. gr.50 - Body - front
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RO: 50 79 55 02
9 Renewing longitudinal member - part
section 2-
WARNING
Observe safety notes!
Safety notes ⇒ General Information; Body Repairs, General Body
Repairs ; Safety notes
9.1 Removing
• Cross member already removed
⇒ „1 Renewing cross member“, page 41 .
Note
Parting cut must be straight.
Amarok 2011 ➤
Body Repairs - Edition 10.2010
Carry out the following work:
9. Renewing longitudinal member - part section 2- 81
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
– Carry out parting cut -1- as per -dimension a-.
Dimension a = 60 mm from mounting bracket
– Remove longitudinal member.
82 Rep. gr.50 - Body - front
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
– Remove remaining material.
– Grind welding surface back to bare metal.
9.2 Installing
9.2.1 Preparing replacement part
Replacement parts
♦ Front longitudinal member complete
♦ Mounting bracket for front for cab mounting
Carry out the following work:
9. Renewing longitudinal member - part section 2- 83
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
– Transfer parting cut -1- from body to new part.
– Make parting cut -1-.
– Grind welding surface back to bare metal.
– Grind welding edges of mounting bracket back to bare metal.
84 Rep. gr.50 - Body - front
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9.2.2 Producing longitudinal member reinforcement
Carry out the following work:
Amarok 2011 ➤
Body Repairs - Edition 10.2010
– Using in-house material, produce longitudinal member rein‐
forcement according to deviations -a-, -b- and -c-.
Dimension a = 90 mm
Dimension b = 40 mm
Dimension c = 60 mm
– Grind welding edges of longitudinal member reinforcement
back to bare metal.
9. Renewing longitudinal member - part section 2- 85
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
9.2.3 Welding in
Carry out the following work:
– Adapt new part to vehicle standing on alignment bracket set
and fix in place.
– Check fit with adjacent parts.
– Weld parting cut all round in longitudinal member -1- adhering
to -air gap dimension a-, SG continuous weld seam.
Dimension a = 3.5 mm + 0.5 mm
Note
♦
Adherence to -air gap dimension a- is vital to guarantee proper through-welding.
♦
Before welding longitudinal member, check welder settings; weld several „test seams“ and check roots of
„test weld seams“ (correct welding parameters if necessary).
♦
SG continuous weld seam must not be reworked (ground or smoothed)!
86 Rep. gr.50 - Body - front
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
– Adapt longitudinal member reinforcement -1- to longitudinal
member -2- and fix in position.
– Weld in longitudinal member reinforcement -1- all round, SG
continuous weld seam.
9. Renewing longitudinal member - part section 2- 87
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
– Adapt mounting bracket -1- to fit and fix in position.
– Weld in mounting bracket, SG continuous weld seam.
– Carry out cavity preservation on front longitudinal member.
– Install front cross member ⇒ „1.2 Installing“, page 43 .
88 Rep. gr.50 - Body - front
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RO: 50 79 55 00
10 Renewing longitudinal member com‐
plete
WARNING
Observe safety notes!
Safety notes ⇒ General Information; Body Repairs, General Body
Repairs ; Safety notes
1 - Longitudinal member com‐
plete
❑ Slid into middle part of
frame and welded.
2 - Cab mounting
3 - Suspension strut mounting
4 - Mounting bracket
❑ Welded to longitudinal
member.
❑ Replaced during repairs
as well.
❑ Welded to longitudinal
member.
❑ Replaced during repairs
as well.
❑ Welded to longitudinal
member.
❑ Replaced during repairs
as well.
5 - Anti-roll bar mounting
❑ Welded to longitudinal
member.
❑ Replaced during repairs
as well.
6 - Brake line mounting
❑ Welded to longitudinal
member.
❑ Replaced during repairs
as well.
7 - Reinforcement
❑ Welded to longitudinal
member.
❑ Replaced during repairs as well.
8 - Mounting for engine mounting
❑ Welded to longitudinal member.
❑ Replaced during repairs as well.
9 - Bracket
❑ Welded to suspension strut.
❑ For ABS hydraulic unit -N55- and ABS control unit -J104- .
❑ Replaced during repairs as well.
Amarok 2011 ➤
Body Repairs - Edition 10.2010
10. Renewing longitudinal member complete 89
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
10 - Mounting for cross member for gearbox mounting
❑ Welded to longitudinal member.
❑ Replaced during repairs as well.
11 - Reinforcing plate
❑ Welded to longitudinal member and frame.
❑ Replaced during repairs as well.
10.1 Removing
Caution
The frame of the Amarok and the parts fitted on it are welded
using SG continuous weld seams.
When separating individual welded seams, ensure that the
weld edges of adjacent parts are not damaged.
If the weld edges of separated parts do not lie on the frame
when rewelding, then replace these parts.
• The cab must be separated from the frame for this repair. Re‐
moving cab ⇒ General body repairs, exterior; Rep. gr. 55 ;
Cab .
• Cross member already removed
⇒ „1 Renewing cross member“, page 41 .
Carry out the following work:
90 Rep. gr.50 - Body - front
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
– Separate original joint of anti-roll bar mounting -1-.
– Remove anti-roll bar mounting -1- from longitudinal member
and cross member.
– Remove material remains on cross member.
– Grind welding surfaces on cross member down to bare metal.
10. Renewing longitudinal member complete 91
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
– Separate original joints of cross members -1- and -2-.
Note
♦
Ensure the weld edges of the cross member are not damaged when separating the SG continuous weld
seams.
♦
If the weld edges of the separated cross member do not lie on the longitudinal member when rewelding,
then replace this part.
92 Rep. gr.50 - Body - front
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Body Repairs - Edition 10.2010
Amarok 2011 ➤
– Separate original joints of reinforcement -1- and remove from
frame.
– Separate original joints of cross members -2- and -3- from be‐
low.
Note
♦
Ensure the weld edges of the cross member are not damaged when separating the SG continuous weld
seams.
♦
If the weld edges of the separated cross members do not lie on the longitudinal member when rewelding,
then replace these parts.
10. Renewing longitudinal member complete 93
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Amarok 2011 ➤
Body Repairs - Edition 10.2010
– Separate original joint of reinforcement -1- and remove from
frame.
– Undo bolts -3- on both sides and remove middle part -2- of
cross member.
94 Rep. gr.50 - Body - front
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