Professional Documents
Culture Documents
Workshop Manual
Amarok 2011 ➤
General body repairs, exterior
Edition 10.2012
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
cted agen
Prote AG.
Repair Group
50 - Body - front
55 - Bonnet, rear lid
57 - Front doors, door components, central locking
58 - Rear doors, door components
60 - Sunroof
61 - Convertible roof, hardtop, canopy
63 - Bumpers
64 - Glazing
66 - Exterior equipment
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
Technical information should always be available to the foremen and mechanics, because their
n
t.
yi Co
op
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
C py
t. rig
gh
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
ht
pyri by
Vo
o
matter of course, be observed.
c by lksw
cted agen
Prote AG.
ce
le
un
1 Lock carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
pt
an
d
itte
1.1 Assembly overview - lock carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
y li
erm
ab
1.2 Assembly overview - support for lock carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ility
1.3 ot p
Assembly overview - air ducting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
wit
is n
h re
1.4 Assembly overview - bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ole,
spec
1.5 Removing and installing front lock carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
urposes, in part or in wh
t to the co
1.6 Removing and installing support for lock carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 Assembly overview - wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
rrectne
2.2 Removing and installing wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
s
3 Bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
s o
cial p
f inform
3.2 Removing and installing plenum chamber cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
mer
atio
m
n
c
i
or
n thi
1 Bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
te
sd
va
o
pr
cum
r
fo
en
ng
t.
yi
1.3 Assembly overview - release lever and mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Co
Cop py
.
1.4 Removing and installing bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ht rig
rig ht
py by
1.5 Adjusting bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
co Vo
by lksw
cted agen
1.6 Bonnet lock and Bowden cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prote
25
AG.
Contents i
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
AG. Volkswagen AG d
agen oes
lksw n
3.4 Removing and installing load bed . . . . . b.y .V. . . . . . . . . . . . . . . . . . . . . . . o.t g. u.a. . . . . . . . . .
o . 61
ed ra
3.5 Removing and installing cross-member horis buffer . . . . . . . . . . . . . . . . . . . . . . . . .nt.ee. . . . . . .
. 63
ut or
4 Cab . . . . . . . . . . . . . . . . . . . . . .ss.a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ac. . . . .
. 65
4.1 Assembly overview - cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
ce
le
un
pt
an
4.2 Assembly overview - front mounting for cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
d
itte
y li
rm
4.3 Assembly overview - centre mounting for cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
ab
pe
ility
4.4 Assembly overview - rear mounting for cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
ot
wit
, is n
4.5 Assembly overview - retaining strap for cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
h re
hole
4.6 Removing and installing cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
spec
es, in part or in w
4.7 Removing and installing retaining strap for cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
t to the co
4.8 Removing and installing pressure hoses and hose connections with screw-type clamps . . 74
5 Tank flap unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
rrectness of i
5.1 Removing and installing tank flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.2 Removing and installing tank flap unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
l purpos
nform
ercia
a
1 Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
com
tion in
1.1 Assembly overview - door hinge on A-pillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
r
te o
thi
1.2 Assembly overview - door hinge on door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
s
iva
do
r
cum
fo
en
ng
t.
yi Co
1.5 Adjusting striker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Cop py
t. rig
1.6 Removing and installing door hinge on A-pillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
gh ht
pyri by
Vo
o
1.7 Removing and installing door hinge on door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
c by lksw
cted agen
Prote AG.
1.8 Removing and installing door arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2 Door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2.1 Assembly overview - door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2.2 Assembly overview - window regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.3 Assembly overview - door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.4 Assembly overview - door lock cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2.5 Assembly overview - cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.6 Assembly overview - window regulator motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.7 Removing and installing window regulator motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.8 Removing and installing window regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
2.9 Removing and installing door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
2.10 Removing and installing door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
2.11 Removing and installing window channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
2.12 Removing and installing lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
2.13 Removing and installing housing (without lock cylinder) . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2.14 Removing and installing inner door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
2.15 Removing and installing door handle bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2.16 Removing and installing striker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2.17 Removing and installing window slot outer seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2.18 Removing and installing window slot inner seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
2.19 Removing and installing top door seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
2.20 Removing and installing bottom door seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
2.21 Assembly overview - impact rail of front door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2.22 Removing and installing loudspeaker in front door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
ii Contents
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
autho eo
ra Amarok 2011 ➤
ss General body repairs, exterior - Edition 10.2012
c
ce
e
nl
pt
du
an
1.4 Adjusting striker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
itte
y li
erm
ab
1.5 Removing and installing door hinge on B-pillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
ility
ot p
wit
, is n
h re
1.7 Removing and installing door arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
hole
spec
1.8 Removing and installing door inner seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
es, in part or in w
t to the co
2 Door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
2.1 Assembly overview - door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
rrectness of i
2.2 Assembly overview - window regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
l purpos
nf
2.5 Assembly overview - cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
ercia
or
2.6 Assembly overview - window regulator motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
m
m
atio
m
n in
or c
thi
te
sd
a
o
r
rp
cu
2.10 Removing and installing door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
o
m
f
en
ng
60 - Sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1 Tilting sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Contents iii
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
4 Glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
4.1 Assembly overview - glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
4.2 Assembly overview - rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
4.3 Removing and installing rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
4.4 Removing and installing sliding window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
4.5 Removing and installing front sliding window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
5 Trims, foam components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
5.1 Assembly overview - hardtop foam components, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
5.2 Assembly overview - foam components, n AG. Volkswagen AG
lkswage top and side . .d.oe.s.n . . . . . . . . . . . . . . . . . . . . . . . 210
Vo o
5.3 Removing and installing topedpanel by . . . . . . . . . . . . . . . . . . . . . t. g.ua. r.a . . . . . . . . . . . . . . . . . . . 211
ir s n
5.4 Removing and installingthright o D-pillar trim . . . . . . . . . . . . . . . . . . . .te.e.o . . . . . . . . . . . . . . . . 213
u ra
5.5 Removing and installing ss left D-pillar trim . . . . . . . . . . . . . . . . . . . . . . . .c . . . . . . . . . . . . . .
a 215
5.6 Removing and installing hardtop middle trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
ce
le
un
pt
an
5.7 Removing and installing hardtop securing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
d
itte
y li
rm
ab
pe
ility
5.9 Removing and installing edge protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
63 - Bumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
1 Front bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
rrectness of i
1.1 Assembly overview - front bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
1.2 Assembly overview - front bumper cover, add-on parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
l purpos
nform
ercia
a
com
tion in
1.7 Removing and installing wheel arch trim, front bumper cover . . . . . . . . . . . . . . . . . . . . . . 239
r
te o
do
cum
fo
t.
yi Co
2.1 Assembly overview - rear bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
Cop py
t. rig
2.2 Assembly overview - bottom step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
gh ht
pyri by
Vo
o
2.3 Assembly overview - rear bumper cover step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
c by lksw
cted agen
Prote AG.
2.4 Assembly overview - closing plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
2.5 Assembly overview - rear bumper carrier to 2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
2.6 Assembly overview - rear bumper carrier from 2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
2.7 Repairing bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
64 - Glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
1 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
1.1 Minimum curing period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
1.2 Window repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
1.3 Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
1.4 Preparing old undamaged windows for fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
1.5 Preparing new window without precoating for glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
1.6 Preparing body flange for fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
1.7 Cleaning off excess adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
2 Windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
2.1 Assembly overview - windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
2.2 Removing and installing windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
3 Rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
3.1 Assembly overview - rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
3.2 Removing and installing rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
4 Door windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
iv Contents
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
ce
e
nl
pt
du
an
66 - Exterior equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
itte
y li
erm
ab
1 Radiator grille and front trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
ility
ot p
wit
1.1 Assembly overview - radiator grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
, is n
h re
1.2 Removing and installing radiator grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
hole
spec
2 Mouldings, trims, extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
es, in part or in w
t to the co
2.1 Assembly overview - heat shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
3 Engine/gearbox guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
rrectness of i
3.1 Assembly overview - engine/gearbox guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
3.2 Removing and installing engine/gearbox guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
l purpos
nf
ercia
or
5 Exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
m
m
atio
m
n in
c
thi
te
sd
iva
o
r
rp
cu
5.4 Removing and installing mirror housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
o
m
f
en
ng
Contents v
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
ce
e
nl
pt
14.7 Removing and installing front mud flaps, with wheel arch trim . . . . . . . . . . . . . . . . . . . . . . 365
du
an
itte
y li
14.8 Removing and installing rear mud flaps, without wheel arch trim . . . . . . . . . . . . . . . . . . . . 366
erm
ab
14.9 Removing and installing rear mud flaps, with wheel arch trim . . . . . . . . . . . . . . . . . . . . . . 368
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.
vi Contents
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
50 – Body - front
1 Lock carrier
(VRL005195; Edition 10.2012)
⇒ “1.1 Assembly overview - lock carrier”, page 1
⇒ “1.2 Assembly overview - support for lock carrier”, page 2
⇒ “1.3 Assembly overview - air ducting”, page 3
⇒ “1.4 Assembly overview - bumper”, page 3
⇒ “1.5 Removing and installing front lock carrier”, page 4
⇒ “1.6 Removing and installing support for lock carrier”,
page 6
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.
1. Lock carrier 1
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
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
cted agen
Prote AG.
ce
e
nl
pt
du
an
❑ Removing:
itte
y li
erm
ab
– Remove front bumper
ility
ot p
cover ⇒ page 236 .
wit
, is n
h re
❑ Remove hose to air vent
hole
spec
housing from rear ⇒
Heater and air condi‐ es, in part or in w
t to the co
tioning system; Rep. gr.
80 ; Air vent housing
❑ Unclip clip -5-, remove
rrectness of i
right air deflector ele‐
l purpos
ment forwards.
❑ Installing:
nform
ercia
at
om
io
2 - Lock carrier
n
c
in t
or
his
e
3 - Bracket
at
do
priv
c
4 - Left air duct
um
for
en
ng
t.
❑ Removing:
yi Co
Cop py
t. rig
– Remove front bumper
gh ht
yri by
cover ⇒ page 236 .
op Vo
by c lksw
cted agen
Prote AG.
❑ Unclip upwards out of
lock carrier -2-.
❑ Installing:
❑ Install in reverse order
of removal.
5 - Clip
❑ Left only
1. Lock carrier 3
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
1 - Air duct
❑ Removing:
❑ Remove front bumper
cover ⇒ page 236 .
❑ Removing foam ele‐
ment - pedestrian pro‐
tection ⇒ page 236 .
❑ Unclip clip -2- on left and
right cross members.
❑ Carefully lever off air
duct upwards using
front end hook -3370- .
❑ Installing: agen
AG. Volkswagen AG d
oes
lksw not
❑ Install in reverse orderby Vo gu
ara
of removal. ris
ed
nte
tho eo
2 - Clip s au ra
c
s
❑ Qty. 2
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
g
t.
yi Co
op py
er
t. C rig
gh ht
pyri by
Vo
co
Special tools and workshop equipment required
by lksw
cted agen
Prote AG.
♦ Torque wrench -V.A.G 1331-
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
Removing
rm
ab
pe
ility
ot
spec
es, in part or in w
– Unclip Bowden cable from front lock carrier -1- and disconnect
t to the co
⇒ page 33 .
– Unfasten air deflector elements ⇒ page 3 .
rrectness of i
tion in
Installing
r
te o
thi
s
iva
following:
um
fo
en
ng
t.
– Ensure joints are parallel and shut lines are equal ⇒ Body Re‐
yi Co
op py
pairs; Rep. gr. 00 ; Technical data; Body gaps; Body, front . t. C rig
gh ht
pyri by
Specified torques
o Vo
by c lksw
cted agen
Prote AG.
♦ ⇒ “1.1 Assembly overview - lock carrier”, page 1
1. Lock carrier 5
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
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.
Removing
– Remove front bumper cover ⇒ page 236 .
– Remove front bumper cover closing piece ⇒ page 236 .
n AG. Volkswagen AG do
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.
1. Lock carrier 7
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
2 Wing
⇒ “2.1 Assembly overview - wing”, page 8
⇒ “2.2 Removing and installing wing”, page 8
Note agen
AG. Volkswagen AG d
oes
olksw not
y V gu
b
Only the left side is shown. The rise right side is similar.
d ara
nte
tho eo
au ra
ss c
ce
e
nl
1 - Wing
pt
du
an
itte
y li
erm
ab
⇒ page 8
ility
ot p
wit
2 - Bolt
, is n
h re
❑ Qty. 1, A-pillar top
hole
spec
❑ Specified torque: 8 Nm.
es, in part or in w
t to the co
3 - Bolt
❑ Qty. 1, A-pillar bottom
rrectness of i
❑ Qty. 1, side member
l purpos
nform
ercia
piece
❑ Specified torque: 5 Nm.
m
at
om
ion
in t
or
his
e
do
riv
cum
or
en
ng
t.
yi Co
op
5 - Spring clip
C py
t. rig
gh ht
yri
❑ Qty. 1, A-pillar bottom p by
co Vo
by lksw
cted
❑ Qty. 1, side member
agen
Prote AG.
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
Note
an
d
itte
y li
rm
ab
pe
Removal and installation are described only for the left wing. Re‐
ility
ot
h re
hole
spec
Removing
es, in part or in w
t to the co
WARNING
rrectness of i
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.
2. Wing 9
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
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
– Remove front wheel housing liner ⇒ page 304 . Prote AG.
Note
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
– Restore bonding -4- between A-pillar and wing -1- using seal‐
om
ion
ing cord -AKD 497 010 04 R10- .
c
in t
or
his
te
– Ensure joints are parallel and shut lines are equal ⇒ Body Re‐
a
do
riv
cum
for
en
g
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
Note
co lksw
by
cted agen
Prote AG.
Carry out corrosion protection measures on wing and securing bolts after assembly and adjustment work.
Specified torques
♦ ⇒ “2.1 Assembly overview - wing”, page 8 .
2. Wing 11
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
3 Bulkhead
⇒ “3.1 Assembly overview - plenum chamber cover”, page 12
⇒ “3.2 Removing and installing plenum chamber cover”,
page 12
n AG. Volkswagen AG do
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
ber cover
m
at
om
Removing
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.
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
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
m
Removing
o
n
c
i
or
n thi
sd
a
o
pr
cum
r
fo
t.
yi Co
Cop py
t. rig
gh
WARNING
ht
pyri by
Vo
co lksw
by
cted agen
The glass could be destroyed.
Prote AG.
The plenum chamber cover must not be levered off with a tool
(screwdriver, wedge). The windscreen will be damaged and
may subsequently crack.
3. Bulkhead 13
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
Installing
WARNING
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.
Note
♦ An insert is fitted in windscreen seal of new windscreens. Remove this insert before installing plenum
chamber cover.
♦ The plenum chamber cover may only be pushed into the windscreen seal by hand using light pressure.
Never fit with blows or with the use of tools.
ce
le
un
pt
– Install windscreen wiper arms ⇒ Electrical system; Rep. gr.
an
d
itte
y li
92 ; Removing and installing windscreen wiper system .
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
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.
3. Bulkhead 15
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
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
16
co Vo
by lksw
cted
Rep. gr.55 - Bonnet, rear lid
agen
Prote AG.
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
1 Bonnet
⇒ “1.1 Assembly overview - bonnet”, page 17
⇒ “1.2 Assembly overview - bonnet lock and release compo‐
nents”, page 18
⇒ “1.3 Assembly overview - release lever and mounting bracket”,
page 19
⇒ “1.4 Removing and installing bonnet”, page 19
⇒ “1.5 Adjusting bonnet”, page 22
⇒ “1.6 Bonnet lock and Bowden cable”, page 25
⇒ “1.7 Removing and installing striker”, page 27
⇒ “1.8 Removing and installing release lever”, page 28
⇒ “1.9 Removing and installing hinges”, page 28
⇒ “1.10 Removing and installing insulation”, page 30
⇒ “1.11 Separating Bowden wcable”,
agen
AGpage
. Volksw33
agen AG
does
ks not
Vol gu
⇒ “1.12 Removing and ed installing adjustable buffer film”,
by ara
nte
page 34 thoris eo
au ra
⇒ “1.13 Removing
ss and installing support rod with bracket”, c
ce
e
page 35
nl
pt
du
an
itte
ab
ility
ot p
1 - Bonnet wit
, is n
h re
❑ Removing and installing
hole
⇒ page 19
spec
es, in part or in w
❑ Adjusting ⇒ page 22
t to the co
2 - Adjustment buffer
❑ Left and right.
rrectness of i
3 - Insulation
❑ Removing and installing
nf
ercia
⇒ page 30
rm
m
atio
m
4 - Hinge
o
n in
or c
sd
⇒ page 28
iva
o
r
rp
cu
❑ Adjusting ⇒ page 22
o
m
f
en
ng
t.
yi
5 - Plenum chamber seal
Co
Cop py
t. rig
❑ Connected to plenum
gh ht
yri by
chamber end wall cop Vo
by lksw
cted agen
Prote AG.
6 - Lid lock
❑ Removing and installing
⇒ page 25
7 - Support rod
❑ Removing and installing
⇒ page 35
8 - Striker
❑ Removing and installing
⇒ page 27
❑ Adjusting ⇒ page 24
1. Bonnet 17
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
1 - Lid lock
❑ Removing and installing
⇒ page 25
2 - Bowden cable coupling
❑ Bowden cable coupling
is located above head‐
light on driver side.
❑ Separating
⇒ page 33 .
3 - Bowden cable olkswagen AG
en AG. V
❑ From Bowden cable olkswag does
not
coupling to release
ed
b lever
y V gu
ara
ris nte
4 - Release lever autho eo
ra
s c
❑ Removings and installing
ce
e
⇒ page 28
nl
pt
du
an
itte
y li
5 - Striker
erm
ab
ility
❑ Removing and installing
ot p
wit
⇒ page 27
, is n
h re
❑ Adjusting ⇒ page 24
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.
1 - Mounting bracket
To work on mounting bracket,
it is necessary to remove A-pil‐
lar trim at bottom ⇒ General
body repairs, interior; Rep. gr.
70 ; A-pillar trim at bottom .
2 - Captive nut
❑ Qty. 2
3 - Bowden cable
❑ Installing:
– Insert ball of Bowden
cable into mounting
bracket and lock Bow‐
den cable in mounting
bracket.
4 - Bolt
❑ Specified torque: 3.0
Nm
❑ Qty. 2
5 - Release lever
❑ Removing and installing
⇒ page 28
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
h re
hole
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
Removing
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Bonnet 19
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
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
f in
– Only now remove bolts -4- and remove bonnet -3- from hinges
form
mer
-1-.
atio
om
Installing
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.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
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. Bonnet 21
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
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
nf
ercia
orm
m
atio
om
n in
or c
thi
te
cu
o
hinges.
f
en
ng
t.
yi Co
op
– Unscrew inner centring buffers -4- with bonnet closed until it C py
t. rig
makes stress-free contact with opposite side.
gh ht
pyri by
Vo
o
by c lksw
Adjusting bonnet cted agen
Prote AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
– Remove front bumper cover ⇒ page 236 .
ce
e
nl
pt
du
an
y li
erm
ab
wit
, is n
spec
t to the co
at
om
closed) ⇒ page 25 .
in t
or
his
ate
– Release and open bonnet -2-. Turn adjustment buffer -3- 180°
do
priv
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Bonnet 23
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
Note
Make sure bonnet and wings are correctly aligned at front corners. If necessary, repeat the work procedure.
Adjusting striker
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331-
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.
Note
ce
le
un
pt
Striker bolts 10 Nm
an
d
itte
y li
erm
ab
1.6 Bonnet lock and Bowden cable
ility
ot p
wit
is n
h re
ole,
page 25
spec
urposes, in part or in wh
t to the co
1.6.1 Removing and installing bonnet lock
and Bowden cable
rrectne
Special tools and workshop equipment required
ss o
♦ Torque wrench -V.A.G 1331-
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.
Removing
1. Bonnet 25
Amarok 2011 ➤ n AG. Volkswagen AG do
wage es n
General body repairs, exterior
yV
o - Edition 10.2012
lks ot g
b ua
ed ran
oris tee
th or
au 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.
– Open bonnet.
– Detach Bowden cable at Bowden cable coupling
⇒ page 33 .
– Unclip Bowden cable -4- from lock carrier.
– Separate connector -5- for bonnet contact switch.
– Remove bolts -2- from lock carrier.
Bonnet lock bolts, from 2013 ⇒ page 27
– Withdraw lid lock -1- with attachment plate -3- (if fitted) up‐
wards.
– Unclip Bowden cable -4- from lid lock -1-.
Installing
– Insert lid lock -1- with attachment plate -3- (if fitted) into lock
carrier.
Note
Attachment plate -3- sits between lock support and lock carrier.
1 - Lock carrier
❑ Removing and installing
⇒ page 4 .
2 - Bonnet lock
❑ Removing and installing
⇒ page 25 .
3 - Securing plate
4 - Bolt
❑ Qty. 2
WARNING
Bolts must always be re‐
placed by new ones after
being removed.
❑ Specified torques: 20
Nm + 180°
5 - Bolt
n AG. Volkswagen AG do
lkswage es n
o ot g
yV
WARNING d b ua
ran
ir se tee
o
Always renew bolt after auth or
ac
loosening. ss
ce
le
un
pt
an
d
itte
❑ Specified torques:
y li
rm
ab
10 Nm
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
Removing
m
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.
1. Bonnet 27
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
ce
le
un
pt
an
d
itte
y li
Specified torques
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectnes
1.8 Removing and installing release lever
s o
cial p
f inform
Removing
mer
atio
m
n
c
i
or
n
– Insert a small screwdriver in gap between release lever -1- and
thi
te
sd
retaining clip -2-.
iva
o
pr
cum
r
– Lever retaining clip -2- out of release lever -1- and remove
fo
en
ng
Note
Removal and installation are described for the right hinge only.
Removal and installation of the left hinge are similar.
Removing
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
urposes, in part or in wh
t to the co
rrectness o
cial p
f in
n
c
n thi
te
sd
a
o
pr
cum
r
fo
Installing
en
ng
t.
yi Co
op
Installation is carried out in reverse order. When doing this, ob‐ C py
t. rig
serve the following:
gh ht
pyri by
Vo
co lksw
by
– Adjust bonnet if hinge -1- has been renewed cted agen
Prote AG.
1. Bonnet 29
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
Note
ce
e
nl
pt
du
an
Hinge bolts 30 Nm
itte
y li
erm
ab
ility
1.10 Removing and installing insulation
ot p
wit
, is n
h re
Special tools and workshop equipment required
hole
spec
♦ Removal lever -80 - 200-
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
Removing
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
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.
– Lever retaining clips -3- (qty. 7) out of bonnet -2- using removal
lever -80-200- .
– Pull insulation -1- out of longitudinal holes.
Installing
1. Bonnet 31
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
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
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
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.
Removing
– Open bonnet.
– Unclip Bowden cable mounting -3- above headlight on driver
side at lock carrier.
– Remove Bowden cables -1- and -2- from Bowden cable
mounting -3- and disconnect.
Installing
Note
When installing, ensure that Bowden cables -1- and -2- are correctly connected in Bowden cable mounting
-3-.
1. Bonnet 33
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
Note
pt
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
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.
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
Removing
wit
, is n
h re
spec
– Unclip mounting bracket -2- with support rod -1- from front lock
es, in part or in w
t to the co
carrier.
Installing
rrectness of i
l purpos
Note
at
ion
c
in t
r
– Position bracket -2- with support rod -1- and clip into front of
o
his
te
lock carrier.
a
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.
1. Bonnet 35
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
n AG. Volkswagen AG do
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.
ce
le
un
pt
an
d
itte
y li
⇒ “2.3 Assembly overview - hinge”, page 39
rm
ab
pe
ility
⇒ “2.4 Assembly overview - tailgate lock”, page 40
ot
wit
, is n
h re
⇒ “2.5 Assembly overview - tailgate handle”, page 41
hole
spec
es, in part or in w
t to the co
page 42
⇒ “2.7 Assembly overview - arrester cable, tailgate”, page 42
rrectness of i
⇒ “2.8 Assembly overview - tailgate spacer”, page 45
l purpos
nform
ercia
a
com
tio
⇒ “2.12 Removing and installing hinge”, page 47
n in
r
te o
thi
⇒ “2.13 Removing and installing tailgate lock”, page 49
s
iva
do
r
rp
cum
⇒ “2.14 Removing and installing tailgate handle”, page 51
fo
en
ng
t.
yi Co
⇒ “2.15 Removing and installing tailgate handle with lock cylin‐
Cop py
der”, page 52
t. rig
gh ht
pyri by
Vo
o
⇒ “2.16 Removing and installing striker plate”, page 54
c by lksw
cted agen
Prote AG.
⇒ “2.17 Removing and installing torsion bar”, page 56
2. Tailgate 37
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
AG. Volkswagen AG d
agen oes
lksw not
2.2 Assembly overview - tailgate with torsion bar
o
byV gu
ara
ed
ris nte
ho eo
aut ra
s c
1 - Tailgate s
ce
le
un
pt
❑ Removing and installing
an
d
itte
⇒ page 45 .
y li
erm
ab
ility
2 - Middle bracket
ot p
wit
is n
3 - Washer
h re
ole,
spec
4 - Bolt
urposes, in part or in wh
t to the co
❑ Specified torques: 25
Nm
5 - Rear panel
rrectne
6 - Torsion bar
ss
7 - Bolt
o
cial p
f in
❑ Qty. 3
form
mer
atio
m
Nm
o
n
c
i
or
n thi
8 - Clip
te
sd
iva
o
r
9 - Bracket
p
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 - Tailgate
❑ Removing and installing
⇒ page 45
2 - Bolt
❑ Qty. 3 on each side
❑ Specified torques: 25
Nm
3 - Hinge
❑ Left and right.
❑ Removing and installing
⇒ page 47
4 - Base
❑ Left and right. 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
urposes, in part or in wh
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. Tailgate 39
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
Note
1 - Lock
❑ Removing and installing
⇒ page 49
2 - Bolt
❑ Qty. 2
❑ Specified torques: 20
Nm.
3 - Arrester cable
4 - Pull rod
❑ To handle
5 - Tailgate
❑ Removing and installing
⇒ page 45
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
40
AG.
Rep. gr.55 - Bonnet, rear lid
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
1 - Tailgate handle
❑ Removing and installing
⇒ page 51
2 - Bolt
❑ Qty. 2
❑ Specified torques: 2.3
Nm
3 - Tailgate
❑ Removing and installing
⇒ page 45
4 - Pull rod
❑ Left and right.
❑ To lock ⇒ page 40
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.
2. Tailgate 41
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
1 - Tailgate handle
❑ With lock cylinder
❑ Removing and installing
⇒ page 52 .
2 - Lock cylinder
Note
3 - Bolt
❑ Qty. 2
n AG. Volkswagen AG do
❑ Specified torques: 2.3 lkswage es n
o ot g
Nm 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
.
2.7 Assembly overview - arrester cable, tail‐
t rig
gh ht
pyri by
Vo
o
gate
c by lksw
cted agen
Prote AG.
Note
ce
e
WARNING
nl
pt
du
an
itte
Bolts must always be re‐
y li
erm
ab
placed by new ones after
ility
being removed. ot p
wit
, is n
h re
hole
❑ Qty. 2
spec
es, in part or in w
❑ Specified torques: 20
t to the co
Nm
2 - Arrester cable, tailgate
rrectness of i
❑ Press tailgate arrester
l purpos
cable in
-direction of arrow a-
against bolt -1- and pull
nform
ercia
in -direction of arrow b-
m
at
3 - Washer
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.
2. Tailgate 43
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
Note
1 - Bolt
WARNING
Bolts must always be re‐
placed by new ones after
being removed.
❑ Qty. 2
❑ Specified torques: 20
Nm
2 - Arrester cable, tailgate
❑ Press tailgate arrester
cable in
-direction of arrow a-
against bolt -1- and pull
in -direction of arrow b- AG. Volkswagen AG d
agen oes
lksw not
3 - Washer d byV
o gu
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
Ensure that the adhesive surfaces are free of dust and grease.
1 - Left seal
❑ Pushed onto edge of
load bed
2 - Right seal
❑ Pushed onto edge of
load bed
3 - Tailgate seal
❑ Bonded on lower edge
n AG. Volkswagen AG do
of tailgate olkswage es n
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
2.10 Removing and installing tailgate
Prote AG.
2. Tailgate 45
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
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.
Removing
– Loosen bolts -2- on left and right hinges (do not remove).
Further dismantling requires the help of a second mechanic.
– Only now remove bolts -2- and remove tailgate -1-.
Installing
Installation is carried out in reverse order. When doing this, ob‐
serve the following:
ce
le
un
pt
an
d
Component Specified torques
itte
y li
erm
ab
Tailgate bolts 40 Nm
ility
ot p
wit
2.11 Adjusting tailgate is n
h re
ole,
spec
urposes, in part or in wh
t to the co
♦ Torque wrench -V.A.G 1331-
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
yri by
Note op Vo
by c lksw
cted agen
Prote AG.
♦ Vehicle must be on the ground when adjusting tailgate.
♦ Tailgate must engage in striker plate -1- and fixture -3- without
excessive force.
2. Tailgate 47
Amarok 2011 ➤ AG. Volkswagen AG d
agen oes
General body repairs, exterior
V olksw - Edition 10.2012 not
g y ua
db ran
rise tee
♦ Torque wrench -V.A.G u1331-
tho or
s a ac
s
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
Note
nf
ercia
or
Removal and installation are described only for the left hinge. Removal and installation of the right hinge are
m
m
atio
similar.
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.
Removing
– Removing tailgate -1- ⇒ page 45 .
Note
Specified torques
♦ ⇒ “2.3 Assembly overview - hinge”, page 39 .
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
Note
nform
ercia
Removal and installation are described only for the left lock. The removal and installation of the right lock are
m
similar.
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.
2. Tailgate 49
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
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
Removing
– Removing tailgate trim ⇒ General body repairs, interior; Rep.
gr. 70 ; Removing and installing tailgate trim .
rrectness of i
Note
com
tion in
r
te o
Arrester cable -3- for tailgate -5- is bolted under lower bolt -2- ⇒ page 42 .
thi
s
iva
do
r
rp
cum
en
ng
t.
yi Co
– Unclip pull rod -4- from lock. Cop py
ht. rig
rig ht
Installing py by
co Vo
by lksw
cted agen
Installation is carried out in reverse order. When doing this, ob‐ Prote AG.
serve the following:
Specified torques
♦ ⇒ “2.4 Assembly overview - tailgate lock”, page 40 .
ce
e
nl
pt
du
an
Special tools and workshop equipment required
itte
y li
erm
ab
♦ Torque wrench -V.A.G 1783-
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
Removing
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.
2. Tailgate 51
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
n AG. Volkswagen AG do
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
urposes, in part or in wh
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.
– Pull on tailgate handle -1-, insert at bottom and swing into po‐
sition.
– Clip pull rods -3- on left and right onto tailgate handle -1-.
Installation is carried out in reverse order. When doing this, ob‐
serve the following:
Specified torques
♦ ⇒ “2.5 Assembly overview - tailgate handle”, page 41 .
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
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
Removing
n
c
i
or
n thi
e
sd
iva
cum
r
fo
en
ng
– Unclip pull rods on left and right from tailgate handle -1-.
t.
yi Co
Cop py
– Unscrew bolts -3- from tailgate -2-.
t. rig
gh ht
pyri by
Vo
o
– Swivel tailgate handle -1- out of tailgate -2-. by c lksw
cted agen
Prote AG.
2. Tailgate 53
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
Installing
• Lock cylinder is installed ⇒ page 42 .
– Installation in unlocked state (lock cylinder slot vertical).
– Pull on tailgate handle -1-, insert at bottom and swing into po‐
sition.
– Clip pull rods on left and right onto tailgate handle -1-.
Specified torques
Component Specified
agentorques
AG. Volkswagen AG d
o
w es n
olks ot g
Tailgate handle bolts 2.3
d bNm
yV ua
ran
e
ris tee
ho
2.16 Removing and installing striker plate
t or
au ac
ss
ce
le
pt
an
d
page 54
itte
y li
rm
ab
⇒ “2.16.2 Removing and installing striker plate 2011 ▶”,
pe
ility
page 55
ot
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
Removal and installation are described only for the left side. The
removal and installation of the right side are similar.
rrectness of i
2.16.1 Removing and installing striker plate ▶
l purpos
2010
nform
ercia
Removing
m
a
com
ti
– Remove bolts -2- and remove locking wedge -1-.
on in
r
te o
thi
Installing
s
iva
do
r
rp
t.
yi Co
op
– Adjusting tailgate ⇒ page 47 .
C py
ht. rig
rig ht
py by
Specified torques
co Vo
by lksw
cted agen
Prote AG.
Component Specified torques
Striker plate bolts 20 Nm
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
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. Tailgate 55
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
Note
n AG. Volkswagen AG do
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
Removing
t to the co
Installing
nf
ercia
atio
m
– Secure washer -3- and bolt -4- to hinge through eyelet of tor‐
o
n in
c
thi
te
sd
a
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
56
by lksw
cted agen
Rep. gr.55 - Bonnet, rear lid Prote AG.
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
Specified torques
♦ ⇒ “2.2 Assembly overview - tailgate with torsion bar”,
page 38
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.
2. Tailgate 57
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
ce
e
nl
pt
du
an
⇒ “3.4 Removing and installing load bed”, page 61
itte
y li
erm
ab
⇒ “3.5 Removing and installing cross-member buffer”,
ility
ot p
page 63
wit
, is n
h re
3.1 Assembly overview - load bed
hole
spec
es, in part or in w
t to the co
1 - Fastening ring
❑ Assembly overview
rrectness of i
⇒ page 59 .
l purpos
2 - Load bed
❑ Removing and installing
⇒ page 61
nf
ercia
orm
m
3 - Support
atio
om
n in
or c
⇒ page 59
thi
te
sd
iva
o
4 - Buffer - cross member
r
rp
cu
o
m
f
en
ng
t.
yi Co
⇒ page 63 . Cop py
rig
ht ht
rig
5 - Tank filler neck py by
co Vo
by lksw
❑ Unscrew ⇒ page 78 . cted agen
Prote AG.
6 - Ladder frame
Note
n AG. Volkswagen AG do
wage es n
Only the left side is shown. The right side is similar. byV
olks ot g
ua
d ran
ir se tee
tho
u or
a ac
1 - Load bed ss
ce
e
nl
pt
❑ Removing and installing
du
an
itte
⇒ page 61
y li
erm
ab
ility
2 - Pop rivet nut
ot p
wit
❑ Insert using pop rivet nut , is n
h re
pliers -V.A.G 1765B- .
hole
spec
es, in part or in w
3 - Bolt
t to the co
❑ Specified torque: 8 Nm
4 - Left support
rrectness of i
5 - Bolt
l purpos
❑ Specified torque: 8 Nm
6 - Bolt
nform
ercia
❑ Qty. 4
m
at
om
i
❑ Specified torque: 8 Nm
on
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.
3. Load bed 59
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
Note
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.
ce
le
un
pt
3.3.2 Lashing eyes, single cab
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
Note
h re
hole
spec
Only the left side is shown. The right side is analogous.
es, in part or in w
t to the co
1 - Rear lashing eye
rrectness of i
❑ Secured with bolts -2-
l purpos
nform
ercia
a
com
ti
❑ Secured with bolts -2-
on in
r
te o
thi
4 - Bolt
s
iva
do
❑ 2 per lashing eye
r
rp
cum
fo
❑ Specified torques: 20
en
ng
t.
yi Co
Nm. . Cop py
rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
3. Load bed 61
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
Note
Removal and installation are described only for the double cab load bed. The removal and installation of the
single cab load bed are similar.
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
Removing
o
m
f
en
ng
t.
yi Co
– Remove towing bracket (if fitted) ⇒ page 355 . Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
62
cted agen
Prote AG.
Rep. gr.55 - Bonnet, rear lid
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
Note
WARNING
Specified torques
Component Specified
swa
torques
gen AG. Volkswagen AG d
oes
k not
Vol
Load bed bolts 90
ed Nm + 90°
by gu
ara
ris nte
ho eo
ut
3.5 Removing and installing cross-member ss
a ra
c
buffer
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
Note
ot
wit
, is n
h re
Installation is described only for the left side. The right side is
hole
spec
similar.
es, in part or in w
t to the co
Removing
• Load bed removed
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.
3. Load bed 63
n AG. Volkswagen AG do
lkswage es n
Amarok 2011 ➤ byV
o ot g
ua
ed ran
General body repairs, exterior - Edition
horis 10.2012 tee
ut or
a ac
ss
– Unclip outer side of buffer -2- -arrow A-.
ce
le
un
pt
– Swivel buffer -2- out of cross member -arrow B-.
an
d
itte
y li
erm
ab
Installing
ility
ot p
wit
Install in reverse order of removal.
is n
h re
ole,
spec
urposes, in part or in wh
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.
. Volkswagen AG
gen AG
4 Cab a does
ksw not
Vol gu
by ara
ed nte
⇒ “4.1 Assembly
tho
ris overview - cab”, page 65 eo
au ra
⇒ “4.2
ss Assembly overview - front mounting for cab”, page 67 c
ce
e
nl
pt
⇒ “4.3 Assembly overview - centre mounting for cab”, page 68
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
⇒ “4.6 Removing and installing cab”, page 71
hole
spec
es, in part or in w
t to the co
page 73
⇒ “4.8 Removing and installing pressure hoses and hose con‐
rrectness of i
nections with screw-type clamps”, page 74
l purpos
nform
ercia
at
om
ion
4.1.1 Double cab
c
in t
or
his
ate
do
priv
cum
1 - Cab
for
en
ng
t.
yi
❑ Removing and installing
Co
op py
⇒ page 71 . t. C rig
gh ht
pyri by
2 - Front mounting
o Vo
by c lksw
cted agen
Prote
❑ Removing and installing
AG.
⇒ page 67 .
3 - Bolt
❑ Specified torque 90 Nm
+ turn 180° further.
❑ Bolts must always be re‐
newed after being loos‐
ened.
4 - Rear mounting
❑ Removing and installing
⇒ page 69 .
5 - Bolt
❑ Specified torque 90 Nm
+ turn 180° further.
❑ Bolts must always be re‐
newed after being loos‐
ened.
6 - Middle mounting
❑ Removing and installing
⇒ page 68 .
7 - Bolt
❑ Specified torque 90 Nm
+ turn 180° further.
❑ Bolts must always be re‐
newed after being loos‐
ened.
4. Cab 65
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
1 - Cab
❑ Removing and installing
⇒ page 71 .
2 - Front mounting
❑ Removing and installing
⇒ page 67 .
3 - Bolt AG. Volkswagen AG d
agen oes
❑ Specified torque 90 Nm Volksw not
gu
y
+ turn 180° further. d b ara
rise nte
❑ Bolts must always be re‐ autho eo
ra
newed after being loos‐ ss c
ened.
ce
le
un
pt
an
d
4 - Rear mounting itte
y li
rm
ab
❑ Removing and installing
pe
ility
⇒ page 70 .
ot
wit
, is n
h re
5 - Bolt
hole
spec
❑ Specified torque 90 Nm
es, in part or in w
t to the co
+ turn 180° further.
❑ Bolts must always be re‐
newed after being loos‐
rrectness of i
ened.
l purpos
6 - Middle mounting
❑ Removing and installing
nform
ercia
⇒ page 68 .
m
7 - Bolt
a
com
tion in
❑ Specified torque 90 Nm
r
te o
thi
s
iva
do
❑ Bolts must always be re‐
r
rp
cum
newed after being loos‐
fo
en
g
ened.
n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
1 - Top mounting
2 - Bottom mounting
3 - Ladder frame
4 - Front mounting support
n AG. Volkswagen AG do
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.
4. Cab 67
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
Note
1 - Top mounting
2 - Bottom mounting
3 - Ladder frame
4 - Middle mounting support
n AG. Volkswagen AG do
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
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.
Note
1 - Rear mounting
❑ Removing:
– Lift cab and remove
bolts -2-.
2 - Bolt
❑ Qty. 2
❑ Specified torque: 55 Nm
3 - Ladder frame
4 - Rear mounting support
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.
4. Cab 69
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
1 - Rear mounting
❑ Removing:
– Lift cab and remove
bolts -2-.
2 - Bolt
❑ Qty. 2
❑ Specified torque: 55 Nm
3 - Ladder frame
4 - Rear mounting support
n AG. Volkswagen AG do
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
70
cted agen
Prote AG.
Rep. gr.55 - Bonnet, rear lid
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
Note
olksw
For single cab and double cab vehicles the retaining strap is installed
swa
gen Aon driveraside.
G. V gen AG
does
k not
Vol gu
d by ara
e nte
ris
tho eo
1 - Retaining strap au ra
c
ss
❑ Removing and installing
ce
le
un
pt
⇒ page 73
an
d
itte
y li
erm
2 - Protective hose
ab
ility
ot p
❑ For retaining strap -1-.
wit
is n
h re
❑ Installation only on left-
ole,
spec
urposes, in part or in wh
of 2012
t to the co
3 - Bolt
❑ For holding together
rrectne
structure/for dust pro‐
tection
s
❑ Specified torque: 75 Nm
s o
cial p
f i
4 - Hexagon nut
nform
mer
❑ Specified torque: 75 Nm
atio
om
5 - Bolt
n
c
i
or
n thi
e
❑ Specified torque: 75 Nm
t
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.
4. Cab 71
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
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
Note
h re
hole
spec
es, in part or in w
Removal and installation are described only for the double cab. The removal and installation of the single cab
t to the co
load bed are analogous.
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.
Removing
– Remove load bed ⇒ page 61
pt
du
an
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
hole
spec
During assembly, it is helpful to guide cab -1- onto body mountings using commercially available threaded rods.
es, in part or in w
t to the co
Specified torques
♦ ⇒ “4.1 Assembly overview - cab”, page 65 .
rrectness of i
for cab
nf
ercia
Removing
orm
m
atio
om
n in
c
Note
or
thi
te
sd
iva
o
r
cu
o
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4. Cab 73
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
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
urposes, in part or in wh
clamps
t to the co
⇒ “4.8.1 Hose connections with push-on couplings”, page 74
rrectne
⇒ “4.8.2 Pressure hose with ribbed union and hose clamp”, page
75
ss
⇒ “4.8.3 Notes on hose connections with screw-type clamps”,
o
cial p
f
page 76
inform
mer
plings n
c
i
or
n thi
te
sd
iva
o
pr
Caution
cum
r
fo
en
ng
t.
yi Co
The sealing ring for the push-on coupling can be damaged if Cop py
.
the retaining clip is in the locked position during installation.
ht rig
rig ht
py by
co Vo
This would result in leaking.
by lksw
cted agen
Prote AG.
Do not use any fluid containing oil, silicone or grease. Only use
clean water.
ce
le
Note
un
pt
an
d
itte
y li
rm
♦ When replacing the sealing ring, place the sealing ring in the
ab
pe
ility
groove of the charge air hose.
ot
wit
, is n
h re
hole
groove all around the hose. Make sure that the sealing ring is
spec
not twisted.
es, in part or in w
t to the co
♦ Apply clean water to sealing surfaces and sealing ring.
rrectness of i
– Move retaining clip -2- to release position.
l purpos
nform
ercia
– Move retaining clip -2- to locking position and then give the
m
a
com
tion in
– Check that the plug-in coupling is correctly engaged and seat‐
r
te o
thi
ed by pulling on the charge air hose.
s
iva
do
r
rp
cum
fo
en
ng
t.
Note Cop
yi Co
py
t. rig
gh ht
♦ If the retaining clip cannot be pushed down fully, the pressure pyri by
Vo
o
by c
hose is not inserted sufficiently in the coupling.
lksw
cted agen
Prote AG.
♦ Press pressure hose again and lock retaining clip.
4. Cab 75
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
. Volkswagen AG
gen AG does
– Push pressure hose together with hose clamp -A- onto ribbed
Vol
ksw
a
not
union as far as it will go. ed
by gu
ara
ris nte
– Tighten screw of hose clamp -A-. utho eo
ra
a c
ss
ce
e
nl
pt
Caution
du
an
itte
y li
erm
ab
The hose clamp screw -A- must be tightened as prescribed. If
ility
ot p
the tightening torque is too low or too high, the pressure hose
wit
, is n
may slip off the ribbed union when the vehicle is being driven.
h re
hole
spec
es, in part or in w
t to the co
Notes on hose connections with screw-type clamps
⇒ page 76 .
rrectness of i
Specified torque for hose clamps:
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
4.8.3 Notes on hose connections with screw- cted agen
Prote AG.
type clamps
Caution
Caution
• Do not loosen these hose clamps and pull them back over
the hose.
• Risk of damage to hose!
• If a clamp has been removed, it must be renewed together
with the hose.
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.
4. Cab 77
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
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
Removing
ate
do
priv
-2-.
en
ng
t.
yi Co
op py
– Pull tank flap -1- in -direction of arrow- off tank flap unit -2-. t. C rig
gh ht
pyri by
Installing
co Vo
by lksw
cted agen
Prote AG.
– Push tank flap -1- onto tank flap unit -2- until it clips in securely.
ce
le
♦ Torque screwdriver -V.A.G 1624-
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.
Removing
– Remove tank flap ⇒ page 78 .
– Remove bolt -2-.
– Peel rubber grommet off fuel filler neck.
– Pull tank flap unit -1- forwards -arrow A-.
– Swivel tank flap unit -1- out of side part -arrow B-.
Note
♦ Bolts -3- are used for securing tank filler neck to load bed. AG. Volkswagen AG d
agen oes
ksw
♦ Specified torque: 5 Nm ol not
y V gu
d b ara
rise nte
tho eo
Installing s au ra
c
s
ce
Installation is carried out in reverse order. When doing this, ob‐
le
un
pt
serve the following:
an
d
itte
y li
rm
ab
Specified torques
pe
ility
ot
wit
, is n
Component Specified torques
h re
hole
Tank flap unit bolts 1.5 Nm
spec
es, in part or in w
t to the co
5.3 Removing and installing actuator
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.
Removing
– Remove fuel tank flap unit ⇒ page 78
– Remove rear wheel housing liner ⇒ page 306
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
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
e
nl
⇒ “1.6 Removing and installing door hinge on A-pillar”,
pt
du
an
page 89
itte
y li
erm
ab
⇒ “1.7 Removing and installing door hinge on door”, page 90
ility
ot p
wit
, is n
h re
hole
spec
1.1 Assembly overview - door hinge on A-
es, in part or in w
t to the co
pillar
rrectness of i
Note
l purpos
nform
ercia
at
hinge. The procedure for the lower door hinge is similar.
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.
1 - Door
❑ Removing and installing
⇒ page 86
❑ Adjusting ⇒ page 88
2 - Door hinge
❑ The hinge is split and wage
n AG. Volkswagen AG do
es n
s
bolted to the A-pillar. yV
olk ot g
ua
d b ran
3 - Bolt ir se tee
tho
u or
❑ Specified torques: 30 ss
a ac
Nm
ce
le
un
pt
an
d
4 - Bolt
itte
y li
erm
ab
❑ Installed from inside ve‐
ility
ot p
hicle.
wit
is n
h re
❑ Specified torques: 30
ole,
Nm
spec
urposes, in part or in wh
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.
1. Door 83
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
Note
The assembly overview is for the right side. The left side is similar.
1 - Front door
❑ Removing and installing
⇒ page 86
❑ Adjusting ⇒ page 88
2 - Door hinge
❑ Hinge is split and bolted
to door.
3 - Bolt
❑ Specified torques: 45
Nm
❑ Always renew after
loosening.
n AG. Volkswagen AG do
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
sd
iva
o
r
rp
cu
m
f
en
ng
which are then placed on the door flange and rolled on.
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
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
urposes, in part or in wh
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.
Removing
– Loosen sill panel strip up to B-pillar ⇒ General body repairs,
interior; Rep. gr. 68 ; Interior equipment; Sill panel strips .
1. Door 85
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
AG. Volkswagen AG d
agen
Note Volksw
oes
not
by gu
d ara
ise n
Removal and installation are described for the
ut
hor
left door. The removal and installation of theteeright
or door are similar.
s a ac
s
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
o
by c lksw
cted agen
Prote AG.
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.
Removing
– Release boot -5- by pressing fastener -arrow a- and pull off A-
pillar.
– Swing locking lever -6- downwards -arrow b- and disconnect
electrical connector from coupling station.
– Unscrew bolts -2- on top and bottom hinges.
– Unscrew bolts -3- for door arrester -4-.
– Lift door -1- upwards out of hinges.
Installing
Installation is carried out in reverse order. When doing this, ob‐
serve the following:
– Observe front door gaps ⇒ Body Repairs; Rep. gr. 00 ; Tech‐
nical data; Body panel gaps/shut lines; Body - front .
Note
1. Door 87
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
Specified torques
Component Specified torques
Bolt -3- on door arrester at 8.8 20 Nm
Bolt -3- on door arrester at 10.9 33 Nm
Hinge bolt 23 Nm
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
ut ra
Note ss a c
ce
le
un
pt
♦ Threaded plate of striker pin is secured in pillar using a method
an
d
itte
y li
which differs from the previous method.
erm
ab
ility
ot p
wit
is n
♦ The door must lock fully when closing without any additional
force being required and must not have any play.
rrectne
• When the front door does not align with the rear door or the D-
atio
m
pillar.
o
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.
. Volkswagen AG
gen AG
1.6 Removing andy Vinstalling door hingeoeon
wa s no d
olks t gu
A-pillar orised b ara
nte
he
ut or
Special tools and workshop
ss
a
equipment required ac
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
Note
atio
om
n
c
i
or
Removal and installation are described for the left door. The removal and installation of the right door are similar.
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.
1. Door 89
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
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
Removing opyri
gh by
Vo
ht
c
– Remove upper door hinge on dash panel cover ⇒ General
by lksw
cted agen
Prote
body repairs, interior; Rep. gr. 70 ; Dash panel cover .
AG.
ce
e
nl
pt
du
♦ Torque wrench -V.A.G 1331-
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
Note
ion
c
in t
or
his
e
Removal and installation are described for the upper door hinge. The lower door hinge is similar.
at
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.
Removing
– Remove front door ⇒ page 86 .
– Remove bolts -3-.
1. Door 91
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
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
Note
l purpos
The removal and installation sequence is only for the right door
arrester. Removal and installation of the left door arrester is sim‐
nform
ercia
ilar.
m
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.
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
urposes, in part or in wh
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
Removing
AG.
1. Door 93
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
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
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2 Door components
⇒ “2.1 Assembly overview - door components”, page 95
⇒ “2.2 Assembly overview - window regulator”, page 97
⇒ “2.3 Assembly overview - door lock”, page 98
⇒ “2.4 Assembly overview - door lock cover”, page 99
⇒ “2.5 Assembly overview - cap”, page 100
⇒ “2.6 Assembly overview - window regulator motor”, page 101
⇒ “2.7 Removing and installing window regulator motor”,
page 101
⇒ “2.8 Removing and installing window regulator”, page 103
⇒ “2.9 Removing and installing door handle”, page 105
⇒ “2.10 Removing and installing door lock”, page 105
⇒ “2.11 Removing and installing window channel”, page 108
⇒ “2.12 Removing and installing lock cylinder”, page 109
⇒ “2.13 Removing and installing housing (without lock cylinder)”,
page 111
⇒ “2.14 Removing and installing inner door handle”, page 113
⇒ “2.15 Removing and installing door handle bracket”,
page 115
⇒ “2.16 Removing and installing striker”, page 117
⇒ “2.17 Removing and installing window slot outer seal”,
page 117
AG . Volkswagen AG
⇒ “2.18 Removing and installing window slot inner seal”,ksw
agen does
not
l
page 119 by
Vo gu
ara
d
ise nte
⇒ “2.19 Removing and installing top door seal”,
ut
ho page 121
r eo
ra
sa c
⇒ “2.20 Removing and installing bottom door
s seal”, page 122 ce
e
nl
pt
du
y li
page 123
erm
ab
ility
ot p
123
h re
hole
spec
t to the co
Note
rrectness of i
1 - Locking rod
nform
ercia
at
io
-2-
n
c
in t
or
his
e
2 - Door lock
at
do
priv
en
g
t.
yi Co
op
⇒ page 105 C py
t. rig
gh ht
yri
3 - Cover
p by
co Vo
by lksw
cted
❑ Emergency locking
agen
Prote AG.
2. Door components 95
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
4 - Bolt
❑ Right and left
❑ Specified torque: 20 Nm.
❑ Qty. 2
5 - Cable
❑ Right and left
❑ From inner door handle -6- to door lock -2-
6 - Door lock cover
❑ Right and left
❑ Assembly sequence ⇒ page 99
7 - Interior door handle
❑ Right and left
❑ Removing and installing ⇒ page .113
Volkswage n AG n AG d
wage oes
8 - Cover Vol
ks not
gu
d by ara
❑ Right and left orise nte
h eo
ut of lock cylinder
❑ For the bolts a-8- ra
s c
ce
e
9 - Bolt
nl
pt
du
an
❑ Right and left
itte
y li
erm
ab
❑ For lock cylinder.
ility
ot p
h re
hole
10 - Cover spec
es, in part or in w
11 - Lock cylinder
❑ Removing and installing ⇒ page 109
rrectness of i
12 - Base
❑ Clipped into door
nf
ercia
or
13 - Cable
m
m
atio
m
n in
or c
thi
sd
iva
cu
o
m
f
t.
yi Co
op
15 - Bolt
C py
t. rig
gh ht
yri
❑ Specified torque: 1.5 Nm.
p by
co Vo
by lksw
cted
❑ Bearing plate is loosened from door when this bolt is loosened
agen
Prote AG.
ce
le
un
pt
2.2 Assembly overview - window regulator
an
d
itte
y li
erm
ab
ility
ot p
1 - Front door
wit
is n
h re
2 - Window regulator
ole,
spec
urposes, in part or in wh
❑ Removing and installing
t to the co
⇒ page 103
3 - Bolt
rrectne
❑ Qty. 2
❑ Specified torque: 9 Nm
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.
2. Door components 97
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
1 - Door lock
❑ Removing ⇒ page 105
2 - Bowden cable
❑ To inner door handle
⇒ page 113
3 - Bowden cable
❑ To door handle bracket
⇒ page 115
4 - Locking rod
❑ For mechanical door
lock
❑ The end of the rod must
always point away from
the B-pillar.
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
urposes, in part or in wh
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.
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
riv
Assembly sequence:
p
cum
for
en
g
t.
yi Co
Cop py
– Slide cover cap -2- downwards and at the same time guide ht. rig
rig ht
door lock -1- into U-profile.
py by
co Vo
by lksw
cted agen
– Lug -arrow- of cover cap -2- must be pressed down and en‐
Prote AG.
2. Door components 99
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
gen AG
. Volkswagen AG
d wa oes
olks not
yV gu
2.5 Assembly overview - cap
b ara
ed nte
ris
tho eo
au ra
c
ss
1 - Cap
ce
le
un
pt
an
d
❑ For vehicles without
itte
y li
door seal erm
ab
ility
ot p
2 - Grommet
wit
is n
h re
❑ For vehicles with door
ole,
spec
seal
urposes, in part or in wh
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.
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
Removing
Note
♦ Removal is described only for the right window regulator motor. Removal of left window regulator motor is
similar.
♦ Removal of manual window regulator -3- is similar.
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
atio
n in
c
– Remove window regulator motor with control unit -1- (or win‐
or
thi
e
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
102
by c lksw
cted
Rep. gr.57 - Front doors, door components, central locking
agen
Prote AG.
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
Installing
Note
WARNING
page 101 . an
itte
y li
erm
ab
2.8 Removing and installing window regula‐
ility
ot p
wit
, is n
tor
h re
hole
spec
t to the co
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Removing Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted
Note
agen
Prote AG.
Removal and installation are described only for the right window regulator. The removal and installation of the
left window regulator is similar.
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
o
– Removing front door trim ⇒ General body repairs, interior;
rm
m
atio
Rep. gr. 70 ; Door trims .
om
n in
c
thi
te
sd
a
o
r
rp
cu
o
m
f
t.
yi Co
op
– Remove the 2 bolts -3-.
C py
t. rig
gh ht
yri by
– Unlock retaining hooks on cable drum. cop Vo
by lksw
cted agen
Prote AG.
– Swing window regulator -2- into door.
– Guide window regulator -2- to cut-out in door -1- and remove
it.
Installing
– Guide window regulator -2- through cut-out into door -1-.
– Guide window regulator to its installation locations.
– Insert thread of window regulator through door and tighten
bolts -3-.
– Push cable drum -1- through holes in door, retaining hooks
must audibly engage.
ce
e
nl
pt
du
2.9 Removing and installing door handle
an
itte
y li
erm
ab
ility
ot p
wit
Note
, is n
h re
hole
spec
Removal and installation are described only for the right door
es, in part or in w
handle. The removal and installation of the left door handle are
t to the co
similar.
rrectness of i
Removing
l purpos
nf
ercia
– Pull door handle -1- backwards slightly out of retainer for bear‐
or
ing bracket.
m
m
atio
m
– Swing door handle around and remove from door -2- at right
o
n in
or c
angles.
thi
te
sd
iva
Installing
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op py
– Swing door handle -1- into door -2-. t. C rig
gh ht
pyri by
– Push door handle -1- forward with force into retainer in bearing
o Vo
by c lksw
cted
bracket.
agen
Prote AG.
Removing
Note
Removal and installation are described only for the left door lock. The removal and installation of the right door
lock are similar.
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
o Vo
– Removing front door trim ⇒ General body repairs, interior; by c lksw
cted agen
Rep. gr. 70 ; Door trim . Prote AG.
Note
Note
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
urposes, in part or in wh
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.
Note
The fitting sequence specified for the bolts -4- must be adhered to.
The sequence in which the bolts -4- are tightened can be seen in
the illustration.
• Afterwards, the function must be checked, as an incorrectly
adjusted or incorrectly engaged cable cannot open the door
lock -2-.
Specified torques
Component Specified torques
Door lock bolts 20 Nm
Note
Removal and installation are described only for the right window channel. The removal and installation of the
left window channel is similar.
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.
Note
Removing
n AG. Volkswagen AG do
lkswage es n
o ot g
Note d byV ua
ran
ir se tee
tho
or
Removal and installation
au are described only for the right lock cylinder.ac Removal and installation of the left lock
ss
cylinder are similar.
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.
n AG. Volkswagen AG do
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
io
in t
or
his
e
do
priv
cum
en
ng
t.
yi
– Screw out bolt -6- to stop.
Co
Cop py
t. rig
gh ht
– Push bolt -6- in again. Only then is the lock cylinder -2- re‐ yri
p by
o Vo
leased.
c by lksw
cted agen
Prote AG.
– Pull door handle -1- off door in -direction of arrow-.
– Pull lock cylinder housing -2- out of door handle bracket at right
angles.
Installing
– Pull door handle -1- off door in -direction of arrow-.
– Insert lock cylinder housing -2- into door handle bracket -3- at
a right-angle.
– Screw bolts -5- and -6- into door handle bracket.
Note
n AG. Volkswagen AG do
lkswage es n
Vo ot g
During installation, elock
d by cylinder housing -2- must be pressed ua
ran
against outer door
thor panel.
is tee
u or
a ac
ss
• It is essential that the function then be checked with the door
ce
e
nl
pt
open.
du
an
itte
y li
Specified torques
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
out lock cylinder)
rrectness of i
For vehicles with central locking
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.
Removing
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
op
– Prise plug -4- out of opening. C py
t. rig
gh ht
yri
– Unclip cover cap -3- from housing -2-.
p by
o Vo
by c lksw
cted agen
– Insert assembly tool -T10389- -5- approx. 55 mm into door
Prote AG.
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
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
m
n
c
i
or
sd
iva
cum
r
fo
et.
en
ng
t.
yi Co
op
– Press housing -2- against door. C py
t. rig
gh ht
yri by
– Press screwdriver -5- far enough in until hook of sliding link op Vo
by c lksw
engages. cted agen
Prote AG.
– Secure plug -4- and clip cover cap -3- onto housing -2-.
Note
Removal and installation are described only for the right inner
door handle. The removal and installation of the left side are sim‐
ilar.
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.
Removing
– Removing front door trim ⇒ General body repairs, interior;
Rep. gr. 70 ; Door trim .
– Pull locking lever out of hole in inside door panel.
– Push inner door handle -1- out of clip in door -3-.
– Remove inside door film of front door ⇒ page 348 .
– Unclip Bowden cable out of door lock ⇒ page 98 .
– Remove inner door handle -1- from door -3-.
Driver side only
– Detach connector from button for inner door lock ⇒ Electrical
system; Rep. gr. 96 ; Removing and installing button for inner
door lock
– Unclip Bowden cable -2- from inner door handle -1-.
Installing
Install in reverse order of removal.
ce
e
♦ Torque wrench -V.A.G 1783- 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
Note
m
at
om
ion
c
Removal and installation are described only for the right door
in t
or
his
e
handle bracket. The removal and installation of the left door han‐
at
do
riv
cum
for
en
ng
t.
yi
Removing
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
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
at
om
io
in t
or
his
e
do
priv
en
ng
t.
yi
Installing
Co
Cop py
t. rig
gh
Installation is carried out in reverse order. When doing this, ob‐
ht
pyri by
Vo
o
serve the following:
c by lksw
cted agen
Prote AG.
Specified torques
Component Specified torques
Bearing bracket bolt 2.0 Nm
Note
Removal and installation are described only for the left striker.
The removal and installation of the right striker is similar.
Removing
– Unscrew bolt -2- and remove striker -1-.
Installing
– Place striker -1- on B-pillar and tighten bolts -2-.
– Adjusting striker pin ⇒ page 88 .
Specified torques
Component Specified torques
Striker 20 Nm
Note agen
AG. Volkswagen AG d
oes
olksw not
byV gu
ara
The removal is and installation sequence is only for the ntewindow slot
ed
or
outer aseal
ut
h on the right. Removal and installation of the eo
rwindow
ac
slot outer
ss seal on the left are analogous.
ce
le
un
pt
an
d
Removing
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
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
117
cted agen
Prote AG.
2. Door components
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
Amarok 2011 ➤rised ran
tee
o
General body au repairs, exterior - Edition 10.2012
th 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
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.
Note
– Pull window slot outer seal -1- evenly upwards -arrows- off
flange.
Installing
Installation is carried out in reverse order. When doing this, ob‐
serve the following:
Note
After installation, the window slot outer seal -1- must be seated
flush -arrow b-.
Note
Removal and installation are described only for the window slot inner seal on the right. Removal and installation
of the window slot inner seal on the left are analogous.
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
– Remove front door trim ⇒ General body repairs, interior; Rep. yri
gh by
ht
gr. 70 ; Trims, insulation; Door trims . cop Vo
by lksw
cted agen
Prote
– Pull window slot outer seal -1- evenly upwards off flange.
AG.
Installing
Only models with dust package . Volkswagen AG
gen AG does
swa
Bond front foam strip -1- and rearyfoam Volk strip -2-. not
gu
d b ara
e nte
Remove protective film before horis
installation. 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.
Note
Removal and installation are described only for the top right seal.
Removal and installation of the top left seal is analogous.
n AG. Volkswagen AG do
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
Removing Prote
cted AG.
agen
– Pull top door seal -1- off door complete with the clips -2-.
Note
When pulling off top seal -1-, bear in mind the adhesive strip -3-.
Installing
Note
ce
le
un
pt
an
d
itte
y li
erm
ab
Note
ility
ot p
wit
is n
h re
Removal and installation are described only for the bottom right
ole,
spec
urposes, in part or in wh
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.
ce
e
– Pull bottom door seal -1- off door -3- complete with the clips
nl
pt
du
-2-.
an
itte
y li
erm
ab
Installing
ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
t to the co
Check clips -2- for damage and renew if necessary.
rrectness of i
2.21 Assembly overview - impact rail of front
l purpos
door
nf
ercia
orm
m
Note
atio
om
n in
or c
The assembly overview is only for the right side. The left side is
thi
te
sd
a
analogous.
iv
o
r
rp
cu
o
m
f
en
ng
Specified torques
t.
yi Co
Cop py
t. rig
Component Specified torques
gh ht
pyri by
Vo
o
by c lksw
Impact rail Prote
cted 30 Nm AG.
agen
Note
Removal and installation are described only for the right side. Removal and installation on the left side are
analogous.
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
– Removing front door trim ⇒ General body repairs, interior;
Rep. gr. 70 ; Door trim . rrectness of i
Removing
l purpos
– Drill out pop rivet -2- using suitably sized drill bit.
– Remove loudspeaker -1- from front door and detach electrical
nform
ercia
connector.
m
a
com
Installing
ion in
r
te o
thi
do
r
– Insert loudspeaker -1- into front door and pull in pop rivets
rp
cum
fo
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
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.
1. Door 125
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
1 Door
⇒ “1.1 Assembly overview - door hinges on B-pillar”, page 126
⇒ “1.2 Assembly overview - door hinge on door”, page 127
⇒ “1.3 Removing and installing door”, page 128
⇒ “1.4 Adjusting striker”, page 129
⇒ “1.5 Removing and installing door hinge on B-pillar”,
page 130
⇒ “1.6 Removing and installing door hinge on door”, page 131
⇒ “1.7 Removing and installing door arrester”, page 132
⇒ “1.8 Removing and installing door inner seal”, page 133
⇒ “1.9 Removing and installing door outer seal”, page 134
Note
1 - Door
❑ Removing and installing n AG. Volkswagen AG do
lkswage es n
⇒ page 128 byV
o ot g
ua
d ran
❑ Adjusting: ir se tee
tho
u or
a ac
2 - Door hinge ss
ce
e
nl
an
bolted to the B-pillar.
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
hole
3 - Bolt
spec
es, in part or in w
❑ Specified torques: 30
t to the co
Nm
4 - Bolt
rrectness of i
hicle.
❑ Specified torques: 30
Nm
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.
Note
olkswagen AG
en AG. V
The assembly overview isofor
lkswthe right side. The left eside
ag do s
not is similar.
yV gu
db ara
rise nte
tho eo
au ra
1 - Front door ss c
ce
e
pt
du
an
⇒ page 128
itte
y li
erm
ab
❑ Adjusting ⇒ page 129
ility
ot p
wit
, is n
h re
❑ Hinge is split and bolted
hole
spec
to door.
es, in part or in w
t to the co
3 - Bolt
❑ Specified torques: 30
Nm
rrectness of i
4 - Door lower hinge
l purpos
nf
ercia
or
5 - Bolt
m
m
atio
m
❑ Specified torques: 30
o
n in
c
Nm
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
co lksw
by
cted agen
Prote AG.
1. Door 127
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
Note
The removal and installation sequence is for the left door. The removal and installation of the right door is
similar.
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.
Removing
– Release bellows -5- by pressing catch -arrow a- and pull off B-
pillar.
– Swing locking lever -6- downwards -arrow b- and disconnect
electrical connector from coupling station.
– Unscrew bolts -2- on top and bottom hinges.
– Unscrew bolts -4- for door arrester -3-.
– Lift door -1- upwards out of hinges.
Installing
Installation is carried out in reverse order. When doing this, ob‐
serve the following:
Note
n AG. Volkswagen AG do
swage es n
Specified torque for bolt -4- differs according to strengthbyrating:
Volk ot g
ua
d ran
ir se tee
ho
Specified torques aut or
ac
ss
ce
le
Component Specified torques
un
pt
an
d
itte
Bolt -4- on door arrester at 8.8 20 Nm
y li
rm
ab
pe
Bolt -4- on door arrester at 10.9 33 Nm
ility
ot
wit
, is n
Hinge bolt 23 Nm
h re
hole
spec
1.4 Adjusting striker
es, in part or in w
t to the co
Note
rrectness of i
♦ Threaded plate of striker pin is secured in pillar using a method
l purpos
nform
ercia
a
com
t
♦ Increased forces must be applied so that striker pin can be
ion in
adjusted with bolts loosened.
r
te o
thi
s
iva
♦ The door must lock fully when closing without any additional
do
r
rp
c
force being required and must not have any play.
um
fo
en
ng
t.
♦ The door must not be pushed up or down due to striker pin
yi Co
op
adjustment.
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
The following can be adjusted at the striker pin: cted agen
Prote AG.
• When the front door does not align with the rear door or the D-
pillar.
– Loosen striker -1- by loosening bolts -2- in C-pillar.
– Adjust the striker -1- with light taps (plastic hammer) so that
the rear door is flush with the C-pillar when shut (wind noise).
– Tighten bolts -2- of striker -1-.
Specified torques
Component Specified torques
Striker 20 Nm
1. Door 129
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
Note
The removal and installation procedure is for the right side. The removal and installation of the left side is similar.
n AG. Volkswagen AG do
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.
Removing
– Remove B-pillar top trim ⇒ General body repairs, interior; Rep.
gr. 70 ; Pillar and side panel trim .
– Remove B-pillar bottom trim ⇒ General body repairs, interior;
Rep. gr. 70 ; Pillar and side panel trim .
– Remove rear door ⇒ page 128 .
– Remove bolts -3- and -4-
Installing
Installation is carried out in reverse order. When doing this, ob‐
serve the following:
ce
e
nl
pt
du
an
♦ ⇒ “1.1 Assembly overview - door hinges on B-pillar”,
itte
y li
page 126 .
erm
ab
ility
ot p
wit
1.6 Removing and installing door hinge on door , 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
by c lksw
cted agen
Prote AG.
Removing
– Remove bolts -3- or -5-.
– Remove upper door hinge -2- or lower door hinge -4- from rear
door -1-.
Installing
Installation is carried out in reverse order. When doing this, ob‐
serve the following:
Specified torques
♦ ⇒ “1.2 Assembly overview - door hinge on door”, page 127 .
1. Door 131
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
ce
le
ilar.
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.
Removing
– Remove rear door trim ⇒ General body repairs, interior; Rep.
gr. 70 ; Door trim .
– Remove inner film of rear door ⇒ page 349 .
– Unscrew bolt -4- on B-pillar.
– Remove bolts -3- and remove door arrester -1- through open‐
ing in door.
Installing
Installation is carried out in reverse order. When doing this, ob‐
serve the following:
Specified torques
Component Specified torques
Door arrester bolt -4- 20 Nm
Door arrester bolt -4- from 05.2012 33 Nm
Door arrester bolts -3- 9.0 Nm
ce
e
nl
pt
du
an
itte
y li
erm
ab
♦ The edges are bent up slightly.
ility
ot p
wit
♦ If the seal is then refitted, sealing and firm seating are no lon‐
, is n
h re
ger guaranteed.
hole
spec
♦ Therefore each seal which is removed completely should be
es, in part or in w
t to the co
replaced by a so-called “tap-on” seal.
♦ If a seal has been partially removed, squeeze sides of seal
together before refitting.
rrectness of i
♦ The removal and installation sequence is only for the right door
l purpos
inner seal. The removal and installation of the left door inner
seal is similar.
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.
1. Door 133
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
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
Removing
ion
c
in t
or
cum
or
en
ng
t.
gr. 68 ; Interior equipment; Sill panel strips .
yi Co
Cop py
ht. rig
– Pull door inner seal -1- off body flange. rig ht
py by
co Vo
by lksw
Installing Prote
cted AG.
agen
– Align door inner seal -1- with mark -2- on fixing point -arrow-.
– Start installing inner door seal in upper radius of door aperture.
Note
♦ Removal and installation are described only for the right door
outer seal. Removal and installation of the left door outer seal
are similar.
♦ Check clips -2- for damage and renew if necessary.
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.
Removing
– Pull door outer seal -1- off door -3- complete with the clips
-2-.
Installing
– Push seal -1- with clips -2- onto door.
1. Door 135
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
n AG. Volkswagen AG do
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.
ce
le
un
pt
⇒ “2.1 Assembly overview - door components”, page 137
an
d
itte
y li
rm
ab
⇒ “2.2 Assembly overview - window regulator”, page 138
pe
ility
ot
wit
⇒ “2.3 Assembly overview - door lock”, page 139
, is n
h re
⇒ “2.4 Assembly overview - door lock cover”, page 140 hole
spec
es, in part or in w
t to the co
⇒ “2.6 Assembly overview - window regulator motor”, page 142
rrectness of i
⇒ “2.7 Removing and installing window regulator motor”,
page 142
l purpos
nform
ercia
a
com
tion in
⇒ “2.11 Removing and installing housing (without lock cylinder)”,
r
te o
thi
page 148
s
iva
do
r
rp
c
⇒ “2.12 Removing and installing inner door handle”, page 150
um
fo
en
ng
t.
yi
⇒ “2.13 Removing and installing door handle bracket”,
Co
op py
page 152
. C rig
ht ht
rig by
py
⇒ “2.14 Removing and installing striker”, page 153
co Vo
by lksw
cted agen
Prote AG.
⇒ “2.15 Removing and installing window channel”, page 153
⇒ “2.16 Removing and installing window slot inner seal”,
page 155
pt
du
an
3 - Bolt
itte
y li
erm
❑ Qty. 2 ab
ility
ot p
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.
ce
e
nl
pt
du
1 - Door lock
an
itte
y li
erm
❑ Removing and installing
ab
ility
⇒ page 146
ot p
wit
, is n
2 - Bowden cable
h re
hole
spec
❑ To inner door handle
es, in part or in w
⇒ page 139
t to the co
3 - Bowden cable
❑ To door handle bracket
rrectness of i
⇒ page 152
l purpos
4 - Locking rod
❑ For mechanical door
nform
ercia
lock
m
at
om
i
always point away from
on
c
in t
the B-pillar.
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.
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.
Assembly sequence:
– Fit cover cap -2- onto door lock -1-.
– Slide cover cap -2- downwards and at the same time guide
door lock -1- into U-profile.
– Lug -arrow- of cover cap -2- must be pressed down and en‐
gage audibly in door lock -1-.
ce
le
un
pt
an
d
itte
y li
erm
1 - Cap
ab
ility
ot p
❑ For vehicles without
wit
is n
door seal
h re
ole,
spec
2 - Grommet
urposes, in part or in wh
❑ For vehicles with door
t to the co
seal
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.
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
sd
iva
tor motor
o
r
rp
cu
o
m
f
en
ng
t.
Removing
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
Note
c by lksw
cted agen
Prote AG.
♦ Removal is described only for the right window regulator motor. Removal of left window regulator motor is
similar.
♦ Removal of manual window regulator -3- is similar.
n AG. Volkswagen AG do
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
atio
m
n in
or c
thi
sd
iva
o
r
cu
o
m
f
en
ng
Note
WARNING
n AG. Volkswagen AG do
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
144
by lksw
cted agen
Rep. gr.58 - Rear doors, door components Prote AG.
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
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
urposes, in part or in wh
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.
Note
Removal and installation are described only for the right window regulator. The removal and installation of the
left window regulator is similar.
Note
Removal and installation are described only for the right door
handle. The removal and installation of the left door handle are
similar. . Volkswag AG en AG
agen does
olksw not
Removing db
yV gu
ara
rise nte
– Remove housing ⇒ tho 148 .
page eo
au ra
c
ss
– Pull door handle -1- backwards slightly out of retainer for bear‐
ce
le
un
pt
ing bracket.
an
d
itte
y li
– Swing door handle around and remove from door -2- at right
erm
ab
ility
angles.
ot p
wit
is n
Installing
h re
ole,
spec
– Insert door handle -1- into bearing bracket at right angles.
urposes, in part or in wh
t to the co
f i
open.
nform
mer
atio
m
n
c
i
or
n thi
e
Removing
t
sd
iva
o
pr
cum
r
fo
en
ng
t.
Note Cop
yi Co
py
t. rig
gh ht
The removal and installation sequence is only for the right door lock. The removal and installation of the left
pyri by
Vo
o
by c
door lock is similar.
lksw
cted agen
Prote AG.
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
atio
n in
c
thi
te
sd
a
o
r
rp
cu
o
m
f
t.
yi Co
Cop py
t. rig
gh ht
yri
Note
p by
co Vo
by lksw
cted agen
Prote AG.
Cover cap -3- for emergency locking need not be removed.
Note
Installing
Installation is carried out in reverse order. When doing this, ob‐
serve the following:
• Afterwards, the function must be checked, as an incorrectly
adjusted or incorrectly engaged cable cannot open the door
lock -2-.
Specified torques
Component Specified torques
Door lock 20 Nm
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
Removing
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.
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
ab
ility
ot p
h re
t to the co
Installing
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
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
engages.
atio
om
n in
c
– Secure plug -5- and clip cover cap -2- onto housing -3-.
or
thi
te
sd
a
o
r
rp
cu
dle
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
Note cop Vo
by lksw
cted agen
Prote AG.
Removal and installation are described only for the right inner
door handle. The removal and installation of the left side are sim‐
ilar.
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.
Removing
– Remove rear door trim ⇒ General body repairs, interior; Rep.
gr. 70 ; Door trim .
– Pull locking lever out of hole in inside door panel.
– Push inner door handle -1- out of clip in door -3-.
– Remove inner film of rear door ⇒ page 349 .
– Unclip Bowden cable out of door lock ⇒ page 139 .
– Remove inner door handle -1- from door -3-.
– Unclip Bowden cable -2- from inner door handle -1-.
Installing
Install in reverse order of removal.
Note
Removal and installation are described only for the right door
handle bracket. The removal and installation of the left door han‐
dle bracket is similar.
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.
Removing
– Remove rear door trim ⇒ General body repairs, interior; Rep.
gr. 70 ; Door trim .
– Remove inner film of rear door ⇒ page 349 .
– Remove housing ⇒ page 148 .
– Remove door handle ⇒ page 146 .
– Remove bolt -3-.
– Remove door handle bracket -1- from door.
– Unclip Bowden cable -2- from door lock.
Installing
Installation is carried out in reverse order. When doing this, ob‐
serve the following:
Specified torques
Component Specified torques
Bearing bracket 2.0 Nm
Note
Removal and installation are described only for the right door
striker. The removal and installation of the left striker is similar.
n AG. Volkswagen AG do
Removing lkswage es n
o ot g
byV ua
ed ran
– Remove bolts -2- and remove striker
oris -1-. tee
th or
u
Installing ss
a ac
ce
e
nl
pt
du
an
itte
y li
– Adjusting striker pin ⇒ page 129 .
erm
ab
ility
ot p
Specified torques
wit
, is n
h re
Component Specified torques
hole
spec
es, in part or in w
Striker 20 Nm
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
sd
iva
nel
r
rp
cu
o
m
f
en
ng
t.
yi
Removing
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
Note Prote
cted AG.
agen
Removal and installation are described only for the right window channel. The removal and installation of the
left window channel is similar.
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
o
by c lksw
cted agen
Prote AG.
Note
Installing
Installation is carried out in reverse order. When doing this, ob‐
serve the following:
– Push window channel -1- into mountings.
– First, roll outer sealing lip of window channel onto door flange.
– Fit window channel -1- onto door flange evenly all round.
Note
Note
Removal and installation are described only for the window slot inner seal on the right. Removal and installation
of the window slot inner seal on the left are analogous.
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
155
by lksw
cted agen
Prote AG.
2. Door components
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
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.
60 – Sunroof
1 Tilting sunroof
Launch of the tilting sunroof is planned for a later point in time.
n AG. Volkswagen AG do
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.
Note
1 - Aluminium rail
❑ Left and right
2 - Bolt
❑ Qty. 3 on each side
3 - Washer
❑ Qty. 3 on each side agen
AG. Volkswagen AG d
oes
olksw not
V gu
4 - Hexagon nut d by ara
rise nte
❑ Qty. 3 on each side utho eo
ra
s a c
❑ Specified torque: 8.0 s
ce
le
Nm
un
pt
an
d
itte
y li
5 - Hexagon nut
erm
ab
ility
wit
is n
Nm
ole,
spec
urposes, in part or in wh
6 - Washer
t to the co
9 - Bolt
atio
m
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
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
Fitting notes
spec
es, in part or in w
t to the co
♦ Use only adhesive remover to remove adhesive residue.
rrectness of i
♦ Ensure that the adhesive surfaces are free of dust and grease.
l purpos
nform
ercia
at
Seal dimensions: length × width × thickness
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.
1. Hardtop 159
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
1 - Seal
❑ 1 × 1596 + 5 × 20 × 6
mm
2 - Seal
❑ 2 × 110 + 3 × 20 × 6 mm
3 - Seal
❑ 2 × 160 + 3 × 15 × 6 mm
4 - Seal
❑ 2 × 486 + 5 × 20 × 6 mm AG. Volkswagen AG d
agen oes
ksw
5 - Seal by
Vol not
gu
ara
ed
❑ 2 × 160 + 3 × 15 × 6 mmhoris nte
eo
aut ra
6 - Seal ss c
ce
le
❑ 2 × 486 + 5 × 20 × 6 mm
un
pt
an
d
itte
y li
7 - Seal
erm
ab
ility
❑ 2 × 160 + 3 × 15 × 6 mm
ot p
wit
is n
8 - Seal
h re
ole,
spec
❑ 2 × 143 + 3 × 20 × 6 mm
urposes, in part or in wh
t to the co
9 - Seal
❑ 2 × 152 + 3 × 10 × 6 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
t. rig
gh
1.3 Assembly overview - protective films
ht
pyri by
Vo
o
by c lksw
cted agen
Special tools and workshop equipment required
Prote AG.
♦ Roller -3356-
Fitting notes
♦ Protective films cannot be removed without being damaged.
♦ Use only adhesive remover to remove adhesive residue.
♦ Ensure that adhesive surfaces are free of dust and grease.
1 - Protective film
❑ Qty. 1 cross member
bulkhead top
2 - Protective film
❑ Qty. 1 side board left
3 - Protective film
❑ Qty. 1 side board right
4 - Protective film
❑ Qty. 1 rear lid
5 - Protective film
❑ Qty. 3 cross member
bulkhead
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
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.
Removing
1. Hardtop 161
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
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
ercia
– Press covers -2- (qty. 3) at left and right onto retaining clips
m
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.
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.
1. Hardtop 163
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
n AG. Volkswagen AG do
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
urposes, in part or in wh
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.
– Unscrew hexagon nut -3- from left and right of hardtop and
bulkhead cross member.
– Remove bolt -1- with washers -2- from left and right of hardtop
and bulkhead cross member.
AG. Volkswagen AG d
agen oes
o lksw not
y V gu
d b ara
rise nte
o eo
– Unplug connection
auth -5- on left inner side of side board. ra
ss c
– Move hardtop -1- slightly to rear with aid of second mechanic.
ce
e
nl
pt
du
an
y li
erm
ab
wit
, is n
spec
es, in part or in w
Caution
t to the co
Place the hardtop -1- on its roof on 2 support trestles fitted with
soft pads.
rrectness of i
l purpos
Installing
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
165
c by lksw
cted agen
Prote AG. 1. Hardtop
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
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.
Note
Pay particular attention to the sealing function between the tailgate and the hinged rear window.
n AG. Volkswagen AG do
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
y li
erm
ab
– Slide clamp element lower part -3- sideways into clamp ele‐
ility
ot p
h re
– Insert bolt -1- into clamp element upper part -2- and clamp
hole
spec
t to the co
– Screw hexagon nut -4- onto bolt -1- and fix in slot of clamp
element lower section -3- to prevent it from turning.
rrectness of i
Specified torques
l purpos
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.
1. Hardtop 167
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
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
t to the co
– Locate washer -3- on bolt -1- and tighten hexagon nut -4-.
nform
Specified torques
mercia
tion in
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.
n AG. Volkswagen AG do
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
– Press cover -1- (qty. 3) onto retaining clip -2- -arrow a-.
wit
is n
h re
ole,
-2-.
– Slide cover -1- up until it engages.
rrectne
f in
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.
1. Hardtop 169
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
Note
Installation is described only for the left side. The right side is analogous.
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
Assembling sequence:
Co
Cop py
t. rig
gh ht
– Position aluminium rail -1- in hardtop and insert bolt -2- yri
p by
o Vo
through hardtop and aluminium rail. by c lksw
cted agen
Prote AG.
– Locate washer -3- on bolt -2- and tighten hexagon nut -4-.
– Move base plate -8- into contact with clamp element upper part
-7-.
– Insert clamp element upper part -7- with bolt -9- into aluminium
rail -1-.
Note
– Screw hexagon nut -5- onto bolt -9- by hand and tighten.
Specified torques
♦ ⇒ “1.1 Assembly overview - hardtop, aluminium rail”,
page 158 .
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.
1. Hardtop 171
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
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.
3 - Seal, lid
nl
pt
du
an
y li
erm
⇒ page 193
ab
ility
ot p
4 - Lock cover
wit
, is n
h re
spec
⇒ page 190
es, in part or in w
t to the co
6 - Gas strut
l purpos
orm
atio
m
⇒ page 185
o
n in
or c
8 - Striker
thi
te
sd
iva
cu
⇒ page 187
o
m
f
en
ng
t.
yi Co
9 - Seal, trim t. Cop py
rig
❑ Removing and installing
gh ht
pyri by
⇒ page 228
o Vo
by c lksw
cted agen
Prote AG.
10 - Hinge
❑ Left and right.
❑ Removing and installing ⇒ page 180
Note
Assembly overview is described only for the left hinge. Assembly overview of right hinge is analogous.
1 - Hinge
❑ Screwed to base plate
-4-
❑ Removing and installing
⇒ page 180
2 - Hexagon nut
❑ For base plate -4-
❑ Qty. 2
❑ Specified torques: 10 ±
1.5 Nm.
3 - Hexagon nut
❑ For hinge -1-
❑ Qty. 2
❑ Specified torques: 10 ±
1.5 Nm. AG. Volkswagen AG d
agen oes
olksw not
yV gu
4 - Base plate ised b ara
nte
or
❑ Bolted to hardtop aut
h 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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
G. Volkswagen
Only the left side is shown. The right
lksw side is analogous.
agen
A AG do
es n
o o t gu
yV
edb ara
ris nte
tho eo
1 - Lock au ra
c
ss
ce
❑ Right
e
nl
pt
du
an
itte
2 - Lock
y li
erm
ab
❑ Left.
ility
ot p
wit
, is n
3 - Lock cover
h re
hole
spec
⇒ page 190
es, in part or in w
t to the co
4 - Hexagon nut
❑ Qty. 2
rrectness of i
❑ Specified torques: 10 ±
1.5 Nm.
l purpos
5 - Pull rod
nform
ercia
❑ To handle
m
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.
1 - Handle
❑ Removing and installing
⇒ page 183
2 - Seal
3 - Hexagon nut
❑ Specified torque:
10 ± 1.5 Nm
4 - Spring hanger
5 - Pull rods
❑ Left to lock
6 - Bolt
❑ Specified torque: 8 Nm
+ 90°
7 - Interior opening mechanism
8 - Pull rods
❑ Right to lock
n AG. Volkswagen AG do
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.
Note
Assembly overview is described only for the left side. Assembly overview of right side is analogous.
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.
Note
Assembly overview is described only for the left side. Assembly overview of right side is analogous.
1 - Striker, lid
❑ Left and right
❑ Removing and installing
⇒ page 187
2 - Bracket, gas strut bottom
3 - Hexagon nut
❑ Qty. 2
❑ Specified torques: 10 ±
1.5 Nm.
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
do
priv
cum
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
n AG. Volkswagen AG do
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
Removing
ercia
orm
m
n in
c
thi
te
sd
a
o
r
rp
cu
o
en
ng
t.
yi Co
op
– Loosen hexagon nuts -2- on left and right hinges (do not re‐ C py
t. rig
move).
gh ht
pyri by
Vo
co lksw
by
cted agen
179
Prote AG.
2. Lid for hardtop
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
Note
ce
le
un
pt
an
d
itte
y li
Removal and installation are described for the right hinge only. Removal and installation of the left hinge are
rm
ab
similar.
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.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
s c
Removing s
ce
e
nl
pt
du
y li
erm
ab
– Only now unscrew hexagon nuts -3- and remove hinges -1-.
wit
, is n
h re
hole
Installing
spec
es, in part or in w
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
181
AG.
2. Lid for hardtop
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
AG. Volkswagen AG d
♦ Torque wrench -V.A.G
lksw
1331-
agen oes
not
o
yV gu
db ara
ir se 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
Note
l purpos
The removal and installation sequence is only for the left lock -1-. The removal and installation of the right lock
-2- is analogous.
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.
Removing
– Remove lock cover -3- ⇒ page 190 .
ce
e
pt
du
an
itte
dle
y li
erm
ab
ility
ot p
wit
, is n
h re
♦ Torque wrench -V.A.G 1331-
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.
n AG. Volkswagen AG do
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
Removing
t.
yi Co
Cop py
– Unclip pull rods -5- and -8- from interior opening mechanism
t. rig
gh ht
yri
-7-.
p by
co Vo
by lksw
cted agen
– Remove bolt -6-.
Prote AG.
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
Note
l purpos
The removal and installation sequence is only for the left side. Removal and installation of the right side is
similar.
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.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
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.
Removing
– Remove left D-pillar trim ⇒ page 215 .
– Remove gas strut ⇒ page 189 .
Bracket, gas strut bottom:
– Unscrew hexagon nuts -2- from striker -3-.
– Remove bottom gas strut bracket -1- and striker -3-.
Bracket, gas strut top:
– Remove hexagon nuts -5-.
– Remove top gas strut bracket -4- from lid.
Installing
Installation is carried out in reverse order. When doing this, ob‐
serve the following:
Specified torques
♦ ⇒ “2.5 Assembly overview - gas strut bracket”, page 177
Note
The removal and installation sequence is only for the left side. Removal and installation of the right side is
similar.
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.
n AG. Volkswagen AG do
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
Removing yri
p by
co Vo
by lksw
cted
– Remove left D-pillar trim ⇒ page 215 .
agen
Prote AG.
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
– Open lid.
wit
, is n
h re
spec
es, in part or in w
– Raise spring clip -3- until it can be moved over ball socket in
t to the co
direction of -arrow-.
– Pull gas strut -1- off ball-head pin -2-.
rrectness of i
After removing gas strut -1-, slide spring clip -3- back immediately.
l purpos
WARNING
nf
ercia
orm
Proceed with care if gas strut is reused. Spring clip must not
m
atio
m
n in
c
damaged.
or
thi
te
sd
a
o
r
to operator.
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.
WARNING
Clamp gas strut only within area -x-; otherwise danger of ac‐
cident!
Note
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.
Removing
– Use small drift to press pin -3- inwards and unclip spreader
rivets -2- (qty. 4 top and bottom).
– Remove lock cover -1- from lid.
Installing
Installation is carried out in reverse order. When doing this, ob‐
serve the following:
Note
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
urposes, in part or in wh
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.
n AG. Volkswagen AG do
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
urposes, in part or in wh
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.
Removing
– Unscrew bolts -4- from inside and remove trim -3-.
– Mask painted area on lid -2- above high-level brake light -1-
with commercially available masking tape to avoid damaging
paintwork.
– Insert wedge -T10039/1- between upper edge of high-level
brake light -1- and lid -2-.
– Press brake light down using wedge -T10039/1- and disen‐
gage upper lugs of brake light to rear.
– From inside lid -2- press through opening.
– Remove high-level brake light -1- to rear from lid opening -2-,
taking due account of connected cable lengths.
– Disengage and unplug connector and remove high-level brake
light -1-.
ce
le
When installing high-level brake light -1-, ensure that seal is correctly seated. Seal must not be kinked or
un
pt
an
damaged. d
itte
y li
rm
ab
pe
ility
– Plug connector to high-level brake light -1-.
ot
wit
, is n
h re
– Clip high-level brake light -1- back into rear lid -2-, starting at
hole
lower edge.
spec
es, in part or in w
t to the co
Specified torques
Component Specified torque
rrectness of i
Trim 2.0 Nm
l purpos
nform
ercia
a
♦ Hot air blower -V.A.G 1416-
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.
Fitting notes
Heat up lid seal using hot air blower -V.A.G 1416- before remov‐
ing.
If lid seal is removed and reattached, only use adhesive remover
-D 002 000 10- to remove the adhesive residue.
Ensure that adhesive surfaces are free of dust and grease.
Lid seal must be bonded in place immediately after cleaning.
Remove backing only immediately before installation and then
bond seal.
Working temperature is approx. 21°C.
Removing and installing hardtop lid seal
Note
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.
Removing
– Heat lid seal -1- with hot air blower -V.A.G 1416- before re‐
moving and then peel off from lid -2-.
Installing
Follow installation instructions ⇒ page 193 .
ce
e
nl
pt
du
3.1 Assembly overview - anchor
an
itte
y li
erm
ab
ility
ot p
wit
Note
, is n
h re
hole
spec
Only the right side is shown. The left side is analogous.
es, in part or in w
t to the co
1 - Tailgate
rrectness of i
❑ Removing and installing
⇒ page 45
l purpos
2 - Anchor
nf
ercia
❑ Right
orm
m
atio
3 - Tailgate trim, rear
om
n in
c
thi
e
sd
iva
o
r
rp
cu
Removing and installing
o
m
f
en
ng
tailgate trim
t.
yi Co
Cop py
4 - Anchor
t. rig
gh ht
pyri by
❑ Left
o Vo
by c lksw
cted agen
Prote AG.
5 - Base plate
❑ Right and left
6 - Threaded plate
❑ Right and left
7 - Bolt
❑ Qty. 2 on each side
❑ Specified torque:
8.0 ± 1.2 Nm
3. Tailgate 195
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
ce
e
load bed
nl
pt
du
an
itte
2 - Right seal
y li
erm
ab
❑ Pushed onto edge of
ility
ot p
load bed
wit
, is n
h re
3 - Tailgate seal
hole
spec
❑ Bonded on lower edge
es, in part or in w
t to the co
of tailgate
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.
n AG. Volkswagen AG do
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
urposes, in part or in wh
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.
Removing
– Remove tailgate trim -3- ⇒ General body repairs, interior; Rep.
gr. 70 ; Removing and installing tailgate trim .
– Unscrew bolts -7- and remove anchor -2- with base plate -5-.
– Pass threaded plate -6- out through tailgate opening -1-.
Installing
– Pass threaded plate -6- in through tailgate opening -1-.
– Bolt base plate -5- and anchor -2- in place.
– Install rear tailgate trim -3-.
Specified torques
♦ ⇒ “3.1 Assembly overview - anchor”, page 195
3. Tailgate 197
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
4 Glazing
⇒ “4.1 Assembly overview - glazing”, page 198
⇒ “4.2 Assembly overview - rear window”, page 199
⇒ “4.3 Removing and installing rear window”, page 199
⇒ “4.4 Removing and installing sliding window”, page 206
⇒ “4.5 Removing and installing front sliding window”, page 207
1 - Hardtop
❑ Removing and installing
AG. Volkswagen AG d
⇒ page 161 ksw
agen oes
not
Vol
by gu
2 - Right-hand sliding window ised ara
nte
or
❑ Removing and installing aut
h eo
ra
⇒ page 206 ss c
ce
le
un
pt
3 - Rear window
an
d
itte
y li
❑ Removing and installing
rm
ab
⇒ page 199
pe
ility
ot
wit
, is n
h re
hole
spec
⇒ page 206
es, in part or in w
t to the co
5 - Front sliding window
❑ Removing and installing
rrectness of i
⇒ page 207
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.
ce
le
2 - Connection for heated rear
un
pt
an
d
window
itte
y li
erm
ab
❑ Right
ility
ot p
wit
3 - PUR adhesive sealant
is n
h re
ole,
❑ Adhesive bead cross-
spec
section: -width- = 6.5 urposes, in part or in wh
mm; -height- = 10 mm
t to the co
❑ The adhesive bead is
butted up against the
rrectne
side edge of the win‐
dow.
s
❑ Minimum curing period
s o
⇒ page 254 .
cial p
f inform
4 - Connection for heated rear
mer
window
atio
om
n
❑ Left.
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.
Note
4. Glazing 199
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
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.
♦ Electric cutter -
V.A.G 1561 A-
♦ Cutting blade -
V.A.G 1561/2-
♦ Scraping blade -
V.A.G 1561/8-
♦ Cutting blade -
V.A.G 1561/10-
♦ Cutting blade -
V.A.G 1561/19-
♦ Double cartridge gun -
VAS 5237-
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
urposes, in part or in wh
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.
4. Glazing 201
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
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
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
m
Removing
o
n
c
i
or
n thi
sd
a
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.
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.
– From inside, prevent end of cutting cord -2- from being pulled
out by attaching it to pull handle -V.A.G 1351/1- -3-.
– Place cutting cord -2- around rear window -1-.
Ensure that cutting cord -2- lies under window in corners.
4. Glazing 203
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
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
at
om
flange.
ion
c
in t
or
do
riv
cum
for
en
g
t.
yi Co
Cop py
– Remove pieces of glass up to adhesive sealing material.
t. rig
gh ht
pyri by
Vo
o
– Pull off connections for rear window heating and aerial.
c by lksw
cted agen
Prote AG.
WARNING
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.
4. Glazing 205
AG. Volkswagen AG d
agen oes
ksw
Amarok 2011 ➤ by
Vol not
gu
d ara
General body repairs, exterior - Edition 10.2012 orise nte
h eo
aut ra
s c
4.4 Removing and installing sliding window s
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
Removal and installation are only shown for the left sliding window. The removal and installation of the right
h re
hole
sliding window is analogous.
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
by c lksw
cted agen
Prote AG.
Removing
– Open side sliding window -1- at front and unscrew bolts -2-
(qty. 3) between window channel and window frame.
– Open side sliding window -1- at rear and unscrew bolts -2- (qty.
5) between window channel and window frame.
– Remove side sliding window -1- from hardtop window aper‐
ture.
Installing
Installation is carried out in reverse order. When doing this, ob‐
serve the following:
Specified torques
Component Specified torque
Side sliding window 3.0 Nm
n AG. Volkswagen AG do
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
Removing
nf
ercia
or
atio
om
– Detach seal -2- from inside out over window flange -3- using
n in
or c
sd
iva
– Press front sliding window -1- with seal -2- out of window
o
r
rp
cu
m
f
en
ng
t.
yi Co
Installing Cop py
t. rig
gh ht
yri
– Spray seal -2- with soapy water. p by
co Vo
by lksw
cted agen
– Insert thread inserting tool -V.A.G 1818- around seal -2-.
Prote AG.
4. Glazing 207
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
Amarok 2011 ir se ➤
d ran
tee
o
Generalaubody repairs, exterior - Edition 10.2012
th or
ac
ss
ce
le
– Locate front sliding window -1- in window aperture using 2
un
pt
an
suction lifters -V.A.G 1344- .
d
itte
y li
rm
ab
– Pull out thread inserting tool for window seal -V.A.G 1818- all
pe
ility
round from inside and thereby pull sealing lip over window
ot
wit
, is n
flange -3-.
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.
ce
le
un
pt
an
♦ Position foam components -4- relative to wooden rails -2- and
d
itte
y li
-3- as specified.
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.
1 - Hardtop
2 - Middle wooden rail
3 - Wooden rail
❑ Left and right
4 - Foam element
❑ Qty. 4
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
urposes, in part or in wh
t to the co
5.2 Assembly overview - foam components, top and side
Fitting notes
rrectne
♦ Foam components cannot be removed without being dam‐
s
aged.
s o
cial p
f i
sive residue.
mer
atio
m
n
c
i
or
n thi
sd
a
fore installation.
iv
o
pr
cum
r
fo
t.
yi
aperture.
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
n AG. Volkswagen AG do
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
urposes, in part or in wh
t to the co
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.
Removing
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
– Remove right D-pillar trim ⇒ page 213 . uthor eo
ra
s a c
– Unscrew bolts -5- and remove load compartment light -4-. s
ce
le
un
pt
y li
erm
ab
wit
h re
ole,
Installing
spec
urposes, in part or in wh
– Locate top panel -1- on roof frame and pass connector for in‐
terior light through.
rrectne
– Position spacers -2- and screw bolts -3- into wooden rails.
inform
mer
n
c
i
or
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
212
cop Vo
by lksw
Rep. gr.61 - Convertible roof, hardtop, canopy Prote
cted AG.
agen
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
Specified torques
Component Specified torque
Bolts -3- and -5- 2.5 Nm
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
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Removing
– Detach right rear seal ⇒ page 228
– Remove bolts -2- and -3- with spacers -4-.
– Guide D-pillar trim -1- with cut-out over striker.
Installing
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.
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
– Align D-pillar trim -1- and screw upper bolt to side trim.
ility
ot p
wit
is n
– Position spacer -4- and screw bolt -3- into wooden rail.
h re
ole,
spec
t to the co
Specified torques
Component Specified torque
ss o
cial p
n
c
i
or
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.
Removing
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
– Detach left rear seal ⇒ page 228
gh ht
pyri by
Vo
co lksw
by
– Unclip momentary-contact switch -6- from D-pillar trim -1- and cted agen
Prote AG.
unplug connector -7-.
– Remove bolts -2- and -3- with spacers -4-.
– Guide D-pillar trim -1- with cut-out over striker.
Installing
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
urposes, in part or in wh
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.
• Locate snap nuts on centre trim ⇒ page 227 .
– Guide D-pillar trim -1- with cut-out over striker -2-.
– Route connector -4- for momentary-contact switch through D-
pillar trim -1-.
– Lay connecting cable -3- to cargo box in recess provided for
that purpose.
n AG. Volkswagen AG do
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
– Align D-pillar trim -1- and screw upper bolt -2- to side trim.
r
te o
thi
s
iva
– Position spacer -4- and screw bolt -3- into wooden rail.
do
r
rp
cum
fo
t.
yi Co
op
– Screw bolt -2- to lower part of D-pillar trim. C py
t. rig
gh ht
yri by
– Plug connector -7- into momentary-contact switch -6- and clip cop Vo
by lksw
momentary-contact switch to D-pillar trim -1-. cted agen
Prote AG.
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.
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
op
– Remove bolts -2- and -3- (Qty. 9) with spacers -4-. C py
t. rig
gh ht
yri by
– Remove middle trim -1- from hardtop with aid of a second me‐ cop Vo
by lksw
chanic. cted agen
Prote AG.
Installing
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.
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.
– Prepare middle front attachment point -3- first and secure with
bolt.
– Centre spacers -4- in any order in securing holes -2- in middle
trim -1- and secure with bolts.
Specified torques
Component Specified torque
Centre trim 2.5 Nm
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
ercia
– Press cover -1- (qty. 3) onto retaining clip -2- -arrow a-.
m
at
ion
c
in t
r
his
te
-2-.
a
do
priv
cum
or
en
ng
t.
yi Co
– Install top panel ⇒ page 211 Cop py
t. rig
gh ht
yri
– Install right D-pillar trim ⇒ page 213 . p by
co Vo
by lksw
cted agen
– Install left D-pillar trim ⇒ page 215 . Prote AG.
n AG. Volkswagen AG do
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
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
i
or
n thi
te
o
r
wooden rail.
p
cum
r
fo
en
ng
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
Removing
es, in part or in w
t to the co
Installing
nf
ercia
⇒ page 210 .
m
m
atio
om
thi
e
sd
iva
o
r
rp
cu
– Roll sliding window seal out -2- all round over front trim.
o
m
f
en
ng
t.
yi
– Remove backing -4- from Velcro tape -3- and press front trim
Co
op py
-1- down evenly over entire width.
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
Note
The removal and installation sequence is only for the left side. Removal and installation of the right side is
AG. Volkswagen AG d
similar. lkswagen oes
n o ot g
yV ua
edb ran
ris tee
tho or
au 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
o
by c lksw
cted agen
Prote AG.
Removing
– Peel edge protector -1- off trim.
Installing
– Locate edge protector -1- uniformly, starting at dividing point
-arrow-.
– Ensure correct seating contact in curved sections and do not
stretch edge protector -1- when fitting.
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
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
Assembling sequence:
or
n thi
te
sd
va
o
pr
cum
trim -1-.
r
fo
en
ng
t.
yi
– Position thread of clamping snap nut -2- on rear of middle trim
Co
Cop py
-1-. ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
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.
Removing
– Peel rear seal -1- off flange.
Installing
– Press rear seal -1- onto flange.
– Fold cover lip of seal -1- over trim edges and ensure it runs
uniformly.
63 – Bumpers
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.
ce
e
nl
pt
du
an
itte
⇒ “1.4 Assembly overview - parking aid retainer”, page 235
y li
erm
ab
ility
⇒ “1.5 Assembly overview - substructure components”,
ot p
wit
page 236
, is n
h re
hole
spec
es, in part or in w
t to the co
cover”, page 239
⇒ “1.8 Repairing bumper cover”, page 242
rrectness of i
⇒ “1.9 Installing brackets for parking aid system”, page 242
l purpos
nf
ercia
orm
m
atio
Note
om
n in
or c
thi
Depending on model slight differences are possible when referring to assembly overview.
te
sd
iva
o
r
rp
cu
1 - Front bumper cover
o
m
f
en
ng
t.
yi
❑ Removing and installing
Co
Cop py
⇒ page 236 ht. rig
rig ht
py by
o Vo
2 - Bolt by c lksw
cted agen
Prote AG.
❑ Qty. 2 on each side
❑ Specified torque: 2.0
Nm
3 - Bolt
❑ Qty. 2
❑ Specified torque: 20 Nm
4 - Bolt
❑ Qty. 2 on each side
❑ Specified torque: 2.0
Nm
5 - Clip
❑ Qty. 4
6 - Bolt
❑ Left and right.
❑ Points upwards.
❑ Bolted to wing
❑ Specified torque: 8.0
Nm
7 - Bolt
❑ Left and right.
❑ Specified torque: 8.5
Nm.
❑ Bolted to wing
ce
e
nl
pt
8 - Bolt
du
an
itte
y li
❑ Left and right.
erm
ab
ility
❑ Specified torque: 2.0 Nm
ot p
wit
, is n
h re
hole
spec
1.2 Assembly overview - front bumper cov‐
es, in part or in w
t to the co
er, add-on parts
⇒ “1.2.1 Assembly overview - front bumper cover, add-on parts”,
rrectness of i
page 231 l purpos
nf
ercia
o
⇒ “1.2.3 Assembly overview - front bumper cover, add-on pieces,
rm
m
atio
om
n in
c
thi
te
sd
iva
o
r
rp
cu
o
m
Note
f
en
ng
t.
yi Co
Cop py
Depending on model slight differences are possible concerning add-on parts.
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1.2.2 Assembly overview - front bumper cover, add-on pieces, PR No. “OFA”
ce
le
un
pt
an
d
5 - Front spoiler
itte
y li
erm
ab
❑ Left.
ility
ot p
wit
is n
removed -1-.
spec
urposes, in part or in wh
7 - Front spoiler
o
cial p
f in
❑ Right.
form
mer
i
or
n thi
e
sd
iva
o
pr
en
ng
t.
❑ Can be unclipped only with front bumper cover removed -1-.
yi Co
Cop py
❑ Different versions. For allocation see ⇒ Electronic parts catalogue “ETKA” .
t. rig
gh ht
pyri by
Vo
o
10 - Fog light trim
c by lksw
cted agen
Prote AG.
❑ Right.
❑ Pull forwards out of detent.
❑ Different versions. For allocation see ⇒ Electronic parts catalogue “ETKA” .
11 - Right wheel arch cover
❑ Removing and installing ⇒ page 239
❑ Holes for positioning pins notes -arrows- ⇒ page 238
12 - Parking aid retainer
❑ Installing ⇒ page 235 .
1.2.3 Assembly overview - front bumper cover, add-on pieces, PR No. “OFX”
ce
le
un
pt
an
d
❑ Centre.
itte
y li
rm
ab
❑ Can be unclipped only
pe
ility
with front bumper cover
ot
wit
, is n
removed -1-.
h re
hole
7 - Front spoiler
spec
es, in part or in w
❑ Right.
t to the co
❑ Can be unclipped only
with front bumper cover
rrectness of i
removed -1-.
l purpos
tion in
thi
s
do
r
rp
❑ Right.
um
fo
en
ng
t.
❑ Pull forwards out of detent.
yi Co
Cop py
❑ Different versions. For allocation see ⇒ Electronic parts catalogue “ETKA” .
t. rig
gh ht
pyri by
Vo
o
11 - Right wheel arch cover
by c lksw
cted agen
Prote AG.
❑ Removing and installing ⇒ page 239 .
12 - Parking aid retainer
❑ Installing ⇒ page 235 .
n AG. Volkswagen AG do
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.
ce
le
un
pt
an
d
itte
y li
rm
ab
Note
pe
ility
ot
wit
, is n
Observe slight deviations in the front bumper cover and parking aid brackets depending on model version.
h re
hole
spec
es, in part or in w
t to the co
1 - Front bumper cover
❑ Removing and installing
⇒ page 236 .
rrectness of i
2 - Parking aid senders in front
l purpos
bumper cover
❑ Installing brackets for
nform
ercia
⇒ page 242
a
com
tio
❑ Front left parking aid
n in
r
te o
sender -G255-
thi
s
iva
do
❑ Front inner left parking
r
rp
cum
aid sender -G254-
fo
en
ng
t.
yi
❑ Front inner right parking
Co
op py
aid sender -G253- t. C rig
gh ht
yri by
❑ Front right parking aid
op Vo
by c lksw
sender -G252-
cted agen
Prote AG.
❑ General information and
work instructions for the
parking aid can be found
in ⇒ Electrical system;
Rep. gr. 94 ; Parking
aid .
1 - Guide bracket
❑ Laterally on left and right
wing
❑ Removing:
– Prise out clip -2- using a
screwdriver.
2 - Clip
❑ Qty. 2 on each side
3 - End plate
❑ For front bumper cover
❑ Attached to front bump‐
er carrier
4 - Foam element
❑ Pedestrian protection
5 - Support
❑ Right and left
❑ For front bumper cover
6 - Bolt
❑ Specified torque 8.0
Nm.
n AG. Volkswagen AG do
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
spec
cover
es, in part or in w
t to the co
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.
Note
♦ The removal and installation procedures for front bumper cover may have to be revised slightly depending
on model variations. agen
AG. Volkswagen AG d
oes
lksw not
For front bumperd bcover with wheel arch trim, the positioning pins -arrows- in the front bumper must be noted
o
♦ yV gu
ara
because it isorpossible
ise that different sorts have been fitted nte ⇒ page 238 .
eo
th
s au ra
c
s
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.
Removing
– Remove fog light trims on left and right ⇒ page 231 .
– Prise out clip -5- using a screwdriver.
– Remove bolts -2- on left and right sides in area of wheel hous‐
ing liner.
– Unclip clip -6-(aligned upward) on left and right.
– Remove bolts -3- and -4- from front.
– Remove bolts -7- and -8- on left and right from below.
– With help of a second mechanic pull front bumper cover -1-
parallel off vehicle.
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
urposes, in part or in wh
t to the co
rrectne
following:
cial p
f inform
mer
atio
Note
om
n
c
i
or
n thi
sd
iva
o
pr
♦ Depending on the wheel arch on the front bumper cover -2- and on the wing -1-, the positioning pins
cum
r
fo
-arrows- must be removed. It is possible that different sorts of pins have been fitted.
en
ng
t.
yi Co
Cop py
t. rig
– Ensure joints are parallel and shut lines are equal ⇒ Body Re‐
gh ht
pyri by
pairs; Rep. gr. 00 ; Body gaps; Body, front .
o Vo
by c lksw
cted agen
Prote AG.
Specified torques
Specified torque of bolts ⇒ page 230
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
♦ Torque wrench -V.A.G 1783-
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
Removing
inform
mer
atio
om
Note
n
c
i
or
n thi
te
sd
a
♦ The removal and installation procedure is for the left side. The right side is similar.
iv
o
pr
cum
r
fo
♦ Front bumper cover wheel arch trim -1- cannot be removed without damaging it.
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
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
spec
– Warm wheel arch trim, front bumper cover, -1- with hot air
es, in part or in w
– Lift one corner of wheel arch trim, front bumper cover, -1- using
removal wedge -3409- .
rrectness of i
– Grip under wheel arch trim, front bumper cover, -1- and care‐
l purpos
Note
orm
m
atio
m
n in
or c
thi
te
sd
a
Installing
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.
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
Installation instructions for wheel arch trims ⇒ page 313 .
ole,
spec
urposes, in part or in wh
n
c
i
or
ponent glass adhesive -DA 009 100 A2- along entire length of
t
sd
iva
cum
r
fo
en
ng
ce
le
un
pt
an
d
itte
y li
rm
Note
ab
pe
ility
ot
wit
, is n
Check fit of wheel arch trim -1-.
h re
hole
spec
Specified torques
es, in part or in w
t to the co
Specified torque of bolts ⇒ page 234 .
rrectness of i
l purpos
Note
nform
ercia
a
com
tion in
r
te o
thi
Description under: ⇒ General Information; Body Repairs, General
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op
tem
C py
t. rig
gh ht
pyri by
Vo
Special tools and workshop equipment required
co lksw
by
cted agen
Prote AG.
♦ Installation tool for PDC bracket -VAS 6614-
Materials
♦ Cleaning solution -D 009 401 1) 1
04-
Installing brackets
Note
The brackets are installed after the bumper cover has been pain‐
ted.
n AG. Volkswagen AG do
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
urposes, in part or in wh
t to the co
rrectness o
cial p
f in
The 4 markings for a bracket -1- can be found on the inside of the
form
mer
bumper cover.
atio
om
i
or
mined.
thi
te
sd
va
– The holes must be drilled from the inside to the outside with
i
o
pr
cum
r
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
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
– Set hole puncher in position with bolt head -1-, washer -2- and
rm
m
n in
c
thi
te
sd
a
o
r
rp
cu
o
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
Note py by
co Vo
by lksw
cted agen
Prote AG.
The punch -4- must not turn on the paint of the bumper cover.
– Pull the punch -4- through the material of the bumper cover
-5- -arrows- by turning the bolt head -1-.
– Remove hole puncher and make the next holes.
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
urposes, in part or in wh
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.
ce
e
⇒ “2.3 Assembly overview - rear bumper cover step”, page 248
nl
pt
du
an
itte
y li
⇒ “2.4 Assembly overview - closing plate”, page 250
erm
ab
ility
ot p
wit
page 250
, is n
h re
hole
spec
251
es, in part or in w
t to the co
⇒ “2.7 Repairing bumper cover”, page 253
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.
Note
The removal and installation procedures for rear bumper cover may have to be revised slightly depending on
model variations.
2 - Bolt
❑ Qty. 7
❑ Specified torque 8 Nm.
3 - Bolt
❑ Qty. 2 on each side
❑ Specified torque 8 Nm.
n AG. Volkswagen AG do
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.
4 - Clip
❑ Left and right.
5 - Cap
❑ Left and right.
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
step
rrectness of i
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.
ce
le
un
pt
2 - Rear bumper cover step
an
d
itte
y li
❑ Removing:
erm
ab
ility
ot p
– Unclip clip -3-.
wit
is n
h re
– Remove bolts -4-. ole,
spec
urposes, in part or in wh
t to the co
cover step from rear
bumper carrier.
rrectne
3 - Clip
❑ Qty. 3
ss o
cial p
f
4 - Bolt
inform
❑ Qty. 4 on each side
mer
atio
❑ Specified torque 4.5
om
n
Nm.
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.
Note
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
urposes, in part or in wh
er to 2011
Special tools and workshop equipment required
rrectne
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.
Note
♦ The assembly overview shows a rear bumper carrier without a towing bracket. The rear bumper carrier with
towing bracket is analogous.
♦ Removing and installing towing bracket ⇒ page 355 .
♦ Observe minor differences among rear bumper carriers depending on model year.
2 - Bolt
❑ Qty. 2 on each side
❑ Specified torque: 90 Nm
+ 90° agen
AG. Volkswagen AG d
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
ti
er from 2011
thi
s
iva
do
r
rp
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
e
nl
pt
du
an
♦ Torque wrench -V.A.G 1331-
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
m
Note
o
n in
or c
thi
e
♦ The assembly overview shows a rear bumper carrier without a towing bracket. The rear bumper carrier with
t
sd
iva
o
towing bracket is analogous.
r
rp
cu
o
m
f
en
ng
2 - Hexagon nut
❑ Left and right
3 - Bolt
❑ Left and right
❑ Specified torque: 90 Nm
+ 180°
4 - Bolt
❑ Left and right
❑ Specified torque: 90 Nm
+ 90°
ce
Details can be found under: ⇒ General Information; Body Repairs,
le
un
pt
General Body Repairs ; Work procedures; Plastic repair proce‐
an
d
itte
y li
dures .
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.
64 – Glazing
1 Repair instructions
WARNING
2-component adhesive
The minimum curing time for the 2-component adhesive is 2 hours
for all windows.
The operational safety of the vehicle is restored completely after
2 hours.
1-component adhesive AG. Volkswagen AG d
agen oes
olksw not
yV gu
The minimum curing time for the ise1-component
d b adhesive is 16 ara
nte
hours for all windows. hor eo
aut ra
s c
The vehicle is definitely safe
s to operate again after 16 hours if the
ce
e
pt
du
an
itte
y li
ab
ility
ot p
Minimum curing period is the time from bonding the window until
spec
t to the co
WARNING
l purpos
at
om
io
in t
or
his
ate
do
priv
cum
or
Note
f
en
ng
t.
yi Co
op py
♦ If windscreen is damaged, determine whether glass can be
. C rig
ht ht
rig
repaired before replacing. py by
co Vo
by lksw
cted
♦ Damaged windscreens can be repaired with the window repair
agen
Prote AG.
kit -VAS 6092- .
♦ This damage must not exceed a certain size or position.
♦ Each window repair kit comes with a set of instructions.
n AG. Volkswagen AG do
lkswage es n
o ot g
yV
1.3 Installation instructions d b ua
ran
ir se tee
tho
u or
⇒ “1.3.1 Installation instructions
ss
a for bonded windows”, ac
page 255
ce
e
nl
pt
du
an
⇒ “1.3.2 Materials”, page 255
itte
y li
erm
ab
1.3.1 Installation instructions for bonded win‐
ility
ot p
wit
dows
, is n
h re
hole
spec
– Apply adhesive material to primed area -1- or to trimmed seal‐
es, in part or in w
t to the co
angle to window.
rrectness of i
Note
l purpos
nform
mercia
WARNING at
om
ion
c
in t
or
cum
or
en
ng
t.
yi
should not be pressed too forcibly on body flange. Windows no
Co
op py
longer have sealing lips and therefore excessive adhesive will
t. C rig
gh ht
be visible in the joint area. pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.3.2 Materials
Note
♦ 2K glass adhesive 1) 2) 3) 6)
♦ 1K glass adhesive 1) 2) 4) 5) 6)
♦ Activator 1) 6)
ce
e
nl
pt
du
♦ Cutting cord 1) 6)
an
itte
y li
erm
ab
♦ Mixing nozzle 1) 6)
ility
ot p
wit
, is n
h re
1)Observe instructions for use on the information sheet provided
hole
spec
by the manufacturer.
es, in part or in w
t to the co
2) Minimum curing period ⇒ page 254
3)
Double cartridge gun -VAS 5237- must be used to apply these
rrectness of i
materials.
l purpos
nform
ercia
5)Small cartridge, 180 ml, for sealing and/or when a 400 ml dou‐
m
at
om
ion
c
in t
The part numbers of the materials can be found in the⇒ elec‐
or
his
e
do
priv
cum
en
ng
t.
yi
fitting
Co
Cop py
ht. rig
rig ht
Cutting back adhesive bead py by
co Vo
by lksw
cted agen
Prote AG.
Note
WARNING
Exception:
If bonding is not performed immediately after cutting back, the
remaining residual material must be activated with activator -D
181 801 A1- .
Note
WARNING
– Using applicator -D 009 500 25- -1-, apply glass and paint pri‐
mer -2- evenly in one pass.
olkswagen AG
g en AG. V
♦ Drying time approx. 10
Vol
kminutes
swa does
not
y gu
db ara
rise nte
tho eo
s au ra
c
s
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
orm
m
atio
om
WARNING
n in
or c
thi
te
sd
a
o
r
rp
cu
o
en
ng
t.
yi
cutting back. Do not prime. Do not treat with cleaning solution.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
WARNING
ce
le
un
pt
an
d
y li
rm
ab
pe
ility
tivator -D 181 801 A1- .
ot
wit
, is n
h re
hole
spec
painting.
es, in part or in w
t to the co
Note
rrectness of i
It is possible that a laser weld seam lies outside the area of the
l purpos
tion in
existing adhesive bead -1-, coat laser weld seam -3- with
r
te o
glass/paint primer -D 009 200 02- -3-. Then fill laser weld seam
thi
s
iva
cum
fo
t.
yi Co
op
Paint structure must be restored according to specifications in the C py
t. rig
⇒ “Paint” workshop manual .
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
WARNING
When cleaning freshly installed glass from the inside in the ve‐
hicle, do not press glass outwards.
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.
2 Windscreen
⇒ “2.1 Assembly overview - windscreen”, page 260
⇒ “2.2 Removing and installing windscreen”, page 261
1 - Windscreen
❑ Removing and installing
⇒ page 261
2 - Depth stop
❑ Qty. 5
3 - PUR adhesive sealant
❑ Cross section of bead:
-width- = 6.5 mm
-height- = 10 mm (in‐
cluding precoating, re‐
sidual material on win‐
dow glass and window
flange).
❑ Minimum curing period
⇒ page 254 .
4 - Body flange
❑ Touch up paintwork
damage ⇒ page 258 .
5 - Windscreen adjuster
❑ Windscreen adjuster
-443 845 631 A-
6 - Windscreen seal AG. Volkswagen AG d
agen oes
olksw not
❑ Is part of windscreen. d by V gu
ara
rise nte
7 - Plenum chamber cover autho eo
ra
s c
❑ Removing and installing s
ce
le
⇒ page 12
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
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.
AG. Volkswagen AG d
Note lksw
agen oes
not
Vo gu
by ara
d
The removal of a bonded window is described using orithe
se Removal kit for flush bonded windows nt-V.A.G
ee 1474 A- .
The respective tools from Removal kit for flushs abonded windows -VAS 6452- may also be used.or ac
th
u
s
ce
e
nl
pt
du
an
itte
Special tools and workshop
y li
erm
ab
equipment required
ility
ot p
wit
♦ Removal kit for flush bon‐
, is n
h re
ded windows - hole
spec
V.A.G 1474 A- or Removal
es, in part or in w
t to the co
dows -VAS 6452-
♦ Suction lifter -V.A.G 1344-
rrectness of i
♦ Cutting tool -V.A.G 1351-
l purpos
nform
ercia
at
om
♦ Cartridge heater -
ion
c
V.A.G 1939-
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.
2. Windscreen 261
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
♦ Electric cutter -
V.A.G 1561 A-
♦ Cutting blade -
V.A.G 1561/2-
♦ Cutting blade -
V.A.G 1561/8-
♦ Setting gauge -3371-
♦ Cutting blade -
V.A.G 1561/19-
♦ Double cartridge gun -
VAS 5237-
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
urposes, in part or in wh
t to the co
Removing
– Removing plenum chamber cover ⇒ page 12 .
– Remove interior mirror ⇒ General body repairs, interior; Rep. rrectne
gr. 68 ; Interior mirror
ss
n
c
i
or
sd
a
o
r
cum
r
fo
en
ng
t.
– Moulded headliner can now be lowered sufficiently to allow
yi Co
op
windscreen to be cut out without damage occurring to moulded
C py
t. rig
gh
headliner.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
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
– Slide protective backing -V.A.G 1474/8- -1- between front Prote
cted AG.
agen
windscreen and dash panel.
– Pull cutting cord -3- through adhesive sealing material into in‐
side of vehicle using awl -V.A.G 1474/2- .
2. Windscreen 263
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
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
urposes, in part or in wh
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.
– Secure inside end of cutting cord against falling out using Pull
toggle -V.A.G 1351/1- -3-.
– Use small tube -1- to insert cutting cord -2- around window
flange.
– Ensure that cutting cord lies under windscreen in corners.
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
– Position reel device -V.A.G 1654 A- -1-.
AG.
2. Windscreen 265
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
3 Rear window
⇒ “3.1 Assembly overview - rear window”, page 266
⇒ “3.2 Removing and installing rear window”, page 267
1 - Rear window
❑ Removing and installing
rear window
⇒ page 267
2 - PUR adhesive sealant
❑ Cross section of bead:
-width- = 6.5 mm
-height- = 10 mm (in‐ n AG. Volkswagen AG do
cluding precoating, re‐ olkswage es n
ot g
sidual material on win‐ d byV ua
ran
dow glass and window o
ir se tee
flange). auth or
ac
ss
❑ The adhesive bead is
ce
le
un
pt
an
d
y li
erm
dow.
ab
ility
ot p
wit
is n
⇒ page 254 .
h re
ole,
spec
3 - Body flange
urposes, in part or in wh
t to the co
4 - Clip
5 - Depth stop
rrectne
❑ Qty. 5
6 - Connectors for window
ss
heater
o
cial p
f i
❑ Left and right.
nform
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.
Note
The removal of a bonded window is described using the Removal kit for flush bonded windows -V.A.G 1474 A- .
The respective tools from Removal kit for flush bonded windows -VAS 6452- may also be used.
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.
♦ Electric cutter -
V.A.G 1561 A-
♦ Cutting blade -
V.A.G 1561/2-
♦ Cutting blade -
V.A.G 1561/8- n AG. Volkswagen AG do
swage es n
♦ Setting gauge -3371- byV
olk ot g
ua
d ran
ir se
♦ Cutting blade - tho tee
or
V.A.G 1561/19- ss
au ac
ce
e
♦ Double cartridge gun -
nl
pt
du
an
VAS 5237-
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.
Removing
Note
If the rear window is reused, make sure that the electrical connections for the rear window heating are not
damaged.
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.
Note
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
cted agen
Prote AG.
– Secure end of cutting cord -2- against falling out using pull
handle -V.A.G 1351/1- -1-.
– Lay ends of cutting cord -2- around rear window and guide
second end of cord inwards as well.
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
wit
is n
spec
window free.
t to the co
Installing
cial p
f inform
atio
m
n
c
i
or
sd
iva
cum
r
fo
en
ng
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.
ce
e
nl
pt
du
an
itte
y li
⇒ “4.1 Assembly overview - front door window”, page 273
erm
ab
ility
ot p
⇒ “4.2 Assembly overview - rear door window”, page 274
wit
, is n
h re
⇒ “4.3 Removing and installing front door window”, page 275
hole
spec
⇒ “4.4 Removing and installing guide rail”, page 276
es, in part or in w
t to the co
⇒ “4.5 Removing and installing rear door window”, page 277
rrectness of i
l purpos
Note
nf
ercia
o
The right side is shown. The left side is similar.
rm
m
atio
om
n in
or c
thi
1 - Door window
te
sd
iva
o
❑ Removing and installing
r
rp
cu
o
m
⇒ page 275
f
en
ng
t.
yi Co
op
2 - Window regulator C py
t. rig
gh ht
❑ Removing and installing yri
p by
co Vo
⇒ page 103
by lksw
cted agen
Prote AG.
3 - Spreader pin
4 - Spreader plug
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.
Note
Removal is described only for the right door window. Removal of left door window is similar.
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
Removing
– Removing front door trim ⇒ General body repairs, interior;
nform
ercia
at
ion
c
in t
r
– Lower door window until spreader pin -4- and spreader plug
o
his
te
do
priv
cum
for
en
ng
t.
yi
Note
Co
Cop py
ht. rig
rig ht
by
If the work sequence cannot be carried out because there is a fault with the electric window motor, remove copy Vo
by lksw
motor to slide window down. cted agen
Prote AG.
– Screw a 5 mm bolt (approx. 70 mm long) into the spreader pinn AG. Volkswagen A
-4- and pull out from spreader plug -3-. olks
wage
G do
es n
o V t gu
by ara
– Screw an 8 mm bolt (approx. 80 mm long) into spreader
ris
ed plug nte
-3-. ut
ho eo
ra
a c
ss
ce
le
un
pt
Note
an
d
itte
y li
rm
ab
♦ When screwing bolt into spreader plug, do not apply excessive pressure on plug.
pe
ility
ot
wit
, is n
♦ It otherwise falls inwards into door.
h re
hole
spec
– Pull spreader plug -3- out of window regulator guide -1- and
es, in part or in w
t to the co
therefore out of door window.
– Lift rear of door window -1- and swing forwards out of window
channels.
rrectness of i
Installing
l purpos
nform
ercia
Note
m
a
com
ti
♦ Installation is described only for the right door window. Instal‐
on in
lation of left door window is similar.
r
te o
thi
s
iva
do
r
rp
c
and spreader pin.
um
fo
en
ng
t.
yi
♦ Before inserting spreader plug -3- and spreader pin -4-, check
Co
op py
window glass -1- for damage. t. C rig
gh ht
pyri by
Vo
co lksw
by
– Centre spreader plug -3- in the middle and insert spreader plug
cted agen
Prote AG.
with the window -1- removed.
– Press spreader pin -4- flush into spreader plug -3-.
– Guide door window -1- into door -2- and insert door window
-1- into slot in window regulator guide.
– Make door window -1- engage in window regulator -2- by
pressing slightly from above.
– Then perform remaining installation in reverse order of remov‐
al.
• Carry out functional test before fitting door trim.
ce
le
un
pt
an
d
4.5 Removing and installing rear door window
itte
y li
rm
ab
pe
ility
ot
wit
, is n
Note
h re
hole
spec
Removal is described only for the right door window. Removal of left door window is similar.
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.
Removing
– Removing rear door trim ⇒ General body repairs, interior;
Rep. gr. 70 ; Door trims .
– Remove inner film of rear door ⇒ page 349 .
– Lower door window until spreader pin -4- and spreader plug
-3- in cut-out of window regulator are accessible.
Note
If the work sequence cannot be carried out because there is a fault with the electric window motor, remove
motor to slide window down.
Note
♦ When screwing bolt into spreader plug, do not apply excessive pressure on plug.
♦ It otherwise falls inwards into door.
– Pull spreader plug -3- out of window regulator guide -1- and
therefore out of door window.
– Put door window -1- down.
– Remove fixed door-window ⇒ page 281 .
– Guide door window -1- upwards out of door.
Installing
Note
♦ Installation is described only for the right door window. Installation of left door window is similar.
♦ When installing a door window, always renew spreader plug and spreader pin.
♦ Before inserting spreader plug -3- and spreader pin -4-, check window glass -1- for damage.
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.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
– Guide door window aut-3- downwards in door -2- and put it down. ra
ss c
ce
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
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
279
cted agen
Prote
4. Door windows
AG.
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
n AG. Volkswagen AG do
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
urposes, in part or in wh
t to the co
rrectne
– Centre spreader plug -3- in the middle and insert spreader plug
with the window -1- removed.
ss
f inform
– Guide door window -1- into door -2- and insert door window
mer
n
c
n thi
sd
iva
o
r
cum
r
fo
al.
en
ng
t.
yi Co
op
• Carry out functional test before fitting door trim.
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
Removal and installation are described only for the right fixed door-window. Removal and installation of the left
fixed door-window is analogous.
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
urposes, in part or in wh
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.
Removing
– Removing rear door trim ⇒ General body repairs, interior;
Rep. gr. 70 ; Door trims .
– Remove inner film of rear door ⇒ page 349 .
– Pull off inside door film.
– Remove window slot inner seal.
– Remove bolts -3-.
– Rotate window bar -2- 90°.
– Guide window bar -2- upwards out of window guide.
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.
n AG. Volkswagen AG do
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
en
ng
t.
yi
– Guide fixed door-window -1- into door -2-.
Co
Cop py
t. rig
– Roll window guide seal onto sheet metal flange.
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
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
y li
erm
ab
wit
is n
spec
t to the co
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.
66 – Exterior equipment
ss c
ce
le
un
pt
an
d
itte
y li
erm
1 Radiator grille and front trim
ab
ility
ot p
wit
is n
h re
ole,
spec
⇒ “1.2 Removing and installing radiator grille”, page 286
urposes, in part or in wh
t to the co
1.1 Assembly overview - radiator grille
rrectne
1 - Radiator grille
❑ Removing and installing
ss
⇒ page 286
o
cial p
f in
2 - Emblem
form
mer
atio
m
⇒ page 311
o
n
c
i
or
n thi
3 - Trim strip
te
sd
va
❑ Upper left
i
o
pr
cum
r
fo
❑ Engaged in radiator
en
ng
t.
yi
grille -1-.
Co
Cop py
t. rig
❑ Can be unclipped only
gh ht
yri by
with radiator grille -1- re‐
op Vo
by c lksw
cted
moved
agen
Prote AG.
4 - Trim strip
❑ Lower left
❑ Engaged in radiator
grille -1-.
❑ Can be unclipped only
with radiator grille -1- re‐
moved
5 - Trim strip
❑ Lower right
❑ Engaged in radiator
grille -1-.
❑ Can be unclipped only
with radiator grille -1- re‐
moved
6 - Trim strip
❑ Upper right
❑ Engaged in radiator
grille -1-.
❑ Can be unclipped only
with radiator grille -1- removed
7 - Clip
❑ Qty. 4
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
urposes, in part or in wh
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.
Removing
– Remove front bumper cover ⇒ page 236 .
– Pull radiator grille -1- parallel in -direction of arrow- out of
catches -arrows- in front bumper cover -2-.
Installing
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
ho
– Guide radiator grille -1- into front aubumper cover -2- in direction
t or
ac
of -arrow-. ss
ce
le
un
pt
– With slight pressure, clip radiator grille -1- into front bumper
an
d
itte
y li
ab
ility
ot p
h re
ole,
spec
urposes, in part or in wh
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
287
by lksw
cted agen
Prote 1. Radiator grille and front trim
AG.
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
❑ Qty. 4
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
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.
3 Engine/gearbox guard
⇒ “3.1 Assembly overview - engine/gearbox guard”, page 289
⇒ “3.2 Removing and installing engine/gearbox guard”,
page 289
1 - Engine/gearbox guard
❑ Removing and installing
⇒ page 289
2 - Bolt
❑ Qty. 4
❑ Specified torque: 20 Nm
3 - Bolt
❑ Qty. 2
❑ Specified torque: 20 Nm
4 - Bolt
❑ Qty. 2 wage
n AG. Volkswagen AG do
es n
olks ot g
❑ Specified torque:
d by V20 Nm ua
r e an
ris tee
utho 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
urposes, in part or in wh
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
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
Removing
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.
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
urposes, in part or in wh
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.
Fitting notes
♦ Warm roof moulding with hot air blower -V.A.G 1416- before
removing.
♦ If a roof moulding is installed for the first time on a new vehicle
and newly painted surfaces, follow the procedure in ⇒ Work‐
shop manual "Paint"; ⇒Paintwork repairs; ⇒Paint finish; ⇒
Mouldings and film .
♦ If a roof moulding is removed and reinstalled, only use adhe‐ G. Volkswagen AG d
sive remover -D 002 000 10- to remove the adhesive remains. lkswagen A oes
not
Vo gu
y
♦ Ensure that the adhesive surfaces are free of dust and grease.
ris
ed b ara
nt ee
tho or
♦ Stick on roof moulding immediately after cleaning.s au ac
s
ce
e
pt
du
an
itte
y li
erm
ab
ility
♦ Roof moulding cannot be removed without damage.
ot p
wit
, is n
h re
hole
Note spec
es, in part or in w
t to the co
Renewing roof moulding is described only for the left side. The right side is similar.
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.
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
Removing
ility
ot p
wit
, is n
– Heat roof moulding -1- with a hot air blower -V.A.G 1416- and
h re
pull it off roof -2-.
hole
spec
es, in part or in w
Installing
t to the co
– Follow installation instructions ⇒ page 292 .
– Thoroughly clean bonding surface immediately before sticking
rrectness of i
on.
l purpos
orm
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.
5 Exterior mirror
⇒ “5.1 Assembly overview - exterior mirror”, page 294 agen
AG. Volkswagen AG d
oes
olksw not
V gu
⇒ “5.2 Removing and installing mirror glass”, page 294 ed b y ara
nte
ris
o eo
⇒ “5.3 Removing and installing housing frame”, page aut 297
h
ra
ss c
⇒ “5.4 Removing and installing mirror housing”, page 299
ce
e
nl
pt
du
an
⇒ “5.5 Removing and installing exterior mirror”, page 300
itte
y li
erm
ab
5.1 Assembly overview - exterior mirror
ility
ot p
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
Only the left side is shown. The right side is similar.
rrectness of i
1 - Mirror mounting
l purpos
nform
ercia
2 - Bolt
m
at
om
i
❑ Qty. 3
on
c
in t
or
his
ate
Nm
do
priv
cum
or
3 - Lower trim
f
en
ng
t.
yi Co
❑ Removing and installing Cop py
⇒ page 299
t. rig
gh ht
pyri by
Vo
co
4 - Housing frame
by lksw
cted agen
Prote AG.
❑ Removing and installing
⇒ page 297
5 - Bolt
❑ Qty. 2
❑ Specified torque: 2.0
Nm
6 - Mirror housing
❑ Removing and installing
⇒ page 299
7 - Mirror glass
❑ Removing and installing
⇒ page 294
Note
The removal and installation sequence is only for the left mirror n AG. Volkswagen AG do
wage
glass. The removal and installation of the right mirror glass
yV
o is
lks es n
ot g
similar. ise
d b ua
ran
r tee
ho
aut or
ac
ss
WARNING
ce
e
nl
pt
du
an
itte
y li
When doing this repair work, always wear safety goggles and
erm
ab
leather gloves!
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.
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
urposes, in part or in wh
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
Removing
ng
t.
yi Co
op py
– Protect housing edges to prevent damage to paintwork with, t. C rig
gh ht
for example, textile reinforced tape. pyri by
Vo
o
by c lksw
cted agen
– Press bottom of mirror glass -1- in -direction of arrow- into Prote AG.
mirror housing.
– Using removal lever -80 - 200- , press mirror glass -1- in
-direction of arrow B- out of adjustment unit.
Note
– Swivel mirror glass -1- to side and detach connectors -2- for
electric anti-dazzle and mirror heating on back of mirror glass
-1-.
Installing
– Push contacts -2- for mirror heating onto mirror glass -1-.
– Push mirror glass -1- centrally onto adjustment unit in housing.
– Mirror glass -1- clicks audibly into clip -3-.
AG. Volkswagen AG d
agen oes
olksw not
Note ed byV gu
ara
ris nte
h o eo
ut
The removal and
ss a installation sequence is only for the left housing ra
cframe. The removal and installation of the
right housing frame is similar.
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.
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
Removing
agen
Prote AG.
Note
♦ The removal and installation sequence is only for the left mirror housing. The removal and installation of the
right mirror housing is similar.
♦ If there is any damage on and inside the exterior mirror, the mirror housing and lower trim must be replaced.
The mirror housing needs to be painted depending on the equipment.
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
yri by
Removing
op Vo
by c lksw
cted agen
Prote AG.
– Remove housing frame ⇒ page 297 .
– Detach connector -2-.
– Disconnect clips from mirror housing -1- and lower trim -4-
(qty. 5).
– To do this, press mirror housing -1- and lower trim -4- apart in
-direction of arrow-.
– Remove mirror housing -1- and lower trim -4- off mirror mount‐
ing -3-.
ce
e
nl
pt
du
an
Further installation is performed in the reverse order of removal.
itte
y li
erm
ab
5.5 Removing and installing exterior mirror
ility
ot p
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
The removal and installation sequence is only for the left exterior mirror. The removal and installation of the
right exterior mirror is similar.
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.
Removing
– Remove front door trim cover ⇒ General body repairs, interior;
Rep. gr. 70 ; Trims/insulation; Door trims .
– Remove front door trim ⇒ General body repairs, interior; Rep.
gr. 70 ; Trims/insulation; Door trims .
– Disconnect earth cable and connectors -3- from subframe.
– Remove screws -2- and take exterior mirror -1- off door.
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.
ce
le
un
pt
an
d
itte
y li
Note
erm
ab
ility
ot p
wit
♦ Only the left side is shown. The right side is similar.
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
1 - Front wheel housing liner
rrectne
❑ Removing and installing
⇒ page 304
ss
2 - Bolt
o
cial p
f i
❑ Qty. 11
nform
mer
atio
m
Nm
o
n
c
i
or
n
3 - Hexagon nut
thi
te
sd
va
❑ Qty. 2
i
o
pr
cum
r
fo
4 - Bolt
en
ng
t.
yi Co
op
❑ Specified torque: 6.0 C py
t. rig
Nm
gh ht
pyri by
Vo
co
❑ Bolted to front bumper
by lksw
cted agen
cover.
Prote AG.
5 - Expanding nut
❑ Qty. 8
Note
1 - Expanding nut
❑ Qty. 8 on each side
2 - T-pin
❑ Qty. 2 on each side
3 - Buffer
❑ Qty. 2 on each side
❑ Buffer must be drawn
over T-pin.
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
urposes, in part or in wh
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.
Note
Nm 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.
Note
♦ The removal and installation sequence is only for the left wheel housing liner. Removal and installation of
the right wheel housing liner are similar.
♦ The removal and installation procedures may have to be modified slightly depending on model variants.
n AG. Volkswagen AG do
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.
Removing
– Remove wheel ⇒ Running gear; Rep. gr. 44 ; Specified tor‐
ques for wheel bolts .
– Remove bolts -2- and -4-.
– Unscrew hexagon nut -3-.
– Pull wheel housing liner -1- out of wing.
Installing
Note
ce
le
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
tio
Note
n in
r
te o
thi
s
iva
♦ The removal and installation sequence is for the rear left wheel housing liner only. Removal and installation
do
r
rp
en
ng
t.
yi
♦ The removal and installation procedures may have to be modified slightly depending on model variants.
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
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
Removing
l purpos
atio
n in
c
thi
te
sd
iva
Installing
o
r
rp
cu
o
m
f
t.
yi Co
op py
Specified torques . C rig
ht ht
rig by
py
♦ ⇒ “6.3 Assembly overview - rear wheel housing liner”,
co Vo
by lksw
cted
page 304
agen
Prote AG.
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
♦ Adhesive strip remover -VAS 6349-
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.
Note
Fitting notes
♦ Heat lettering or emblem with hot air blower -V.A.G 1416- be‐
fore removing.
♦ If lettering or an emblem is applied for the first time to a new
vehicle or a newly painted surface, follow the procedure de‐
scribed in ⇒ Workshop manual "Paint" ⇒ Paintwork repairs ⇒
Paint finish ⇒ Mouldings and film .
♦ If the lettering or emblem is removed and reinstalled, use only
adhesive remover -D 002 000 10- to remove residual adhe‐
sive.
♦ Remove existing adhesive residue of adhesive tape using ad‐
hesive strip remover -VAS 6349- .
♦ Ensure that the adhesive surfaces are free of dust and grease.
ce
le
Follow the fitting notes when applying the lettering ⇒ page 308
un
pt
an
d
itte
y li
rm
ab
pe
ility
1 - Lettering
ot
wit
, is n
h re
❑ Model designation.
hole
spec
2 - Rear lid
es, in part or in w
t to the co
3 - Height dimension
❑ 66 mm from edge in rear
lid to lettering.
rrectness of i
4 - Horizontal dimension
l purpos
nform
ercia
5 - Lettering
m
a
com
tio
❑ Engine designation.
n in
r
te o
thi
6 - Height dimension
s
iva
do
r
cum
fo
lid to lettering.
en
ng
t.
yi Co
op
7 - Horizontal dimension C py
t. rig
gh ht
yri
❑ 41 mm from outer edge p by
co Vo
of rear lid to lettering.
by lksw
cted agen
Prote AG.
Note
Follow the fitting notes when applying the lettering ⇒ page 308
1 - Lettering
❑ Engine designation.
2 - Lettering
❑ Model designation.
3 - Rear lid
4 - Height dimension
❑ 12 mm gap between
edges of lettering.
5 - Height dimension
❑ 66 mm from edge in rear
lid to lettering.
6 - Horizontal dimension
❑ 41 mm from outer edge
of rear lid to lettering.
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.
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
– Guide emblem -1- with its retaining hooks in notches into ra‐
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.
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
Removing t. Cop py
rig
gh ht
yri
– Warm emblem -2- with hot air blower -V.A.G 1416- before re‐ p by
o Vo
by c
moving.
lksw
cted agen
Prote AG.
– Lever off emblem -2- from tailgate -1- using removing wedge
-3409- .
Installing
– Follow installation instructions ⇒ page 308 .
– Remove protective paper from adhesive foam tape.
– Position emblem -2- with centring pins in embossings
-arrows- on tailgate -1-.
– Press emblem -2- on firmly.
ce
le
⇒ “8.2 Removing and installing wheel arch trim, wing”,
un
pt
an
page 317
d
itte
y li
erm
ab
⇒ “8.3 Removing and installing wheel arch trim - left load bed”,
ility
ot p
page 321
wit
is n
h re
⇒ “8.4 Removing and installing wheel arch trim - right load bed”,
ole,
spec
page 325
urposes, in part or in wh
t to the co
8.1 Repair instructions
⇒ “8.1.1 Safety requirements”, page 313
rrectne
⇒ “8.1.2 Installation instructions for wheel arch trims”, page 313
s
⇒ “8.1.3 Preparing new add-on part for bonding”, page 314
s o
cial p
f in
⇒ “8.1.4 Preparing body component for bonding”, page 314
form
mer
atio
om
n
c
i
or
n thi
te
sd
a
o
pr
cum
r
fo
en
ng
t.
yi
page 316
Co
Cop py
ht. rig
⇒ “8.1.9 Cleaning guidelines”, page 317 rig ht
py by
co Vo
by lksw
8.1.1 Safety requirements
cted agen
Prote AG.
Caution
Note
Temperatures of the room, the work bay and the vehicle must be
approximately the same (18 °C and max. 30 °C).
Remove existing adhesive tape residues with adhesive remains
remover -VAS 6349- . n AG. Volkswagen A G do ge
es n swa
Always use a clean, lint-free
by
Vcloth
olk for cleaning. ot g
ua
ed ran
oris
Immediately before attaching add-on parts, clean bonding surfa‐ tee
th or
ces using adhesive
ss
aremover and then carefully remove dirt,
u ac
grease, wax and other impurities using plastic cleaner.
ce
e
nl
pt
du
an
• Observe the appropriate safety precautions when cleaning.
itte
y li
erm
ab
Remove backing only immediately before installation.
ility
ot p
wit
Before washing and preserving the vehicle, ensure that the wheel
, is n
h re
arch trims have been bonded for at least 3.5 hours.
hole
spec
8.1.3 Preparing new add-on part for bonding
es, in part or in w
t to the co
WARNING
rrectness of i
Before painting, use masking tape to precisely demarcate all
l purpos
nform
ercia
at
om
ion
– The bonding surfaces of the add-on parts must be prepared
c
in t
or
do
riv
cum
or
en
ng
t.
yi Co
op
8.1.4 Preparing body component for bonding
C py
t. rig
gh ht
pyri by
Vo
o
– Remove existing adhesive residue of double-sided adhesive by c lksw
cted agen
tape using adhesive strip remover -VAS 6349- . Prote AG.
Note
ce
le
un
pt
an
d
itte
y li
WARNING
erm
ab
ility
ot p
Exception: if bonding is performed later than one day after cut‐
wit
is n
ting back adhesive bead, the remaining residual material must
h re
ole,
spec
urposes, in part or in wh
t to the co
Activator must not come in contact with paint, or the paintwork
will be damaged.
rrectne
Drying time approx. 10 minutes.
ss o
cial p
f in
8.1.5 Installation instructions for wheel arch
form
mer
trims
atio
om
n
c
i
or
n
Installation instructions
thi
te
sd
iva
o
pr
cum
WARNING
r
fo
en
ng
t.
yi Co
op
Add-on parts should be installed within 10 minutes, or bonding
C py
t. rig
gh
properties of adhesive will be impaired.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
Note
♦ 1K glass adhesive 1) 2) 3) 4) 5)
♦ Activator 1) 5)
♦ Plastic primer 1) 5)
♦ Cleaning solution 1) 5)
♦ Primer applicator 1) 5)
♦ Adhesive remover 1) 5)
♦ Cutting cord 5)
ce
le
pt
an
d
itte
y li
Do not apply any direct load to bonding surfaces for at least 24
rm
ab
hours after installation.
pe
ility
ot
wit
, is n
h re
WARNING
hole
spec
es, in part or in w
tion in
material
r
te o
thi
s
iva
do
r
rp
cum
fo
Note
en
ng
t.
yi Co
op py
Use adhesive remover as a cleaning solution. Observe the ap‐
t. C rig
gh ht
yri
propriate safety precautions when performing this work. p by
co Vo
by lksw
cted agen
Prote AG.
– If necessary, lift off escaping adhesive with a piece of card‐
board.
– Clean painted surface as well as possible using a dry cloth.
– Remove residue using adhesive remover.
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
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
Note
agen
Prote AG.
The removal and installation procedure is for the left side. The
right side is similar.
ce
e
Bead section -a-
nl
pt
du
an
itte
❑ -Length- = approx.
y li
erm
ab
900 mm -height- = ap‐
ility
ot p
prox. 9.0 mm -width- =
wit
, is n
approx. 5.0 mm
h re
hole
spec
Bead section -b-
es, in part or in w
t to the co
❑ -Length- = approx. 500
mm -height- = approx.
12 mm -width- = approx.
rrectness of i
8.0 mm
l purpos
nf
ercia
mm -height- = approx.
or
6.0 mm -width- = ap‐
m
m
atio
prox. 3.0 mm
om
n in
or c
Section -d-
thi
te
sd
iva
o
r
rp
cu
material to hole, approx.
o
m
f
en
ng
15 mm (adhesive must
t.
yi Co
op
not enter hole) C py
t. rig
gh ht
yri
Section -e-
p by
o Vo
by c lksw
cted agen
❑ Distance of PUR sealing
Prote AG.
Removing
Note
♦ Wheel arch trim, wing, -1- cannot be removed without damaging it.
♦ Depending on wheel arch trim on front bumper cover, the locating pins -arrows- must be noted. It is possible
that the types of pins are mixed.
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
thi
s
iva
do
– Before removing wheel arch cover, wing -1-, heat the bonding
r
rp
cum
en
ng
t.
yi
– Lift one corner of wheel arch trim, wing, -1- using removal
Co
Cop py
wedge -3409- .
t. rig
gh ht
pyri by
Vo
o
– Grip under wheel arch trim, wing, -1- and carefully but firmly
by c lksw
cted agen
pull from wing -3-.
Prote AG.
Installing
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
do
cum
fo
en
g
t.
yi Co
Cop py
Installation instructions ⇒ page 315
t. rig
gh ht
pyri by
Vo
o
by c
– Apply PUR adhesive beneath rib (primed area) ⇒ page 318 .
lksw
cted agen
Prote AG.
Note
Depending on wheel arch trim, front bumper cover, the locating pins -arrows- must be removed.
– Insert the 2 locating pins -arrows- in the wheel arch trim, front
bumper cover.
– Position wheel arch trim, wing, -1- using swage line -3- and
check that edges are flush and aligned.
– Bolt on wheel arch trim, wing, -1- using wheel housing liner
bolts -5- ⇒ page 304 .
– Pull protective backing -4- off double-sided adhesive tape
-2-.
ce
e
Observe minimum curing period ⇒ page 316 .
nl
pt
du
an
itte
y li
Specified torques
erm
ab
ility
ot p
wit
, is n
h re
Bolt -6- 2.0 Nm
hole
spec
es, in part or in w
t to the co
- left load bed
rrectness of i
Special tools and workshop equipment required
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.
♦ Removal wedge -3409-
pt
du
Section -g-
an
itte
y li
erm
ab
wit
Section -h-
, is n
h re
hole
Section -i-
t to the co
❑ Distance of PUR sealing material to hole, approx. 15 mm (adhesive must not enter hole)
rrectness of i
Section -j-
l purpos
❑ Distance of PUR sealing material to edge, approx. 15 mm (adhesive must not go over edge)
nf
ercia
Removing
rm
m
atio
om
n in
or c
Note
thi
te
sd
iva
o
r
rp
cu
Wheel arch trim, left load bed, -1- cannot be removed without damaging it.
o
m
f
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
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.
n AG. Volkswagen AG do
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
at
om
io
in t
or
his
e
do
priv
cum
for
en
ng
t.
Note
yi Co
Cop py
t. rig
gh ht
yri
It is advisable to position wheel arch trim, left load bed -1- with the help of a second mechanic. p by
co Vo
by lksw
cted agen
Prote AG.
– Position wheel arch trim, left load bed, -1- using swage line
-6- and check flushness.
– Bolt on wheel arch trim, left load bed, -1- using rear wheel
housing liner bolts -4- ⇒ page 304 .
– Pull backing -7- off double-sided adhesive tape -2-.
– Forcefully press on wheel arch trim -1- along the entire area
of the double-sided adhesive tape -2-, starting from the centre
under the tank flap aperture and moving first towards the front
and then towards the rear.
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.
ce
e
nl
pt
du
an
Bead section -b-
itte
y li
erm
ab
❑ -Length- = approx. 300
ility
ot p
mm -height- = approx.
wit
, is n
12 mm -width- = approx.
h re
hole
7.0 mm
spec
es, in part or in w
t to the co
❑ -Length- = approx.
1,350 mm -height- = ap‐
rrectness of i
prox. 9.0 mm -width- =
approx. 5.0 mm
l purpos
nf
ercia
orm
mm -height- = approx.
m
atio
m
12 mm -width- = approx.
o
n in
c
6.0 mm
or
thi
te
sd
a
o
r
rp
cu
o
m
❑ -Length- = approx. 40
f
en
ng
t.
yi
mm -height- = approx.
Co
op py
6.0 mm -width- = ap‐
. C rig
ht ht
rig
prox. 3.0 mm py by
co Vo
by lksw
cted
Section -f-
agen
Prote AG.
Removing
Note
Wheel arch trim, right load bed, -1- cannot be removed without damaging it.
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.
n AG. Volkswagen AG do
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
yri by
Installation instructions for wheel arch trims ⇒ page 313 . cop Vo
by lksw
cted agen
Prote
Preparing new add-on part for bonding ⇒ page 314 .
AG.
Note
It is advisable to position wheel arch trim, left load bed -1- with the help of a second mechanic.
– Position and secure wheel arch trim, right load bed -1- using
threaded connection -7-.
– Position wheel arch trim, left load bed, -1- using swage line
-6- and check flushness.
– Bolt on wheel arch trim, right load bed, -1- using rear wheel
housing liner bolts -4- ⇒ page 304 .
– Pull backing -5- off double-sided adhesive tape -2-.
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
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
le
un
pt
Caution
an
d
itte
y li
rm
ab
When removing extensions, use suitable gloves and protective
pe
ility
eyewear.
ot
wit
, is n
h re
Do not use cutting wire to remove extensions.
hole
spec
Extensions must cure at least 3 hours after being bonded be‐
es, in part or in w
t to the co
fore work on the vehicle is continued.
rrectness of i
l purpos
Note
tio
genuine parts.
n in
r
te o
thi
do
traffic regulations.
r
rp
cum
fo
en
ng
t.
yi
9.1.2 Installation instructions for wheel arch
Co
Cop py
t. rig
trims
gh ht
pyri by
Vo
co lksw
by
cted
The wheel arch trim is factory-bonded with double-sided adhesive
agen
Prote AG.
tape and 1-component PU adhesive.
The wheel arch trim is primed by the supplier and delivered with
double-sided adhesive tape.
Ensure that backing of double-sided adhesive tape strips remains
free of paint and paint mist when painting extensions.
Temperatures of the room, the work bay and the vehicle must be
approximately the same (18 °C and max. 30 °C).
Remove existing adhesive tape residues with adhesive remains
remover -VAS 6349- .
Always use a clean, lint-free cloth for cleaning.
Immediately before attaching add-on parts, clean bonding surfa‐
ces using adhesive remover and then carefully remove dirt,
grease, wax and other impurities using plastic cleaner.
• Observe the appropriate safety precautions when cleaning.
Remove backing only immediately before installation.
Before washing and preserving the vehicle, ensure that the wheel
arch trims have been bonded for at least 3.5 hours.
WARNING
ce
le
un
pt
without damaging paintwork.
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
Note
hole
spec
es, in part or in w
t to the co
adhesive sealing compound.
rrectness of i
– Observe cleaning instructions for adjacent components
⇒ page 317 .
l purpos
If the body part has been repaired or partially renewed, the area
m
tion in
r
If a body part is fitted for the first time on a new vehicle or on newly
te o
thi
do
r
cum
fo
en
ng
t.
yi Co
op
WARNING C py
t. rig
gh ht
pyri by
Vo
o
Exception: if bonding is performed later than one day after cut‐
c by lksw
cted agen
ting back adhesive bead, the remaining residual material must Prote AG.
WARNING
ce
le
un
pt
♦ Gaps/shut lines should be kept to an absolute minimum.
an
d
itte
y li
erm
ab
ility
minimum curing time.
ot p
wit
is n
h re
ole,
spec
♦ If no cleanser is specified in the respective repair procedure,
urposes, in part or in wh
t to the co
– Remove adhesive residue using adhesive remover.
rrectne
– Clean application area for adhesive bead twice thoroughly us‐
ing cleanser named in repair procedure and allow to dry.
ss o
– Now apply glass/paint primer evenly in one stroke using ap‐
cial p
f in
plicator.
form
mer
atio
♦ Drying time approx. 10 minutes
om
n
c
i
– Apply adhesive sealing material to primed areas of attachment
or
n thi
e
parts.
t
sd
iva
o
pr
en
ng
♦ 1K glass adhesive 1) 2) 3) 4) 5)
♦ Activator 1) 5)
♦ Plastic primer 1) 5)
♦ Cleaning solution 1) 5)
♦ Primer applicator 1) 5)
♦ Adhesive remover 1) 5)
♦ Cutting cord 5)
ce
e
nl
the room and object temperatures must be at least 18 ℃.
pt
du
an
itte
y li
Do not apply any direct load to bonding surfaces for at least 24
erm
ab
hours after installation.
ility
ot p
wit
, is n
h re
WARNING
hole
spec
es, in part or in w
t to the co
It is safe to use vehicle only after the curing period is comple‐
ted.
rrectness of i
9.1.7 Touching up paint damage
l purpos
nform
ercia
at
om
ion
c
material
in t
or
his
ate
do
priv
cum
or
Note
f
en
ng
t.
yi Co
Cop py
Use adhesive remover as a cleaning solution. Observe the ap‐ ht. rig
rig ht
propriate safety precautions when performing this work.
py by
co Vo
by lksw
cted agen
Prote AG.
– If necessary, lift off escaping adhesive with a piece of card‐
board.
– Clean painted surface as well as possible using a dry cloth.
– Remove residue using adhesive remover.
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
Note
pe
ility
ot
wit
, is n
The removal and installation procedure is for the left side. The
h re
hole
t to the co
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
334
c by lksw
cted agen
Rep. gr.66 - Exterior equipment Prote AG.
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
ce
e
nl
pt
mm -height- = approx. 5
du
an
itte
mm -width- = approx. 3
y li
erm
ab
mm
ility
ot p
wit
Section -d-
, is n
h re
hole
spec
prox. 30 mm parallel to
es, in part or in w
t to the co
edge, distance approx.
15 mm
Section -e-
rrectness of i
❑ End of application, ap‐
l purpos
prox. 30 mm parallel to
edge, distance approx.
15 mm.
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 py
Removing
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
♦ Wheel arch trim, wing, -1- cannot be removed without damaging it.
♦ Depending on wheel arch trim on front bumper cover, the locating pins must be noted. It is possible that the
types of pins are mixed ⇒ page 238 .
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
– Remove bolts -3-.
an
d
itte
y li
erm
– Warm wheel arch trim, wing, -1- with hot air blower -V.A.G
ab
ility
1416- before removing.
ot p
wit
is n
– Raise wheel arch trim, wing, -1- at one corner using removal
h re
ole,
– Grip under wheel arch trim, wing, -1- and carefully pull off from
t to the co
wing -5-.
Installing
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.
n AG. Volkswagen AG do
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
urposes, in part or in wh
t to the co
rrectne
f inform
atio
n
c
i
or
o
pr
cum
r
– Position wheel arch trim, wing, -1- with the help of the posi‐
fo
en
ng
tioning tool -6- and the swage line -5- and that edges are flush
t.
yi Co
op
and aligned. C py
t. rig
gh ht
yri by
– Bolt on wheel arch trim, wing, -1- using wheel housing liner
cop Vo
by lksw
bolts -3- ⇒ page 304 . cted agen
Prote AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
♦ Torque wrench -V.A.G 1783- 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
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.
❑ -Length- = approx. 70
nl
pt
du
an
mm -height- = approx. 5
itte
y li
mm -width- = approx. 3
erm
ab
mm
ility
ot p
wit
, is n
Section -g-
h re
hole
spec
t to the co
Section -h-
❑ End of application, approx. 30 mm parallel to edge, distance approx. 15 mm.
rrectness of i
Section -i-
l purpos
at
om
ion
c
in t
or
his
te
Removing
a
do
priv
cum
for
en
ng
t.
yi
Note
Co
Cop py
t. rig
gh ht
yri by
Wheel arch trim, left load bed, -1- cannot be removed without damaging it. cop Vo
by lksw
cted agen
Prote AG.
n AG. Volkswagen AG do
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
ercia
at
om
– Warm wheel arch trim, left load bed, -1- with hot air blower -
ion
c
his
ate
– Lift one corner of wheel arch trim, left load bed, -1- using re‐
do
riv
cum
for
en
ng
t.
– Grip under wheel arch trim, left load bed, -1- and carefully but
yi Co
op
firmly pull off from component.
C py
t. rig
gh ht
yri by
Installing cop Vo
by lksw
cted agen
Prote AG.
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
urposes, in part or in wh
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.
pt
du
an
itte
y li
❑ -Length- = approx. 60
erm
ab
mm -height- = approx. 5
ility
ot p
mm -width- = approx. 3
wit
, is n
mm
h re
hole
spec
Section -f-
es, in part or in w
t to the co
❑ Start of application,
30 mm parallel to edge,
distance approx.
rrectness of i
15 mm.
l purpos
Section -g-
❑ End of application, approx. 30 mm parallel to edge, distance approx. 15 mm.
nf
ercia
orm
m
atio
m
Removing
o
n in
or c
thi
te
sd
iva
o
r
Note
rp
cu
o
m
f
en
ng
t.
yi
Wheel arch trim, right load bed, -1- cannot be removed without damaging it.
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
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
– Warm wheel arch trim, right load bed, -1- with hot air blower -
V.A.G 1416- before removing.
nform
ercia
– Lift one corner of wheel arch trim, right load bed, -1- using
removal wedge -3409- .
m
at
om
io
– Grip under wheel arch trim, right load bed, -1- and carefully
n
c
in t
r
his
ate
do
riv
Installing
p
cum
for
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
byV gu
ara
ed
ris nte
ho eo
ut ra
Installation instructions for wheel arch trims ⇒ page 330
ss a c
ce
e
pt
du
an
itte
y li
ab
ility
ot p
h re
spec
t to the co
– Position wheel arch trim, right load bed, -1- with the help of the
assembly tool -6- and the swage line.
– Check flushness with load bed -5- and swage line.
rrectness of i
– Bolt on wheel arch trim, right load bed, -1- using rear wheel
l purpos
-2-.
rm
m
atio
m
n in
c
thi
sd
iva
o
r
rp
cu
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
344
cted agen
Prote AG.
Rep. gr.66 - Exterior equipment
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
10 Protective film
⇒ “10.1 Fitting notes”, page 345
⇒ “10.2 Renewing window frame films”, page 346
⇒ “10.3 Removing and installing inner film of front door”,
page 348
⇒ “10.4 Removing and installing inner door film of rear door”, page
349
⇒ “10.5 Scuff protection film”, page 350
⇒ “10.6 Protective film, B-pillar”, page 351
⇒ “10.7 Anti-abrasion film, tailgate and D-pillar, load bed”,
page 353
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
ut ra
♦ Adhesive strip remover -VAS
ss a
6349- 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
Before removing the protective film, heat it with a hot air blower -
V.A.G 1416- .
nform
ercia
If the protective film is installed for the first time on a new vehicle
m
a
com
thi
and film .
s
iva
do
r
rp
t.
yi Co
op py
Remove existing adhesive residue of adhesive tape using adhe‐ t. C rig
gh ht
sive strip remover -VAS 6349- . yri
p by
o Vo
by c lksw
cted
Ensure that the adhesive surfaces are free of dust and grease.
agen
Prote AG.
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
o
Note
rm
m
atio
om
Renewing window frame films is described only for the left side. The right side is similar.
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.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
Removing ss
ce
le
un
pt
– Heat window frame films -1- or -2- using hot air blower -V.A.G
an
d
itte
y li
1416- and pull off front door frame -3- or rear door frame -4-.
erm
ab
ility
ot p
Installing
wit
is n
h re
spec
urposes, in part or in wh
on.
– Pull off backing.
rrectne
– Position window frame films -1- or -2- on front door frame -3-
or rear door frame -4-.
ss
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.
ce
e
nl
pt
du
♦ If corrective work is necessary, completely remove inner door film -1- and adhesive residue.
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.
Removing
– Pull inner door film -1- off door.
Use inner door film -1- once only.
Installing
– Follow installation instructions ⇒ page 345 .
– Position inner door film -1- at markings -arrows- and glue on
the area between the two markings without subjecting the film
to any stress.
– Pull inner door film -1- smoothly over the door aperture -2- and
position so that it does not have any wrinkles.
Note
Note
♦ Renewing inner door film is described only for the right side. The left side is analogous.
♦ If corrective work is necessary, completely remove inner door film -1- and adhesive residue.
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
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
va
Removing
i
o
pr
cum
r
fo
en
ng
Installing
– Follow installation instructions ⇒ page 345 .
– Position inner door film -1- at markings -arrows- and glue on
the area between the two markings without subjecting the film
to any stress.
– Pull inner door film -1- smoothly over the door aperture -2- and
position so that it does not have any wrinkles.
– Smooth inner door film -1- outwards, ensuring that it is free of
wrinkles.
Note
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
Note
ot p
wit
is n
h re
♦ Renewing scuff protection films is described only for the left side. The right side is similar.
ole,
spec
urposes, in part or in wh
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.
n AG. Volkswagen AG do
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
Removing
erm
ab
ility
ot p
h re
– Heat scuff protection film -1- using hot air blower -V.A.G 1416-
ole,
spec
t to the co
Installing
– Follow installation instructions ⇒ page 345 .
rrectne
f i
towel.
nform
mer
i
or
n thi
te
sd
va
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.
Note
Removing
– Heat scuff protection film of B-pillar -1- using hot air blower -
V.A.G 1416- and pull off from step area. AG. Volkswagen AG d
agen oes
Installing olksw not
byV gu
ara
ed
nte
– Follow installation instructions ⇒ page 345 . horis
eo
aut ra
– Pull backing off scuff protection film of B-pillar -1-. ss c
ce
le
un
pt
– Position protective film for B-pillar -1- in the radius of side
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.
1 - Tailgate
2 - D-pillar, load bed
AG. Volkswagen AG d
3 - Anti-abrasion film lksw
agen oes
not
Vo gu
❑ Dimension -a- = 135 ± 2 d by ara
mm from lower edge of rise nte
tho eo
D-pillar to anti-abrasion s au ra
c
film. s
ce
le
un
pt
4 - Anti-abrasion film
an
d
itte
y li
❑ Dimension -b- = 88 ± 2 rm
ab
pe
ility
mm from lower edge of
ot
wit
anti-abrasion film -5- to
, is n
h re
edge of anti-abrasion
hole
spec
film -4-.
es, in part or in w
t to the co
5 - Anti-abrasion film
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.
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
Note
nform
ercia
a
com
tio
♦ During mounting, pull rubber lip -arrow- back with your fingers.
n 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.
12 Towing bracket
⇒ “12.1 Assembly overview - towing bracket with ball head”, page
355
Note
ce
le
capacity.
un
pt
an
d
itte
y li
rm
ab
current flow diagram workshop manual .
pe
ility
ot
wit
♦ There is no engine-stop function when the towing bracket is in
, is n
h re
use.
hole
spec
♦ The towing bracket cannot be removed.
es, in part or in w
t to the co
12.1 Assembly overview - towing bracket rrectness of i
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.
1 - Towing bracket
❑ Towing bracket for 3.2
tonne towing capacity
Installation and bolting se‐
quence:
ce
e
present)
nl
pt
du
an
itte
y li
3 - Bolt
erm
ab
❑ Qty. 2
ility
ot p
wit
, is n
h re
Nm + 120°
hole
spec
es, in part or in w
t to the co
WARNING
Bolts must always be re‐
placed by new ones after
rrectness of i
being removed.
l purpos
4 - Bolt
nf
ercia
atio
n in
Nm + 180°
or c
thi
te
sd
iva
o
r
WARNING
rp
cu
o
m
f
en
ng
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
1 - Spare wheel winch
ce
le
un
pt
an
d
y li
rm
ab
2 - Spare wheel winch
pe
ility
ot
❑ On ladder frame
wit
, is n
h re
hole
3 - Bolt
spec
es, in part or in w
❑ Qty. 2
t to the co
❑ Specified torque: 55 Nm
4 - Bolt
rrectness of i
❑ Qty. 2
l purpos
❑ Specified torque: 55 Nm
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.
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
urposes, in part or in wh
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.
14 Mudflaps
⇒ “14.1 Assembly overview - front mudflap, without wheel arch
trim”, page 359
⇒ “14.2 Assembly overview - front mudflap, with wheel arch trim”,
page 360
⇒ “14.3 Assembly overview - rear mudflap, without wheel arch
trim”, page 361
⇒ “14.4 Assembly overview - rear mudflap, with wheel arch trim”,
page 362
⇒ “14.5 Assembly overview - rear mudflap bracket”, page 363
⇒ “14.6 Removing and installing front mud flaps, without wheel
AG. Volkswagen AG d
arch trim”, page 363 lkswagen oes
n o ot g
yV u
⇒ “14.7 Removing andris
einstalling
db front mud flaps, with wheel arch
ara
nte
trim”, page 365 utho eo
r
sa ac
⇒ “14.8 Removings
and installing rear mud flaps, without wheel
ce
le
pt
an
d
itte
y li
⇒ “14.9 Removing and installing rear mud flaps, with wheel arch
erm
ab
trim”, page 368
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
Note
f inform
⇒ page 304
atio
om
n
c
2 - Expanding nut
i
or
n thi
e
❑ Qty. 1
t
sd
iva
o
pr
cum
r
3 - Front mudflap
fo
en
ng
t.
yi
❑ Removing and installing
Co
op py
⇒ page 363 t. C rig
gh ht
pyri by
4 - Bolt
o Vo
by c lksw
cted agen
Prote
❑ Qty. 2
AG.
Note
tachment”.
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.
Note
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
urposes, in part or in wh
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
by
361
copy Vo
by lksw
cted agen 14. Mudflaps
Prote AG.
Amarok 2011 ➤
General body repairs, exterior - Edition 10.2012
Note
ce
e
3 - Rear mudflap
nl
pt
du
an
❑ Removing and installing
itte
y li
erm
⇒ page 368
ab
ility
ot p
4 - Bolt
wit
, is n
h re
❑ Qty. 2
hole
spec
❑ Specified torque: 2.0
es, in part or in w
Nm
t to the co
❑ These two bolts are re‐
quired parts for attach‐
rrectness of i
ing wheel housing liner.
l purpos
5 - Bolt
❑ Qty. 5
nf
ercia
orm
Nm
m
atio
om
6 - Spreader rivet
n in
or c
thi
e
❑ Qty. 1
t
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.
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
14.6 Removing and installing front mud flaps,
AG.
Note
♦ The removal and installation sequence is only described for the left side. Removal and installation of the
right side is similar.
♦ The removal and installation procedures may have to be modified slightly depending on model variants.
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
urposes, in part or in wh
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.
Removing
– Remove bolts -4- and -5-.
– Remove front mudflap -3- from front wheel housing liner -1-.
Installing
– Slide front mudflap -3- onto wing flange.
Specified torques
♦ ⇒ “14.1 Assembly overview - front mudflap, without wheel arch
trim”, page 359
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
Note
pt
du
an
itte
y li
erm
ab
♦ The removal and installation sequence is only described for the left side. Removal and installation of the
ility
ot p
h re
♦ The removal and installation procedures may have to be modified slightly depending on model variants.
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.
n AG. Volkswagen AG do
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
Removing gh ht
pyri by
Vo
co lksw
by
– Remove bolts -4- and -5-. Prote
cted AG.
agen
– Remove front mudflap -3- from front wheel housing liner -1-.
Installing
– Slide front mudflap -3- onto wing flange.
Specified torques
♦ ⇒ “14.2 Assembly overview - front mudflap, with wheel arch
trim”, page 360
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
Note
an
d
itte
y li
rm
ab
♦ The removal and installation sequence is only described for the left side. Removal and installation of the
pe
ility
right side is similar.
ot
wit
, is n
h re
♦ The removal and installation procedures may have to be modified slightly depending on model variants.
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.
Removing
– Unscrew bolts -3- and -4-
– Use small drift to press pin inwards and unclip spreader rivet
-5-.
– Remove rear mudflap -2- from front wheel housing liner -1-.
Installing
• Rear mudflap bracket is fitted ⇒ page 363 .
– Locate rear mudflap -2- and secure clip -5-.
Specified torques
♦ ⇒ “14.3 Assembly overview - rear mudflap, without wheel arch
trim”, page 361
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
Note
♦ The removal and installation sequence is only described for the left side. Removal and installation of the
rrectness of i
♦ The removal and installation procedures may have to be modified slightly depending on model variants.
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.
n AG. Volkswagen AG do
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
or
Removing
f
en
ng
t.
yi Co
– Unscrew bolts -4- and -5- Cop py
t. rig
gh ht
yri
– Use small drift to press pin inwards and unclip spreader rivet p by
co Vo
-6-.
by lksw
cted agen
Prote AG.
– Remove rear mudflap -3- from front wheel housing liner -1-.
Installing
• Rear mudflap bracket is fitted ⇒ page 363 .
– Locate rear mudflap -3- and secure clip -6-.
– Secure clip -6-.
Specified torques
♦ ⇒ “14.4 Assembly overview - rear mudflap, with wheel arch
trim”, page 362