Body Repairs PDF

Service
Body Repairs
Amarok 2011
Edition 10.2010
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Service Department. Technical Information

Service
Repair Group overview for Body Repairs
Repair Group
00 - Technical data
50 - Body - front
51 - Body - centre
53 - Body - rear
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Technical information should always be available to the foremen and mechanics, because their
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careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and cted agen
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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

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
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7.4 Alignment bracket fixture overview of vehiclelkcab gen AG
o swa . . . . . . . . . . . . . .do. e.s.no. . . . . . . . . . . . . . . 38
7.5 Alignment bracket fixture overview of vehicle ed
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cab . . . . . . . . . . . . . . . . . . t.gu. a.ra. . . . . . . . . . . 39
ris nte
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50 - Body - front . . . . . . . . . . . . . . . .s a.ut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .or .ac . . . . . 41
s
1 Renewing cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
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1.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
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1.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
erm
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2 Renewing deformation element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

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2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
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2.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
spec
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2.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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3 Renewing headlight mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
rrectness of i
3.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
l purpos
3.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4 Renewing wing connecting plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
nform
ercia
4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
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4.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
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5 Renewing connection piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

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5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
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5.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
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5.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
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6 Renewing upper wheel housing longitudinal member . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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66
6.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
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Contents i
Amarok 2011
6.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7 Renewing front wheel housing . . . . . . n. A. G. ..V.ol.ks. w. a.g.en. A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
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7.1 Removing . . . . . . . . . . . . . . . .V.ol.ks.w.a. . . . . . . . . . . . . . . . o.e.s n. o.t . . . . . . . . . . . . . . . . . . . . . . 71
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7.2 Installing . . . . . . . . . . . . .is.e.d b. . . . . . . . . . . . . . . . . . . . . . . . . . . . .ar.an. . . . . . . . . . . . . . . . . . . 72
r tee
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8 Renewing front part of alongitudinal
ut member - part section 1- . . . . . . . .or.a . . . . . . . . . . . . . . . 75
s c
8.1 Removing . . . . . . . .s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
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8.2 nl
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
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9 Renewing longitudinal member - part section 2- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
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9.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
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9.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
, is n
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10 Renewing longitudinal member complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
spec
10.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
es, in part or in w
t to the co
10.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
51 - Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
rrectness of i
1 Renewing roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
l purpos
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

1.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
nform
ercia
1.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

m
at
2 Renewing front cross member for roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
om
ion
2.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
c
in t
or
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2.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

at
do
riv
3 Renewing roof reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

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cum
for
en
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3.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

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op
3.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
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4 Renewing rear roof cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
py by
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4.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
cted
125
agen
Prote AG.
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
Amarok 2011
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
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Contents iii
Amarok 2011
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iv Contents
Amarok 2011
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.
AG. Volkswagen AG d
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t to the co
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cial p
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mer
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i
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Vehicle identification number (chassis number) on the body:

The vehicle identification number (chassis number) is visibly
stamped into the lower left windscreen flange -arrow A-.
1. Key vehicle data 1

Amarok 2011
Vehicle identification number (chassis number) on the vehicle

frame:
The vehicle identification number (chassis number) is visibly
stamped into the right vehicle frame longitudinal member
AG. Volkswagen AG d
-arrow B-. ksw
agen oes
n
Vol ot g
d by ua
ran
ise tee
or
Noteauth or
ac
ss
ce
e
According to the legislation in Brazil, Argentina and Mexico, a shortened vehicle ID number (chassis num
nl
pt
du
an
ber) is located at 3 further points within the vehicle.
itte
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ab
The additional identification consists of an identification plate which cannot be removed without destroying
ility
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it.
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Additional, shortened vehicle identification number (chassis num

ber) for Brazil, Argentina and Mexico:
The vehicle identification number (chassis number) is stuck on
to the right wheel housing in the engine compartment
-arrow A-.
to the right front passenger seat -arrow C-.
2 Rep. gr.00 - Technical data

AG. Volkswagen AG d
agen oes
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V
d by gu
ara Amarok 2011
ise nte
thor Body Repairs
eo - Edition 10.2010
au ra
ss c
ce
le
un
pt
to the right B-pillar -arrow B-.
an
d
itte
y li
erm
1.2 Identification plate
ab
ility
ot p
wit
The identification plate -arrow- is stuck on the left B-pillar.
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n
1.3 Vehicle data sticker
thi
te
sd
iva
o
pr
c
The vehicle data sticker -arrow- is located in the footwell on
um
r
fo
en
the driver's side.
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1. Key vehicle data 3

Amarok 2011
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.
AG. Volkswagen AG d
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Prote AG.

Amarok 2011
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.180C, 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 AG. Volkswagen AG d
agen oes
ksw
between A-pillar rein by
Vol not
gu
ara
forcement and inner rised
nte
panel. ut
ho eo
ra
s a c
s
2 - Lower C-pillar
ce
e
nl
pt
du
an
itte
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between C-pillar outer
erm
ab
skin and C-pillar rein
ility
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forcement.
wit
, is n
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hole
between C-pillar rein
spec
forcement and inner
es, in part or in w
t to the co
panel.
3 - Lower B-pillar
rrectness of i
between B-pillar outer
l purpos
skin and B-pillar rein

forcement.
nform
ercia

between B-pillar rein
m
at
om
forcement and inner

ion
c
panel.
in t
or
his
te
4 - Lower A-pillar
a
do
priv
cum

for
en
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between A-pillar outer

n
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skin and A-pillar rein Cop py
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forcement. opyri
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Moulded foam element by c lksw

cted agen
between A-pillar rein Prote AG.
forcement and inner

panel.
As these temperatures cannot be achieved under normal work

shop conditions, proceed as follows:
Remove foam material remains on vehicle.
3. Moulded foam elements 5

Amarok 2011
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. gen AG
. Volkswagen AG
a does
lksw not
Fix moulded foam element to vehicle.
db
yV
o gu
ara
e nte
ris
Secure new part (e.g. A-pillar)ut in position. Apply gentle pres
ho eo
ra
sure to contact new part in sarea
sa of moulded foam element and c
weld in.
ce
e
nl
pt
du
an
Do not do perform shielded arc welding within 15 mm on either
itte
y li
side of moulded foam element.
erm
ab
ility
ot p
Carry out cavity preservation on repair area after painting ve
wit
, is n
hicle.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
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ate
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Prote AG.

Amarok 2011
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 .
AG. Volkswagen AG d
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Prote AG.
4. Galvanized body parts 7

Amarok 2011
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
AG. Volkswagen AG d
agen oes
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Rep. gr.00 - Technical data Prote AG.
Amarok 2011
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
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Prote AG.
5. Body panel gaps/shut lines 9

Amarok 2011
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
AG. Volkswagen AG d
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Prote AG.

Amarok 2011
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 agen
AG. Volkswagen AG d
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P - 2.0 mm 0.5 mm ed by
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R - 35.0 mm 5.0 mm aut
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V - 1.0 mm 0.3 mm
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Prote AG.

Amarok 2011
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
AG. Volkswagen AG d
agen oes
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nl
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du
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es, in part or in w
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nf
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Prote AG.

Amarok 2011
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.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
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erm
ab
ility
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wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
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r
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by c lksw
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Prote AG.

Amarok 2011
U - 10.5 mm 3.0 mm
Shut line between rear
bumper and drop sides.
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
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un
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d
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t to the co
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cial p
f inform
mer
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c
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Prote AG.

Amarok 2011
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
Ma a - 1,320 mm 4.0 mm
Dimension between cab
mounting 2
Ma b - 1,015 mm 3.0 mm
Dimension between
suspension strut mount
ings
Ma c - 660 mm 3.0 mm
Dimension diagonally
between assembly swa
gen AG
. Volkswagen AG
does
mountings by
Volk not
gu
ara
ed nte
Ma d - 645 mm 3.0 ris
ho mm e
ut or
Dimension sbetween
s a
as ac
sembly mountings
ce
le
un
pt
an
d
Ma e - 1,040 mm 4.0 mm
itte
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rm
ab

pe
ility
mounting 1
ot
wit
, is n
h re
Ma f - 800 mm 3.0 mm
hole
spec
Inner dimension be
es, in part or in w
tween frame longitudi

t to the co
nal members
rrectness of i
l purpos
nform
mercia
a
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tion in
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Front lower frame dimensions co Vo
by lksw
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Prote AG.
6. Body dimensions 15
lkswage es n
Amarok 2011 d by Vo ot g
ua
ran
Body Repairs - hEdition
orise
10.2010 tee
ut or
a ac
ss
Ma a - 800 mm 3.0 mm
ce
le
un
pt
Inner dimension be
an
d
tween frame longitudi itte
y li
rm
ab
nal members
pe
ility
ot
wit
Ma b - 815 mm 2.0 mm
, is n
h re
Dimension between an
hole
spec
ti-roll bar bolting points
es, in part or in w
t to the co
Ma c - 840 mm 2.0 mm
Dimension between
front axle mountings
rrectness of i
l purpos
nform
mercia
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tion in
r
te o
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cted agen
Prote AG.

Amarok 2011
6.1.2 Centre frame dimensions

Lower centre frame dimensions
Ma a - 780 mm 2.0 mm
Dimension between
front axle rear mount
ings
Ma b - 810 mm 3.0 mm
Dimension between
gearbox mountings
Ma c - 490 mm 2.5 mm
Dimension between re
bound strap bolting
points
AG. Volkswagen AG d
agen oes
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d by ara
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or eo
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nl
pt
du
an
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ility
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hole
spec
es, in part or in w
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nf
ercia
orm
m
atio
om
n in
c
Upper centre frame dimensions

or
thi
te
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Prote AG.
Amarok 2011
Ma a - 1,340 mm 4.0 mm
mounting 3
Ma b - 1,100 mm 4.0 mm
Dimension between AG. Volkswagen AG d
load surface bolting lksw
agen oes
not
point 1 d by Vo gu
ara
rise nte
Ma c - 1,100 mm 4.0 mm utho eo
ra
a
Dimension between ss c
ce
le
load surface bolting
un
pt
point 2
an
d
itte
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erm
ab
Ma d - 1,100 mm 4.0 mm
ility
ot p
Dimension between
wit
is n
h re
ole,
point 3
spec
Ma e - 910 mm 3.0 mm
t to the co
Inner dimension be
tween frame rear longi
rrectne
tudinal members
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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Cop py
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Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011
6.1.3 Rear frame dimensions

Upper centre frame dimensions
Ma a - 1,340 mm 4.0 mm
mounting 3
Ma b - 1,100 mm 4.0 mm
Dimension between
point 1
Ma c - 1,100 mm 4.0 mm
Dimension between
point 2
Ma d - 1,100 mm 4.0 mm
Dimension between
point 3
Ma e - 910 mm 3.0 mm
Inner dimension be
tween frame rear longi
tudinal members
AG. Volkswagen AG d
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d by ara
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du
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erm
ab
ility
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, is n
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hole
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es, in part or in w
t to the co
rrectness of i
l purpos
Rear diagonal frame dimensions

nf
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orm
m
atio
om
n in
or c
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Prote AG.
Amarok 2011
Ma a - 1,345 mm 4.0 mm
between load surface
bolting point 1 on left
and load surface boltingwage
es n
point 2 on right y Volks ot g
u b ara
ed
Ma b - 1,658 mm ris 4.0 mm nte
utho e or
Dimension
ss
a diagonally ac
ce
e
nl
pt
bolting point 1 on right
du
an
itte
and load surface bolting
y li
erm
ab
point 3 on left
ility
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wit
Ma c - 1,195 mm 4.0 mm
, is n
h re
hole
spec
es, in part or in w
bolting point 2 on left
t to the co
and load surface bolting
point 3 on right
rrectness of i
Ma d - 1,488 mm 2.5 mm
l purpos
Dimension between
front leaf spring mount
ing and rear leaf spring
nform
ercia
mounting
m
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Prote AG.

Amarok 2011
AG. Volkswagen AG d
agen oes
lksw not
6.2 Single cab frame dimensions
o
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
6.2.1 Front frame dimensions
ce
le
un
pt
an
d
itte
Frame dimensions between front frame longitudinal members
y li
rm
ab
pe
ility
ot
wit
, is n
Ma a - 1,320 mm 4.0 mm
h re
hole
spec
mounting 2
es, in part or in w
t to the co
Ma b - 1,015 mm 3.0 mm
Dimension between
rrectness of i
suspension strut mount
ings
l purpos
Ma c - 660 mm 3.0 mm
nform
ercia
between assembly
m
mountings
a
com
tion in
Ma d - 645 mm 3.0 mm
r
te o
thi
Dimension between as
s
iva
do
r
sembly mountings
rp
cum
fo
en
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Ma e - 1,040 mm 4.0 mm
n
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Ma f - 800 mm 3.0 mm Prote AG.
Inner dimension be
nal members
Front lower frame dimensions
Amarok 2011
Ma a - 800 mm 3.0 mm
Inner dimension be
nal members
Ma b - 815 mm 2.0 mm
Dimension between an
ti-roll bar bolting points n AG. Volkswagen AG do
lkswage es n
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Ma c - 840 mm 2.0 mm ir se
d b ran
o tee
Dimension between auth or
ac
front axle mountings ss
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e
nl
pt
du
an
itte
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erm
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ility
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Prote AG.
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!

Amarok 2011
6.3 Double cab box dimensions
6.3.1 Front box dimensions

lksw
agen
AG. Volkswagen AG d
oes
n
o ot g
yV ua
Front engine compartment
ise
db box dimensions ran
r tee
ho
aut or
ac
ss
Ma - 956 mm 1.0 mm
ce
e
nl
pt
du
Dimension between
an
itte
y li
lock carrier bolting
erm
ab
points
ility
ot p
wit
Ma - 1,412 mm 2.0 mm
, is n
h re
hole
Dimension between
spec
lamp carriers
es, in part or in w
t to the co
Ma - 982 mm 2.0 mm
Dimension between
wheel housings
rrectness of i
Ma - 758 mm 2.0 mm
l purpos
Dimension wing mount

ing flange
nf
ercia
orm
Ma - 1,742 mm 2.0 mm
m
atio
m
o
n in
or c
between left wing

thi
e
mounting flange at rear

t
sd
iva
o
and right wing mounting
r
rp
cu
o
flange at front
f
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Prote AG.
Front box dimensions
Amarok 2011 AG. Volkswagen AG d
Body Repairs - Edition 10.2010 agen oes
olksw not
byV gu
ara
ed
is nte
Ma - 1,500 mm 2.0 mm hor eo
aut ra
Dimension between ss c
lower part of front lamp
ce
e
nl
pt
du
carriers
an
itte
y li
erm
ab
Ma - 943 mm 2.0 mm
ility
ot p
Dimension between
wit
, is n
middle of lamp carriers
h re
hole
spec
Ma - 935 mm 1.0 mm es, in part or in w
t to the co
Dimension between up
per part of lamp carriers
Ma - 217 mm 2.0 mm
rrectness of i
Dimension cross mem
l purpos
ber to lamp carrier

Ma - 270 mm 2.0 mm
nf
ercia
o
Dimension cross mem
rm
m
ber to lamp carrier
atio
om
n in
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Prote AG.
Front end box dimensions

AG. Volkswagen AG d
agen oes
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ed b ara
nte
Amarok 2011
ris
ut
ho eo
ra
s a c
s
Ma - 950 mm 3.0 mm
ce
e
nl
pt
du
an
Dimension between A-
itte
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pillar and front end
erm
ab
ility
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Ma - 1,067 mm 2.0 mm
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
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Prote AG.
Amarok 2011
6.3.2 Centre box dimensions

Centre box dimensions
Ma - 1,870 mm 3.0 mm
pillars
Ma - 1,870 mm 3.0 mm
Dimension between B-
pillars
Ma - 420 mm 2.0 mm: Di
mension
Upper door hinge to low
er door hinge on A-pillar
Ma - 445 mm 2.0 mm
Upper door hinge to low
er door hinge on B-pillar
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itte
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es, in part or in w
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by
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Prote AG.

Amarok 2011
6.3.3 Rear box dimensions

Rear box dimensions
Ma - 1,195 mm 2.0 mm
Dimension between
roof side members
Ma - 1,465 mm 2.0 mm
Dimension rear panel
aperture
Ma - 340 mm 2.0 mm
Dimension rear window
aperture
Ma - 1,524 mm 3.0 mm
Dimension between
side members
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
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om
n in
or c
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te
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Prote AG.
Amarok 2011
6.4 Single cab box dimensions
6.4.1 Front box dimensions

Front engine compartment box dimensions
Ma - 956 mm 1.0 mm
Dimension between
lock carrier bolting lkswage es n
points d byV
o ot g
ua
ran
ir se tee
Ma - 1,412 mm 2.0 mm utho
or
a ac
Dimension between ss
ce
le
lamp carriers
un
pt
an
d
itte
Ma - 982 mm 2.0 mm
y li
erm
ab
Dimension between
ility
ot p
wheel housings
wit
is n
h re
ole,
Ma - 758 mm 2.0 mm
spec
Dimension wing mount
t to the co
ing flange
Ma - 1,742 mm 2.0 mm
rrectne
between left wing
mounting flange at rear
ss
and right wing mounting
o
cial p
f i
flange at front
nform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
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Cop py
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by
cted agen
Prote AG.
Front box dimensions

Amarok 2011
Ma - 1,500 mm 2.0 mm
Dimension between
lower part of front lamp
carriers
Ma - 943 mm 2.0 mm
Dimension between
middle of lamp carriers
Ma - 935 mm 1.0 mm
AG. Volkswagen AG d
Dimension between up lksw
agen oes
not
per part of lamp carriers d by
Vo gu
ara
ise nte
r
Ma - 217 mm 2.0 mm ut
ho eo
ra
a
Dimension cross mem ss c
ce
e
ber to lamp carrier

nl
pt
du
an
itte
Ma - 270 mm 2.0 mm
y li
erm
ab
Dimension cross mem
ility
ot p
ber to lamp carrier
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
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ion
c
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Front end box dimensions Prote AG.
Amarok 2011
Ma - 950 mm 3.0 mm
Ma - 1,067 mm 2.0 mm
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d ran
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ss
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un
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an
d
itte
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6.4.2 Centre box dimensions

erm
ab
ility
ot p
wit
is n
h re
ole,
Note
spec
Centre box dimensions were not yet available at time of going to

t to the co
print!
rrectne
6.4.3 Rear box dimensions

ss o
cial p
Note
inform
mer
Rear box dimensions were not yet available at time of going to

atio
m
print!
o
n
c
i
or
n thi
te
sd
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pr
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Prote AG.

Amarok 2011
6.5 Double cab load surface dimensions
6.5.1 Upper load surface dimensions

Outer/inner load surface dimensions
Ma - 1,547 mm 2.0 mm AG. Volkswagen AG d

agen oes
Dimension inner side of Volksw not
gu
y
load area side panel d b ara
rise nte
ho eo
Ma - 1,810 mm 2.0 mm aut ra
c
ss
Dimension outer side of
ce
le
un
load area side panel
pt
an
d
itte
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Ma - 2,122 mm 2.0 mm
rm
ab
pe
ility
Diagonal dimension for
ot
wit
, is n
load surface
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
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by
cted agen
Prote AG.
Lashing eye deviations
Amarok 2011
Ma - 1,574 mm 2.0 mm
Dimension between
lashing eyes
Ma - 1,656 mm 2.0 mm
Diagonal dimension be
tween lashing eyes
lkswage es n
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d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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ion
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Prote AG.

Amarok 2011
6.5.2 Lower load surface dimensions

Lower load surface deviations
Ma - 1,663 mm 2.0 mm
Dimension between
front part of wheel hous
ings AG. Volkswagen AG d
agen oes
olksw not
yV gu
Ma - 1,653 mm 2.0 mm ed b ara
nte
ris
Dimension between aut
ho eo
ra
rear part of wheel hous ss c
ings
ce
e
nl
pt
du
an
itte
Ma - 1,420 mm 2.0 mm
y li
erm
ab
Dimension lower part of
ility
ot p
tailboard aperture
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
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Cop py
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rig ht
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co Vo
by lksw
cted agen
Prote AG.
Amarok 2011
6.5.3 Rear load surface dimensions

Rear load surface deviations
Ma - 1,421 mm 2.0 mm
tailboard aperture
Ma - 1,362 mm 2.0 mm
Dimension between D-
pillars
Ma - 1,421 mm 2.0 mm
Dimension upper part of
tailboard aperture
Ma - 381mm 1.0 mm
Dimension tail light
aperture
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
6.6 Single cab load surface dimensions

spec
es, in part or in w
t to the co
6.6.1 Upper load surface dimensions

rrectness of i
l purpos
Note
nform
ercia
Upper load surface dimensions were not yet available at time of

going to print!
m
at
om
ion
c
in t
r
6.6.2 Lower load surface dimensions

o
his
ate
do
priv
cum
for
en
g
Note
n
t.
yi Co
Cop py
t. rig
gh
Lower load surface dimensions were not yet available at time of
ht
pyri by
Vo
going to print!
co lksw
by
cted agen
Prote AG.

Amarok 2011
6.6.3 Rear load surface dimensions

Rear load surface deviations
Ma - 1,421 mm 2.0 mm
tailboard aperture
Ma - 1,362 mm 2.0 mm
Dimension between D-
pillars
Ma - 1,421 mm 2.0 mm
Dimension upper part of
tailboard aperture
Ma - 381mm 1.0 mm
Dimension tail light
aperture
lkswage es n
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d ran
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ss
ce
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nl
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du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
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te
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Prote AG.
Amarok 2011
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-
. Volkswage n AG n AG d
wage oes
Alignment bracket set Amaroky-VAS
Vol
ks 6637- not
gu
b ara
ed
Portal gauge supplement,
ho Amarok -VAS 5007/48-
ris nte
eo
t
au ra
7.2 Alignment bracket fixture overview of complete vehicle ss c
ce
e
nl
pt
du
an
Alignment bracket fixture overview of complete vehicle with align
itte
y li
ment bracket set Amarok -VAS 6637-
erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
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at
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ion
c
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ate
do
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Cop py
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rig ht
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co Vo
by lksw
cted agen
Prote AG.

Amarok 2011
Note
Detailed information on setting up the alignment bracket set can be found in the installation plans enclosed with
the alignment bracket set.
7.3 Alignment bracket fixture overview of vehicle chassis

Alignment bracket fixture overview of vehicle chassis with align
G. Volkswagen AG d
ment bracket set Amarok -VAS 6637- lkswagen A oes
n o ot g
yV ua
db ran
ir se tee
ho
aut or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
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Prote AG.
Note
7. Alignment jig 37
Amarok 2011
7.4 Alignment bracket fixture overview of vehicle cab

Alignment bracket fixture overview of vehicle cab with alignment
bracket set Amarok -VAS 6637-
lkswage es n
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d
itte
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ab
ility
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wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
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Cop py
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Prote AG.
Note

Amarok 2011
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-
lkswage es n
o ot g
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d ran
ir se tee
tho
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ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Alignment bracket fixture overview of rear of vehicle cab with

alignment bracket set Amarok -VAS 5007/48-
m
at
om
ion
c
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or
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ate
do
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for
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Prote AG.
7. Alignment jig 39
AG. Volkswagen AG d
agen oes
olksw not
Amarok 2011 d by
V gu
ara
e nte
Body Repairs - Edition 10.2010 tho ris
eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
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fo
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Cop py
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by c lksw
cted agen
Prote AG.
Note
Detailed information on setting up the portal gauge supplementary set can be found in the installation plans
enclosed with the portal gauge set.

Amarok 2011
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
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
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do
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Cop py
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Prote AG.
1. Renewing cross member 41

Amarok 2011
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.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
en
ng
t.
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Cop py
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rig ht
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by lksw
cted agen
Prote AG.
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

Amarok 2011
lkswage es n
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d ran
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
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do
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rp
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
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

Amarok 2011
Body Repairs - Edition 10.2010 n AG. Volkswagen AG do
lkswage es n
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es, in part or in w
t to the co
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tion in
r
te o
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cum
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en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Grind welding edges back to bare metal from inside.

Grind support down to bare metal.

Amarok 2011
1.2.2 Welding in
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.
AG. Volkswagen AG d
agen oes
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nl
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du
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erm
ab
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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n in
or c
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sd
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
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.

Amarok 2011
RO: 50 34 55 10
2 Renewing deformation element
WARNING

2.1 Tools
Resistance spot welder -VAS 6239 A-
Resistance spot welder -VAS 6535-
Accessory pack -VAS 6535 /1-
2.2 Removing
lkswage es n
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cial p
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mer
atio
om
n
c
i
or
n thi
te
sd
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o
pr
cum
r
fo
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
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agen oes
not
Amarok 2011
ol
byV gu Body Repairs - Edition 10.2010
d ara
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or eo
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Separate original joint.
s aut ra
c
s
Remove deformation element from body.
ce
le
un
pt
an
d
itte
Remove remaining material.
y li
erm
ab
ility
Grind welding edges back to bare metal. ot p
wit
is n
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spec
t to the co
rrectness o
cial p
f inform
mer
2.3 Installing
atio
om
n
c
i
or
n thi
e
Note
t
sd
iva
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pr
cum
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The use of different types and different thicknesses of steel re
en
ng
t.
yi
quires that one of the welding units (inverter) listed under Tools
Co
op py
must be used for proper spot welding 2.1 Tools, page 46 .
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2.3.1 Preparing replacement part
agen
Prote AG.
Replacement part
Deformation element
Grind welding surfaces on both sides back to bare metal.
2. Renewing deformation element 47

Amarok 2011
2.3.2 Welding in
AG. Volkswagen AG d
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es, in part or in w
t to the co
rrectness of i
l purpos
Adapt new part on both sides according to -dimension a- and

nf
ercia
fix in place.
orm
m
atio
m
Dimension a = 270 mm
o
n in
or c
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f
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
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nl
pt
du
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ab
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es, in part or in w
t to the co
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nf
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n in
or c
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sd
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rp
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f
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t.
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Cop py
t. rig
gh
Weld in deformation element, RP spot weld seam.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Renewing deformation element 49

Amarok 2011
RO: 50 60 55 00
3 Renewing headlight mounting
WARNING

3.1 Tools
3.2 Removing
Deformation element already removed
2 Renewing deformation element, page 46 .
AG. Volkswagen AG d
agen oes
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d by ara
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or eo
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aut ra
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ce
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un
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d
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rm
ab
pe
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
ce
le
un
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an
d
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ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3. Renewing headlight mounting 51

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Unscrew bolt -1- for cab mounting.

Heat bonding surface -1- with hot air blower -V.A.G 1416- .
Remove headlight mounting -2- from body.

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
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un
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an
d
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ab
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ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Grind bonding surface and welding surfaces on both sides
back to bare metal.
3.3 Installing
Note


Replacement parts
Headlight mounting
Body adhesive 2K adhesive -D 180 KD3 A2-

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
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ce
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un
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an
d
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ab
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ot p
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is n
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spec
t to the co
Drill specified holes in new part, 7.0 mm.

rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Amarok 2011
3.3.2 Welding in
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
swa
geof
es
adhesive will be impaired. by
Vol
k not
gu
d ara
e nte
ris
utho eo
ra
a c
ss
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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orm
m
atio
om
n in
or c
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cu
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f
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011
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.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
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ce
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un
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wit
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hole
spec
Install bolt -1- for cab mounting.

es, in part or in w
t to the co
Weld in headlight mounting, SG plug weld seam.

Install deformation element 2.3 Installing, page 47 .
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
56
cted agen
Prote
Rep. gr.50 - Body - front
AG.
Amarok 2011
RO: 50 53 55 00
4 Renewing wing connecting plate
WARNING

1 - Bonded areas
2 - Cutting point
The parting cut is per
mitted for other forms of
damage.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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rp
cu
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m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
4.1 Tools
Prote AG.

4. Renewing wing connecting plate 57

Amarok 2011
Body Repairs - Edition 10.2010 agen
AG. Volkswagen AG d
oes
olksw not
y V gu
b ara
4.2 Removing
d
rise nte
tho eo
au ra
Carry out the following work: ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Bend up metal tab -1-.

Heat bonded areas with hot air blower -V.A.G 1416- .
Remove wing connecting plate from body.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
c
Amarok 2011
s
s Body Repairs - Edition 10.2010
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

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


Replacement parts
Wing connecting plate

Amarok 2011

4.3.2 Welding in
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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ris nte
ho eo
aut ra
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ce
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un
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an
d
itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

surface.

Amarok 2011
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.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r

rp
cum
fo
ment bracket set and fix in position.

en
ng
t.
yi Co
op
Check fit with all add-on parts. C py
t. rig
gh ht
yri by
Weld in wing connecting plate, RP spot weld seam and SG cop Vo
by lksw
plug weld seam. cted agen
Prote AG.
Bend metal tab -1- back.

Amarok 2011
RO: 50 53 55 10
5 Renewing connection piece
WARNING
AG. Volkswagen AG d
agen oes
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Observe safety notes! by
Vol not
gu
ara
ed
ris nte
ho eo
aut ra
Safety notes General Information; Body Repairs, General Body ss c
ce
le

un
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an
d
itte
5.1 Tools
y li
erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
5.2 Removing
rrectness
Note
o
cial p
f inform
mer
Make parting cuts with pneumatic jig-saw -V.A.G 1523- only. Do not damage inner reinforcements.
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
rised
Amarok 2011 nte
o eo
aut
h
Body Repairs - Edition 10.2010 ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Make parting cut.

Heat bonding surface -1- with hot air blower -V.A.G 1416- .
Remove connection piece from body.
Grind bonding surfaces and welding surfaces on both sides
back to bare metal.
5. Renewing connection piece 63

Amarok 2011
5.3 Installing
Note


Replacement parts
A-pillar reinforcement
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.
AG. Volkswagen AG d
Grind bonding surface back to bare metal. lksw
agen oes
not
Vo gu
y
Grind welding surfaces on both sides back to bare metal.ise d b ara
nte
or eo
th
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
5.3.2 Welding in
rrectness of i
l purpos

nf
ercia
surface.
orm
m
atio
om
n in
c
Note
or
thi
te
sd
iva
Apply adhesive bead sufficiently thickly so that optimal bond

o
r
rp
cu

o
m
f
en
ng
t.
yi Co
New part must be welded in within 90 minutes or adhesion of Cop py
adhesive will be impaired.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
o Vo
by c lksw
cted agen
Prote AG.
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.
5. Renewing connection piece 65

Amarok 2011
AG. Volkswagen AG d
agen oes
RO: 50 72 55 70 olksw not
y V gu
b ara
6 Renewing upper wheel housing lon
d
rise nte
tho eo
gitudinal member au ra
ss c
ce
le
un
pt
an
d
itte
WARNING
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
6.1 Tools
rrectne
s
s o
cial p
f i
nform
mer
atio
om
n
c
6.2 Removing
i
or
n thi
te
sd
va

i
o
pr
cum
r
2 Renewing deformation element, page 46

fo
en
ng
t.
yi Co
Headlight mounting already removed t. Cop py
3 Renewing headlight mounting, page 50
rig
gh ht
pyri by
Vo
co
Wing connecting plate already removed
by lksw
cted agen
Prote
4 Renewing wing connecting plate, page 57
AG.
Connection piece already removed

5 Renewing connection piece, page 62

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
Separate original joint. co Vo
by lksw
cted agen
Prote
Remove upper longitudinal member for wheel housing from
AG.
body.
6. Renewing upper wheel housing longitudinal member 67

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

6.3 Installing
Note


Replacement part
Upper longitudinal member for wheel housing

Amarok 2011

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
6.3.2 Welding in
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Weld in upper longitudinal member for wheel housing, RP spot
weld seam and SG plug weld seam.
6. Renewing upper wheel housing longitudinal member 69

Amarok 2011
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 .
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
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un
pt
an
d
itte
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ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

lkswage es n
o ot g
byV ua
d ran
ir se
tho tee
or Amarok 2011
u
ss
a ac
ce
e
nl
pt
du
an
itte
y li
RO: 50 74 55 00
erm
ab
ility
7 Renewing front wheel housing
ot p
wit
, is n
h re
hole
spec
WARNING
es, in part or in w
t to the co
rrectness of i
l purpos
7.1 Removing
nform
ercia

m
at
om
2 Renewing deformation element, page 46
ion
c
in t
or
Headlight mounting already removed
his
ate
3 Renewing headlight mounting, page 50
do
priv
cum
or
Wing connecting plate already removed

f
en
ng
t.
4 Renewing wing connecting plate, page 57
yi Co
Cop py
t. rig
Connection piece already removed
gh ht
pyri by
5 Renewing connection piece, page 62
co Vo
by lksw
cted agen
Prote AG.
Upper longitudinal member for wheel housing already re
moved
6 Renewing upper wheel housing longitudinal member,
page 66 .
7. Renewing front wheel housing 71

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab

ility
ot p
Remove front wheel housing from body.

wit
, is n
h re
hole

spec
es, in part or in w
Grind welding surface on both sides back to bare metal.

t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
7.2 Installing
p
cum
for
en
ng
t.
yi Co
Cop py

ht. rig
rig ht
py by
co Vo
by lksw
Replacement part
cted agen
Prote AG.
Front wheel housing

Amarok 2011

Punch holes in new part, 7.0 mm.
Grind welding surface on both sides back to bare metal.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
7.2.2 Welding in
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Weld in front wheel housing, SG plug weld seam.
7. Renewing front wheel housing 73

Amarok 2011
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 .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Amarok 2011
RO: 50 80 55 00
8 Renewing front part of longitudinal

member - part section 1-
WARNING

8.1 Removing
Cross member already removed
1 Renewing cross member, page 41 .
Note
Parting cut must be straight.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
75
cted agen
Prote AG.
8. Renewing front part of longitudinal member - part section 1-
Amarok 2011
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Carry out parting cut -1- as per -dimension a-.

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

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Grind welding surface back to bare metal.
8.2 Installing

Replacement part
Front longitudinal member complete
8. Renewing front part of longitudinal member - part section 1- 77

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Transfer parting cut -1- from body to new part.
l purpos
Make parting cut -1-.

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Amarok 2011
8.2.2 Welding in
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
Adapt new part to vehicle standing on alignment bracket set orm

m
atio
m
and fix in place.

o
n in
or c
Check fit with adjacent parts.

thi
te
sd
iva
Weld parting cut all round in front section of longitudinal mem

r
rp
cu
o
ber -1- adhering to -air gap dimension a-, SG continuous weld

f
en
ng
t.
seam.
yi Co
Cop py
ht. rig
Dimension a = 3.5 mm + 0.5 mm rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
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)!
Carry out cavity preservation on front longitudinal member.
8. Renewing front part of longitudinal member - part section 1- 79

Amarok 2011
Install front cross member 1.2 Installing, page 43 .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011
RO: 50 79 55 02
9 Renewing longitudinal member - part

section 2-
WARNING

9.1 Removing
Note
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
9. Renewing longitudinal member - part section 2- 81

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Carry out parting cut -1- as per -dimension a-.

Remove longitudinal member.

Amarok 2011
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
Remove remaining material. wit

, is n
h re
hole

spec
es, in part or in w
9.2 Installing
t to the co
rrectness of i

l purpos
Replacement parts
nform

mercia
Mounting bracket for front for cab mounting

a
com
tion in

r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
Transfer parting cut -1- from body to new part. opyri
gh by
Vo
ht
c
by lksw
cted agen
Prote AG.
Grind welding edges of mounting bracket back to bare metal.

Amarok 2011
9.2.2 Producing longitudinal member reinforcement

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
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.

Amarok 2011 agen
AG. Volkswagen AG d
oes
ksw
by
Vol not
gu
ara
ed nte
oris e
9.2.3 Welding in th or
au ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Adapt new part to vehicle standing on alignment bracket set

and fix in place.
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


Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
Adapt longitudinal member reinforcement -1- to longitudinal
ole,
spec
member -2- and fix in position.
t to the co
Weld in longitudinal member reinforcement -1- all round, SG
continuous weld seam.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

olkswagen AG
wag en AG. V
Amarok 2011 olks
does
not
yV gu
Body Repairs - Edition
se
d 10.2010
b ara
nte
ri
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
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.

Amarok 2011
RO: 50 79 55 00
10 Renewing longitudinal member com

plete
WARNING

AG. Volkswagen AG d
agen oes
olksw not
1 - Longitudinal member d b com
y V gu
ara
plete rise nte
tho eo
u ra
Slid intossmiddle
a part of c
frame and welded.
ce
le
un
pt
an
d
2 - Cab mounting
itte
y li
rm
ab
Welded to longitudinal
pe
ility
member.
ot
wit
, is n
Replaced during repairs
h re
hole
as well.
spec
es, in part or in w
3 - Suspension strut mounting
t to the co
member.
Replaced during repairs rrectness of i
as well.
l purpos
4 - Mounting bracket
nform
ercia
member.
m
a
com
ti

on in
as well.
r
te o
thi
s
iva
5 - Anti-roll bar mounting

do
r
rp
cum
fo
en
ng
t.
member.
yi Co
Cop py
t. rig
gh ht
yri
as well.
p by
co Vo
by lksw
cted agen
6 - Brake line mounting
Prote AG.
member.
as well.
7 - Reinforcement
member.
Replaced during repairs as well.
8 - Mounting for engine mounting
Welded to longitudinal member.
9 - Bracket
Welded to suspension strut.
For ABS hydraulic unit -N55- and ABS control unit -J104- .
10. Renewing longitudinal member complete 89

Amarok 2011
10 - Mounting for cross member for gearbox mounting

Welded to longitudinal member.
11 - Reinforcing plate
Welded to longitudinal member and frame.
Replaced during repairs as well. agen
AG. Volkswagen AG d
oes
lksw n o ot g
yV ua
edb ran
ris tee
tho
10.1 Removing ss
au
or
ac
ce
e
nl
pt
du
an
Caution
itte
y li
erm
ab
ility
The frame of the Amarok and the parts fitted on it are welded
ot p
wit
using SG continuous weld seams.
, is n
h re
hole
When separating individual welded seams, ensure that the
spec
weld edges of adjacent parts are not damaged.
es, in part or in w
t to the co
If the weld edges of separated parts do not lie on the frame
when rewelding, then replace these parts.
rrectness of i
l purpos
The cab must be separated from the frame for this repair. Re
moving cab General body repairs, exterior; Rep. gr. 55 ;
Cab .
nform
ercia

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
Separate original joint of anti-roll bar mounting -1-.

an
itte
y li
erm
ab
Remove anti-roll bar mounting -1- from longitudinal member

ility
ot p
and cross member.

wit
, is n
h re
Remove material remains on cross member.

hole
spec
Grind welding surfaces on cross member down to bare metal.

es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Amarok 2011
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Separate original joints of cross members -1- and -2-.

es, in part or in w
t to the co
Note
rrectness of i
Ensure the weld edges of the cross member are not damaged when separating the SG continuous weld
l purpos
seams.
If the weld edges of the separated cross member do not lie on the longitudinal member when rewelding,
nf
ercia
then replace this part.

orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

lkswage es n
o ot g
byV ua
ir se
d ran
tee Amarok 2011
o
uth or Body Repairs - Edition 10.2010
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
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.

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
Separate original joint of reinforcement -1- and remove from

ercia
frame.
rm
m
atio
m
Undo bolts -3- on both sides and remove middle part -2- of
o
n in
c
cross member.
or
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Amarok 2011
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
op
Separate original joint of longitudinal member to middle part C py
t. rig
of frame all round.
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
Separate longitudinal member -1- from frame and pull out of

, is n
h re
middle part of frame.

hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Remove material remains from cross members -1- and -2- and
nform
ercia
from middle part of frame -3-.

m
at
om
Grind welding surfaces back to bare metal.

ion
c
in t
or
10.2 Installing
his
ate
do
priv
cum
for
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
yri
Replacement parts
p by
co Vo
by lksw
cted agen
Prote AG.
Front mounting bracket

Anti-roll bar mounting
Reinforcement
Brake line mounting
Suspension strut mounting
Cab mounting
Mounting for cross member for gearbox mounting
Mounting for engine mounting

Amarok 2011
Bracket for hydraulic unit

Reinforcing plate
Grind weld surfaces on front longitudinal member -1- down to
bare metal.
AG. Volkswagen AG d
agen oes
olksw not
Grind welding edges of d bmounting
yV bracket -1- down to baregu
ara
metal. orise nte
eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Grind welding edges of anti-roll bar mounting -1- down to bare

rrectness of i
metal.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Amarok 2011
Grind welding edges of reinforcing -1- down to bare metal.
Grind welding edges of brake line mounting -1- down to bare

metal.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
Grind welding edges of suspension strut mounting -1- down to
spec
bare metal.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
Grind welding edges of cab mounting -1- down to bare metal.

r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011
Grind welding edges of mounting for cross member for gear

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

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

metal.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
Grind welding edges of reinforcing panel -1- down to bare

nl
pt
du
metal.
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
100
by c lksw
cted
Rep. gr.50 - Body - front
agen
Prote AG.
lkswage es n
o ot g
byV ua Amarok 2011
d ran
ir se
tho Body Repairs - Edition
tee
or 10.2010
au ac
ss
10.2.2 Welding in
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Grind welding surfaces -2- on new part down to bare metal.

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

weld several test seams and check roots of test weld
seams (correct welding parameters if necessary).
SG continuous weld seam must not be reworked (ground or
smoothed)!

Amarok 2011
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Weld longitudinal member -1- to middle part of frame -4- all

round, SG continuous weld seam.
Weld cross member -3- to front longitudinal member -1-, SG
Weld cross member -2- to front longitudinal member -1-, SG
Note
For clarity, the alignment jig with alignment bracket set is not shown in the following figures.

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
t
Weld cross member -2- to front longitudinal member -1- from
ion in
below, SG continuous weld seam.
r
te o
thi
s
iva
Weld cross member -3- to front longitudinal member -1- from do

r
rp
c
below, SG continuous weld seam.
um
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Position reinforcing panel -1- on longitudinal member -2- and

weld in all round, SG continuous weld seam.
Adapt mounting for cross member for gearbox mounting -3-
using alignment bracket set and fix in place.
Weld in mounting for cross member for gearbox mounting
-3- all round, SG continuous weld seam.

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
g
Adapt mounting for engine mounting -2- using alignment

n
t.
yi Co
op
bracket set and fix new part -1- in place. C py
ht. rig
rig ht
by
Weld in mounting for engine mounting -2- all round, SG con copy Vo
by lksw
tinuous weld seam. cted agen
Prote AG.

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness
Adapt mounting bracket -1- and anti-roll bar mounting -3- us

o
cial p
f i
ing alignment bracket set and fix in place.

nform
mer
Adapt reinforcing -2- to fit and fix in position.

atio
om
Weld in new parts -1-, -2- and -3-, SG continuous weld seam.
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Amarok 2011
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Adapt cab mounting -2- using alignment bracket set on front
wit
, is n
longitudinal member -1- and fix in place.
h re
hole
spec
Weld in cab mounting -2-, SG continuous weld seam.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Adapt suspension strut mounting -1- using alignment bracket
co Vo
by lksw
cted agen
set on front longitudinal member -2- and fix in place. Prote AG.
Adapt brake line mounting -3- and fix in place, using dimen
sions of old part as an aid.
Weld in suspension strut mounting -1- and brake line mounting
-3-, SG continuous weld seam.

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
Adapt hydraulic unit bracket -1- to suspension strut mounting

spec
-2- and fix in place, using dimensions of old part as an aid.

es, in part or in w
t to the co
Weld in hydraulic unit bracket -1-, SG continuous weld seam.

Carry out cavity preservation on front longitudinal member
rrectness of i
-3-.
l purpos

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
51 Body - centre byV gu

ara
ed
ris nte
ho eo
aut ra
ss c
ce
RO: 51 03 55 00, 51 03 55 20 e
nl
pt
du
an
1 Renewing roof
itte
y li
erm
ab
ility
ot p
wit
WARNING
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
1 - Roof
nform
ercia
2 - Bonded areas of C-pillar

m
3 - Bonded areas of roof cross
at
om
io
members
n
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1.1 Tools
110 Rep. gr.51 - Body - centre

Amarok 2011
Pneumatic cartridge gun -V.A.G 1761/1-
Setting gauge -3371-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Renewing roof 111

Amarok 2011
1.2 Removing
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Release bonded joints of C-pillars Item 2 (page 110) and to
front and rear roof cross members Item 3 (page 110) . To
release, heat bonded surfaces with hot air blower -V.A.G
1416- .
Remove roof -1- from body.

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt

an
d
itte
y li
erm
Remove adhesive residues and grind bonding surfaces back

ab
ility
to bare metal.
ot p
wit
is n

h re
ole,
spec
1.3 Installing
t to the co
Note
rrectne

s
s o
cial p
f inform
mer

atio
om
n
c
i
or
Replacement parts
thi
te
sd
va
Roof
i
o
pr
cum
r
fo
en
ng
1K assembly adhesive -D 190 MKD A3-

t.
yi Co
op py
2K body adhesive -D 180 KD3 A2-
t. C rig
gh ht
pyri by
Vo
o
c by lksw
cted agen
Prote AG.

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
Grind bonding surfaces down to bare metal
ut on one side (from
ho eo
ra
inside). ss a c
ce
le
un

pt
an
d
itte
y li
1.3.2 Welding in
rm
ab
pe
ility
ot
wit
, is n
h re
Note
hole
spec
es, in part or in w
t to the co
To ensure sufficient sturdiness, the RP weld points must be set

as far as possible from the outer edge of the welding flange.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r

te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
114
co Vo
by lksw
cted
Rep. gr.51 - Body - centre
agen
Prote AG.
Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op
Apply 1K assembly adhesive -D 190 MKD A3- to bonding sur C py
t. rig
faces -1-, -2- and -3-. gh ht
pyri by
Vo
o
by c lksw
Apply 2K body adhesive -D 180 KD3 A2- to bonding surfaces Prote
cted AG.
agen
-4-.
Note
Apply adhesive beads sufficiently thickly so that optimal bonding with the body is guaranteed.

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia

orm

m
atio
om
n in
Set roof joint gap Item L (page 9) on both sides with setting
or c
gauge -3371- .
thi
te
sd
iva

r
rp
cu
o
m
f
en
ng
Weld in roof, RP spot weld seam.

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Amarok 2011
RO: 51 07 55 70
2 Renewing front cross member for

roof
WARNING

2.1 Removing olksw

agen
AG. Volkswagen AG d
oes
not
y V gu
b ara
Roof already removed 1 Renewing roof,
rise page 110 .
d
nte
tho eo
Carry out the following work: ss au ra
c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Remove front cross member -1- from body.
2. Renewing front cross member for roof 117

AG. Volkswagen AG d
agen oes
olksw not
V gu
Amarok 2011 d by ara
ise nte
r
Body Repairs - Edition 10.2010 ut
ho eo
ra
s a c
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

2.2 Installing

Replacement parts
Front roof cross member

Amarok 2011

Grind welding surfaces on both sides down to bare metal.
2.2.2 Welding in
Note

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
or
Carry outs athe
u following work: ac
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Renewing front cross member for roof 119

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Adapt front cross member -1- with vehicle standing on its

wheels or on alignment bracket set and fix in position.
rrectness of i
Weld in front roof cross member, RP spot weld seam.

l purpos
Install roof 1.3 Installing, page 113 .

nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011
RO: 51 08 55 70
3 Renewing roof reinforcement
WARNING

3.1 Removing
Roof already removed 1 Renewing roof, page 110 .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c
lksw
cted agen
Prote AG.
Remove roof reinforcing -1- from body.
3. Renewing roof reinforcement 121

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

3.2 Installing

Replacement parts
Roof reinforcement

Amarok 2011

3.2.2 Welding in
Note

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
Carry out the following work: ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
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Prote AG.
3. Renewing roof reinforcement 123

Amarok 2011
AG. Volkswagen AG d
agen oes
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or eo
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ce
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nl
pt
du
an
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erm
ab
ility
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wit
, is n
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hole
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es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
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n in
or c
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
Adapt roof reinforcing -1- with vehicle standing on its wheels

or on alignment bracket set and fix in position.
Weld in roof reinforcement, RP spot weld seam.

Amarok 2011
RO: 51 09 55 70
4 Renewing rear roof cross member
WARNING

4.1 Removing AG. Volkswagen AG d

agen oes
olksw not
Roof already removed 1 Renewing roof, d by page
V 110 . gu
ara
rise nte
Carry out the following work: utho eo
ra
s a c
s
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
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n in
or c
thi
te
sd
iva
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Remove rear cross member -1- from body.
4. Renewing rear roof cross member 125

AG. Volkswagen AG d
agen oes
Amarok 2011 olksw not
byV gu
ara
Body Repairs - Edition 10.2010 rised
nte
ho eo
aut ra
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ce
le
un
pt
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d
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

4.2 Installing

Replacement parts
Rear roof cross member

Amarok 2011

4.2.2 Welding in
Note
To ensure sufficient sturdiness, the RP weld points must be set AG. Volkswagen AG d
as far as possible from the outer edge of the welding flange. olkswagen oes
no
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pe
ility
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wit
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hole
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
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t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
4. Renewing rear roof cross member 127

Amarok 2011
lkswage es n
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byV ua
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u or
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ss
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un
pt
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d
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Adapt rear cross member -1- with vehicle standing on its

wheels or on alignment bracket set and fix in position.
Weld in rear cross member for roof, RP spot weld seam.

Amarok 2011
RO: 51 13 55 00, 51 13 55 20
5 Renewing rear window frame
WARNING

1 - Rear window frame

2 - Bonded areas
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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ce
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un
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an
d
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
5. Renewing rear window frame 129

AG. Volkswagen AG d
agen oes
olksw not
Amarok 2011 d byV gu
ara
e
Body Repairs - Edition 10.2010 horis nte
eo
aut ra
ss c
5.1 Removing
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Release bonded joints -1-. To release, heat bonded surfaces
with hot air blower -V.A.G 1416- .
Remove rear window frame from body.

Amarok 2011
lkswage es n
o ot g
byV ua
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ir se tee
tho
u or
a ac
ss
ce
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nl
pt
du
an
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
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t.
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Remove adhesive residues and grind bonding surfaces down
Co
op py
to bare metal. t. C rig
gh ht
pyri by
co Vo
by lksw
cted agen
Prote AG.
5.2 Installing

Replacement parts
Rear window frame

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
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ce
e
nl
pt
du
an
itte
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ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
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m
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n in
or c
thi
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t
sd
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rp
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Grind bonding surfaces down to bare metal on one side (from

o
m
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en
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inside).
t.
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Cop py
Grind welding surfaces on both sides back to bare metal. ht. rig
rig ht
py by
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by lksw
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Prote AG.

Amarok 2011
5.2.2 Welding in
AG. Volkswagen AG d
agen oes
olksw not
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hole
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t to the co
rrectness of i
Apply 2K body adhesive -D 180 KD3 A2- to bonding surfaces.

l purpos
Note
nform
mercia
com
tion in
r
te o
thi
s
iva
do
r
rp
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fo
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
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n in
or c
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sd
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Cop py
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ment bracket set and fix in position. op Vo
by c lksw
cted agen
Prote
Check fit with rear-view window.
AG.
Weld in rear window frame, RP spot weld seam and SG plug

weld seam.

Amarok 2011
RO: 51 14 55 70
6 Renewing cross member

G. Volkswagen
nA AG do
wage es n
Volks ot g
WARNING by ua
ed ran
oris tee
th or
au
Observe safety
ss notes! ac
ce
le
un
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an
d
itte
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erm
ab
ility
ot p
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is n
6.1 Removing
h re
ole,
spec
Rear window frame already removed

5 Renewing rear window frame, page 129 .
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Remove cross member -1- from body.

Amarok 2011
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i

l purpos
6.2 Installing
nf
ercia
orm
m
atio
om
n in
c

or
thi
te
sd
iva
Replacement parts
o
r
rp
cu
o
m
f
en
Cross member
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011

lkswage es n
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6.2.2 Welding in utho tee
or
a ac
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nl
pt
du
Note
an
itte
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erm
ab
ility
ot p
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
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n in
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te
sd
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Adapt cross member -1- with vehicle standing on its wheels or

ng
t.
yi Co
on alignment bracket set and fix in position. t. Cop py
rig
gh ht
Weld in cross member, RP spot weld seam. pyri by
Vo
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by c lksw
cted agen
Install rear window frame 5.2 Installing, page 131 . Prote AG.

Amarok 2011
RO: 51 37 55 00, 51 37 55 02
7 Renewing hinge pillar (A-pillar)
WARNING

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

Note
Specified parting cuts -1- to -5- can be combined

wage
n AG. Volksfor
wagother
en AG forms of damage.
doe
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Vol t
Description for other forms ofeddamage
by must be derived from this gaccordingly.
ua
ra
ris nte
ho eo
ut ra
Assembly overview for vehicles
ss
a with double cab c
ce
e
nl
pt
du
an
itte
1 - Upper parting cut
y li
erm
ab
Carry out as per dimen
ility
ot p
sion -a-.
wit
, is n
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hole
spec
es, in part or in w
2 - Parting cut for partial re

newal t to the co
rrectness of i
damage
l purpos

newal
nf
ercia

rm

m
atio
m
damage
o
n in
or c
thi
4 - Parting cut for side member

te
sd
iva

r
rp
cu
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sion -b-.
f
en
ng
t.
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op
Dimension b = 250 mm C py
t. rig
gh ht
yri by
op Vo
by c lksw
cted agen
Prote AG.
sion -c-.
Dimension c = 750 mm
6 - Moulded foam element

Reduces the amount of
driving noise transmit
ted into the interior.
Moulded foam elements
must be inserted again
and must not be left out
page 5 .
7. Renewing hinge pillar (A-pillar) 139

Amarok 2011
7 - Bonded area
Cannot be restored in event of repair.
8 - Wing retainer
Renewing wing retainer page 146 .
Assembly overview for vehicles with single cab

sion -a-.
newal
damage
newal
damage
sion -b-.
Dimension b = 250 mm

sion -c-. n AG. Volkswagen AG do
lkswage es n
o ot g
yV
Dimension c = 750 mm sed b ua
ran
ir tee
tho
or
ss
au ac
ce
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nl
pt
du

an
itte
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erm
ab

ility
ot p

wit
, is n
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hole
page 5 .
spec
es, in part or in w
7 - Bonded area
t to the co
Cannot be restored in event of repair.

8 - Wing retainer
rrectness of i
Renewing wing retainer page 146 .

l purpos
nf
ercia
7.1 Tools
rm
m
atio
m

o
n in
or c
thi
e
Pneumatic sabre saw -V.A.G 1523B-

t
sd
iva
o
r
rp
cu

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m
f
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011
MIG brazing and welding system -VAS 6382-
7.2 Removing
For vehicles with single and double cab
Note
Make parting cuts with pneumatic jig-saw -V.A.G 1523B- only.

Parting cuts must be straight.
Do not damage inner reinforcements when carrying out part
ing cuts.
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
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au ra
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ce
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un
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an
d
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ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Mark parting cut -1- as per Item 1 (page 139) (400 mm from
top edge of windscreen aperture) and cut.
centre of hole) and cut.

Amarok 2011
Release bonded joint Item 7 (page 139) . To release, heat

bonded surface with hot air blower -V.A.G 1416- .
Remove hinge pillar (A-pillar) from body.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
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es, in part or in w

t to the co

to bare metal.
rrectness of i

l purpos
Prepare moulded foam elements -1- for installation

page 5 .
nform
ercia
7.3 Installing
m
at
om
ion
c
in t
or
his
e
Note
at
do
priv
cum
or

f
en
ng
t.
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op
C py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

Amarok 2011
7.3.1 Preparing new part, vehicles with dou

ble cab
Replacement parts
Side panel
Wing retainer agen
AG. Volkswagen AG d
oes
olksw not
Carry out the following by V work: gu
ara
ed
ris nte
ho eo
aut ra
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un
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an
d
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rm
ab
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ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Transfer parting cuts -1- and -2- from body to new part.
Make parting cuts and remove shaded area.
Prepare wing retainer, drill holes, 7.0 mm.
7.3.2 Preparing new part, vehicles with single

cab
Replacement parts
Side panel

Amarok 2011
Wing retainer
lkswage es n
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tho
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a ac
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un
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d
itte
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erm
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ility
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wit
is n
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ole,
spec
t to the co
rrectne

ss

o
cial p
f in
Prepare wing retainer, drill holes, 7.0 mm.

form
mer
atio

om
n
c
i
or
n thi
te
sd
iva
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pr
cum
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en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011
7.3.3 Welding in
For vehicles with single and double cab
Note
To ensure sufficient sturdiness, the RP weld points must be

set as far as possible from the outer edge of the welding flange.
MIG brazed seams are permitted at the parting cuts shown in
the illustration.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Weld in hinge pillar (A-pillar), RP spot weld seam, SG plug
weld seam and SG stitch weld seam.

Amarok 2011
Optically process visible weld joints.

Use 2K filler to smooth out rough spots.
7.3.4 Renewing wing retainer

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Position wing with wing retainer on body -1-.

Adapt wing to vehicle (door in position on vehicle).
nform
ercia
Remove door.
m
a
com
tion in
Tack weld wing retainer from wheel housing -2-.

r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

Amarok 2011
Remove wing.
Weld in wing retainer, SG plug weld seam.
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Amarok 2011
RO: 51 38 55 70
8 Renewing hinge pillar (A-pillar) rein

forcement
WARNING


Hinge pillar (A-pillar) already removed
7 Renewing hinge pillar (A-pillar), page 139
1 - Upper moulded foam ele

ment AG. Volkswagen AG d
agen oes
Reduces the amount of Volksw not
gu
driving noise transmit ed by ara
nte
is
hor eo
aut ra
Moulded foam s elements
s c
ce
e
nl
pt
du

an
itte
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page 5 .
erm
ab
ility
ot p
2 - Lower moulded foam ele

wit
ment
, is n
h re
hole

spec

es, in part or in w

t to the co

rrectness of i

page 5 .
l purpos
3 - Bonded area
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.

Amarok 2011
8.1 Tools AG. Volkswagen AG d

agen oes
lksw not
Special tools and workshop equipment by required
Vo gu
ara
d
ise nte
Resistance spot welder -VAS utho6239
r
A- eo
a ra
s c
Resistance spot welder -VAS
s 6535-
ce
e
nl
pt
du
an
itte
y li
erm
ab
8.2 Removing
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Release bonded joint -1-. To release, heat bonded surface
Remove hinge pillar (A-pillar) reinforcement from body.
8. Renewing hinge pillar (A-pillar) reinforcement 149

AG. Volkswagen AG d
agen oes
olksw not
y V gu
Amarok 2011 rise d b ara
nte
Body Repairs - aEdition
ut
ho
10.2010 eo
ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Remove adhesive residues and grind bonding surface back to
bare metal.
Prepare moulded foam elements -1- and -2- for installation
page 5 .
8.3 Installing
Note


Replacement parts
Hinge pillar (A-pillar) reinforcement

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Drill out hinge pillar (A-pillar) reinforcement upper part and re rrectness of i
l purpos
move shaded area.

Punch and drill specified holes in new part, 7.0 mm.
nform
ercia

m
a
com
tio
8.3.2 Welding in
n in
r
te o
thi
s
iva
do
r
rp
cum
Note
fo
en
ng
t.
yi Co
op py
To ensure sufficient sturdiness, the RP weld points must be set t. C rig
gh ht
as far as possible from the outer edge of the welding flange. pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Amarok 2011

Note
Apply adhesive beads sufficiently thickly so that optimal bond

New part must be welded in within 90 minutes or adhesion of
adhesive will be impaired.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum

for
en
g

n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
152
c by lksw
cted agen
Rep. gr.51 - Body - centre Prote AG.
Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
Check fit with all add-on parts. d by V gu
ara
rise nte
Weld in hinge pillar (A-pillar) reinforcement,
utho RP spot weld eo
ra
seam, SG plug weld seam and SG ss a
continuous weld seam. c
ce
e
nl
Hinge pillar (A-pillar) 7.3 Installing, page 142
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011
RO: 51 41 55 00
9 Renewing centre pillar (B-pillar)
WARNING

G. Volkswagen AG d
Welding, parting using spark generating machines/tools or tin lksw
agen
A
oes
not
ning in foam treated areas creates gases which are particularly by
Vo gu
ara
hazardous to health and environment. Therefore, refrain fromris
ed nte
using these processes under all circumstances. tho eo
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
Repairs ; Safety notes erm
ab
ility
ot p
wit
is n
h re
Note
ole,
spec
Specified parting cuts -1- to -5- and -7- can be combined for other forms of damage.
t to the co
Description for other forms of damage must be derived from this accordingly.
rrectne
ss
o
cial p
f
sion -a-.
inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
r
sion -d-.
p
cum
r
fo
en
ng
Dimension d = 250 mm
t.
yi Co
Cop py
.
t rig
gh ht
yri by
mitted for other forms of cop Vo
by lksw
damage cted agen
Prote AG.

sion -e-.
Dimension e = 520 mm

sion -c-.
Dimension c = 680 mm
damage
sion -b-.


Amarok 2011
Moulded foam elements must be inserted again and must not be left out page 5 .
7 - Centre parting cut
The parting cut is permitted for other forms of damage
9.1 Tools
wage
Resistance spot welder -VAS 6535- olks es n
ot g
byV ua
ed ran
Accessory pack -VAS 6535 /1- hor is tee
ut or
a ac
MIG brazing and welding system
ss -VAS 6382-
ce
le
un
pt
9.2 Removing
an
d
itte
y li
erm
ab
ility
ot p
Note
wit
is n
h re
ole,
spec
t to the co
ing cuts.
rrectne
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
9. Renewing centre pillar (B-pillar) 155

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
top edge of roof side member) and cut.

wit
, is n
h re
hole
spec
reference edge) and cut.

es, in part or in w
t to the co
centre of hole) and cut.
rrectness of i

Remove centre pillar (B-pillar) from body.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Prepare moulded foam element -1- for installation page 5 .
9.3 Installing
Note


Replacement parts
Side panel

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
Transfer parting cuts -1-, -2- and -3- from body to new part.
mer
atio

om
n
c
i
or

thi
te
sd
va

i
o
pr
cum
r
fo
en
ng
9.3.2 Welding in
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
Note
by lksw
cted agen
Prote AG.

the illustration.

Amarok 2011
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
op py
t. C rig
gh ht
yri
ment bracket set and fix in position. p by
co Vo
by lksw
cted agen
Check fit with all add-on parts. Prote AG.
Weld in centre pillar (B-pillar), RP spot weld seam, SG plug

weld seam and SG stitch weld seam.

Amarok 2011
RO: 51 42 55 70
10 Renewing centre pillar (B-pillar) rein

forcement
WARNING


Centre pillar (B-pillar) already removed
9 Renewing centre pillar (B-pillar), page 154
AG. Volkswagen AG d
agen oes
olksw not
y V gu
b
Note rise
d ara
nte
tho eo
au ra
Specified parting cut -1- and scutting points -3- and -4- can be combined for otherc forms
s of damage.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011
AG. Volkswagen AG d
agen oes
1 - Upper parting cut olksw not
y V gu
d b ara
Carry out as per dimen orise nte
eo
sion -a-. auth
ra
ss c
ce
le
un
pt
an
d
itte
2 - Middle pillar (B-pillar) rein
y li
rm
ab
forcement
pe
ility
ot
wit
, is n
h re
Parting at this point is
hole
spec
permitted for other
es, in part or in w
forms of damage.
t to the co
rrectness of i
l purpos

nform
ercia

m
a
com
ti
on in
page 5 .
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
10.1 Tools
10.2 Removing
Note
Make parting cut using body saw -V.A.G 1523B- only!

10. Renewing centre pillar (B-pillar) reinforcement 161

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
top edge of roof side member) and cut.
Remove centre pillar (B-pillar) reinforcement from body.

Amarok 2011
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia

m
a
com
tio
n in
r
te o
thi
s
iva
do
r
rp
10.3 Installing
um
fo
en
ng
t.
yi Co
Cop py
t. rig
gh
Note
ht
pyri by
Vo
co lksw
by
cted agen
Prote
AG.

Replacement parts
Middle pillar (B-pillar) reinforcement

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n

h re
hole
spec
Make parting cut and remove shaded area.

es, in part or in w
t to the co

rrectness of i
10.3.2 Welding in
l purpos
nform
ercia
Note
m
a
com

ion in

r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted
agen
Prote AG.

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p

wit
is n
ment bracket set and fix in position. h re

ole,

spec
t to the co
Weld in centre pillar (B-pillar) reinforcement, RP spot weld

seam, SG plug weld seam and SG continuous weld seam.
Centre pillar (B-pillar) 9.3 Installing, page 157
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e nte
Amarok 2011 horis
eo
ut
ss a ra
c
ce
le
un
pt
an
d
itte
y li
RO: 51 39 55 20
erm
ab
11 Renewing lock pillar (C-pillar)
ility
ot p
wit
is n
h re
ole,
WARNING
spec
t to the co
rrectne
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
a
Note
iv
o
pr
cum
r
fo
en
ng
Specified parting cuts -1- and -4- to -6- can be combined for other forms of damage.
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Can be positioned in this
area depending on
damage.
2 - Bonded area
Cannot be restored in
event of repair.
page 5 .
4 - Lower parting cut
Parting cut is permitted
for other forms of dam
age.
sion -a-.

age.
sion -b-.

Amarok 2011
AG. VolkswBody
agen ARepairs - Edition 10.2010
agen G do
es n
olksw ot gu
yV
11.1 Tools rise
db ara
nte
ho eo
ut
ss a ra
c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
MIG brazing and welding system -VAS 6382- es, in part or in w
t to the co
11.2 Removing
rrectness of i
Note
l purpos
nf
ercia
o
rm
m
atio
m

o
n in
c
ing cuts.
or
thi
te
sd
iva
o
r

rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
11. Renewing lock pillar (C-pillar) 167

Amarok 2011
AG. Volkswagen AG d
agen oes
Mark parting cut -1- and carry out. o lksw not
byV gu
ara
e d
Parting cut -2- as per Item 5 (pagehoris 166) . Mark (250 mm from nte
eo
reference edge) and cut. aut ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Mark parting cut -1- and carry out.

Separate original joint along metal edge of rear window frame
-3-.
Bend metal edge of rear window frame -3- upwards in
-direction of arrow-.
Release underlying, original joint of lock pillar (C-pillar).
Release remaining original joint.
Remove lock pillar (C-pillar) from body.

Amarok 2011
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p

wit
is n

h re
ole,
spec
Remove remaining section of lock pillar (C-pillar) -1-.

t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Drill holes for installation in rear window frame, 5.0 mm.
11.3 Installing
Note


Replacement parts
Side panel

Amarok 2011
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
11.3.2 Welding in
Note

the illustration.

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

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

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
Weld in lock pillar (C-pillar), RP spot weld seam, SG plug weld
op Vo
by c lksw
seam and SG stitch weld seam.
cted agen
Prote AG.
After welding in lock pillar (C-pillar), smooth SG plug weld

seams in area -1-.
Bend metal edge of rear window frame -2- back in
-direction of arrow-.
Weld metal edge of rear window frame -2-, SG plug weld
seam.

Amarok 2011
RO: 51 70 55 20
12 Renewing mounting bracket for front

seat
WARNING

12.1 Removing
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
r

o
his
ate
do
riv
Remove mounting bracket for front seat -1- from body.

p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
174
Prote AG.
Rep. gr.51 - Body - centre
Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
Remove remaining material. ab

ility
ot p
Grind welding surfaces down to bare metal.

wit
, is n
h re
hole
12.2 Installing
spec
es, in part or in w
t to the co

rrectness of i
Replacement parts
l purpos
Mounting bracket for front seat

nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
12. Renewing mounting bracket for front seat 175

Amarok 2011
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
c

or
thi
te
sd
a

iv
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011
12.2.2 Welding in
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
Adapt mounting bracket for front seat -1- to fit and fix in posi
thi
te
sd
a
tion.
iv
o
pr
cum
r
fo
Weld in mounting bracket for front seat, SG plug weld seam.

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
12. Renewing mounting bracket for front seat 177

Amarok 2011
53 Body - rear
RO: 53 05 55 00
1 Renewing rear cross panel

gen AG
. Volkswagen AG
d a oes
ksw not
Vol gu
d by ara
WARNING ris
e nte
tho eo
au ra
c
Observe safety notes! ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
1 - Bonded areas
spec
es, in part or in w
t to the co
2 - Rear cross panel
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
178 Rep. gr.53 - Body - rear

Amarok 2011
1.1 Removing
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

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

rm
m
atio
m
Remove rear cross panel from load surface.

o
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Renewing rear cross panel 179

Amarok 2011
AG. Volkswagen AG d
Body Repairs - Edition 10.2010 ksw
agen oes
not
ol
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

to bare metal.
1.2 Installing

Replacement parts
Rear cross panel

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Grind bonding surfaces down to bare metal on one side (from

inside).

Amarok 2011
1.2.2 Welding in
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
Adapt new part to fit and fix in position.

c
i
or
n thi
te
Weld in rear cross panel, RP spot weld seam.

sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Amarok 2011
RO: 53 48 55 70
2 Renewing rear longitudinal member -

part section
WARNING AG. Volkswagen AG d

agen oes
olksw not
V gu
d by ara
Observe safety notes! orise nte
eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
2.1 Removing
ility
ot p
wit
, is n
Load surface already removed General body repairs, ex
h re
hole
terior; Rep. gr. 55 ; Load surface .
spec
es, in part or in w
t to the co
Note
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V
d by Amarok gu2011
ara
ise nte
thor Body Repairs - Edition 10.2010eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Mark parting cut as per -dimension a- and cut.

Remove longitudinal member.
2. Renewing rear longitudinal member - part section 185

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

2.2 Installing

Replacement part
Rear longitudinal member complete
Mounting bracket

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

nform
ercia

m
at
om
io
Remove shaded area.

n
c
in t
or
his
e
Grind welding surfaces down to bare metal.

at
do
priv
Grind welding surfaces of mounting bracket back to bare met

um
for
en
g
al.
n
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Amarok 2011
2.2.2 Welding in
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Adapt new part to vehicle standing on alignment bracket set

and fix in place.
Weld parting cut all round in rear longitudinal member -1- ad
hering to -air gap dimension a-, SG continuous weld seam.
Dimension a = 3.5 mm + 0.5 mm
Note


Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Adapt rear mounting bracket for load surface -1- to fit and fix
in position page 19 .
Weld in rear mounting bracket with longitudinal member -2-,
SG continuous weld seam.
Carry out cavity preservation on rear longitudinal member.

Amarok 2011
RO: 53 55 55 20
3 Renewing rear side panel
WARNING

Load surface already removed General body repairs, ex
terior; Rep. gr. 55 ; Load surface .
1 - Bonded areas
newal
age.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011
3.1 Removing
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
op
Separate original joint. C py
ht. rig
rig ht
py by
Release bonded joints -1-, -2- and -3-. To release, heat bon co Vo
by lksw
ded surfaces with hot air blower -V.A.G 1416- . cted agen
Prote AG.
3. Renewing rear side panel 191

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Drill open original joint -2- through 2 material thicknesses.
Release bonded joint -1-. To release, heat bonded surface rrectne
ss
Remove rear side panel from load surface.

o
cial p
f in
Release original joint from bracket -2-.

form
mer
atio

om

n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Amarok 2011
Remove bracket -2- from load surface.

to bare metal.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
3.2 Installing
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Replacement parts
Rear side panel

Amarok 2011
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Grind bonding surfaces -1- to -6- down to bare metal on one

l purpos
side (from inside).

nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011
3.2.2 Welding in
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva

o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op
Note
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Amarok 2011
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
Adapt rear side panel
s aut -1- to fit and fix in position. ra
c
s
ce
e
nl
pt
du
an
itte
Weld in rear of side panel, RP spot weld seam.

y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
197
by lksw
cted agen
Prote AG.
3. Renewing rear side panel
Amarok 2011
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Weld in rear side panel, RP spot weld seam, SG plug weld

seam and SG continuous weld seam.

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Service

Service Department. Technical Information

All rights reserved.

Copyright 2010 Volkswagen AG, Wolfsburg D3E8027D416

2 Renewing deformation element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

3 Renewing headlight mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

5 Renewing connection piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

10 Renewing longitudinal member complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

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

1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

1.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

2.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

3 Renewing roof reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

3.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

11.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

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

1.1 Vehicle identification number

Vehicle identification number (chassis number) on the body:

1. Key vehicle data 1

Vehicle identification number (chassis number) on the vehicle

Additional, shortened vehicle identification number (chassis num

2 Rep. gr.00 - Technical data

1. Key vehicle data 3

Before beginning any cutting, alignment or dent removal, refer

4 Rep. gr.00 - Technical data

3 Moulded foam elements

Various body cavities in the Amarok 2010 have been fitted

Moulded foam element

between C-pillar rein

skin and B-pillar rein

Moulded foam element

forcement and inner

Moulded foam element

between A-pillar outer

Moulded foam element by c lksw

forcement and inner

As these temperatures cannot be achieved under normal work

3. Moulded foam elements 5

Restore the paint work structure. If necessary, apply two coats

Carry out cavity preservation on repair area after painting ve

6 Rep. gr.00 - Technical data

4 Galvanized body parts

4. Galvanized body parts 7

5 Body panel gaps/shut lines

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

5.1 Body - front

5.2 Body - centre, vehicles with double cab

5. Body panel gaps/shut lines 9

5.3 Body - centre, vehicles with single cab

10 Rep. gr.00 - Technical data

5.4 Body - rear, vehicles with double cab

5. Body panel gaps/shut lines 11

5.5 Body - rear, vehicles with single cab

12 Rep. gr.00 - Technical data

5.6 Body add-on parts

S - 1.0 mm + 0.5 mm / - 1.0 mm

5. Body panel gaps/shut lines 13

14 Rep. gr.00 - Technical data

Dimensions only given for checking purposes. The alignment

6.1 Double cab frame dimensions

6.1.1 Front frame dimensions

Dimension between cab

tween frame longitudi