D3E802237C9 Body Repairs

Service
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Service Department. Technical Information

Service
Repair Group overview for Body Repairs
Repair Group
00 - General, Technical Data
50 - Body Front
51 - Body Center, Chassis, Roof
53 - Body Rear
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2014 Volkswagen AG, Wolfsburg D3E802237C9

Golf 2009 ➤
Body Repairs - Edition 10.2011
Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Vehicle Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Alignment Bracket Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Portal Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Molded Foam Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4 Galvanized Body Parts and High-Strength/Highest Strength Hot Formed Body Panels . . 8
2.5 Laser Welds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.1 Body Gap Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2 Body Panel Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
50 - Body Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
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1 Removal and Installation . . . . . . . . . . l.ks.w.ag. e.n.A. . . . . . . . . .A.G. d.o.es. n. . . . . . . . . . . . . . . . . . . 42
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1.1 Right Console . . . . . . . . . . . . . . e.d.b.y V. . . . . . . . . . . . . . . . . . . . . . . . .t .gu. a.ra. . . . . . . . . . . . . . . 42
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1.2 Left Console . . . . . . . . . . . . t.ho.ri. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .te.e o. . . . . . . . . . . . 45
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1.3 Subframe Mounting Bracketss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ac. . . . . . . . . .
a 50
1.4 Front Bumper Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
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1.5 Upper Wheel Housing Longitudinal Member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
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1.6 Front Wheel Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
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1.7 Subframe Mount Thread, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
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1.8 Front Longitudinal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
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1.9 Front Longitudinal Member, Partial Section, Removing and Installing . . . . . . . . . . . . . . . . 86
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2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
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51 - Body Center, Chassis, Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
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1 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.1 Roof, Vehicles without Sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
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1.2 Roof, Vehicle with Sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

1.3 Roof Pillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
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1.4 Front Roof Crossmember . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

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1.5 Roof Reinforcement, Vehicles without Sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

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1.6 Rear Roof Cross Member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

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1.7 A-Pillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

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1.8 A-Pillar Reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

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1.9 B-Pillar, 4-Door Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

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1.10 B-Pillar Reinforcement, 4-Door Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
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1.11 B-Pillar Reinforcement, 2-Door Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
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1.12 Outer Sill Panel, 4-Door Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
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1.13 Outer Sill Panel, 2-Door Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
1.14 Outer Seat Cross Member Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
1.15 Inner Seat Cross Member Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
1.16 Sill Panel Front Reinforcement, Vehicles with 4-Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
1.17 Sill Panel Front Reinforcement, Vehicles with 2-Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
1.18 Sill Panel Rear Reinforcement, Vehicles with 4-Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
1.19 Sill Panel Rear Reinforcement, Vehicles with 2-Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
1.20 Center Seat Cross Member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
Contents i
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53 - Body Rear . . . . . . .ss.a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a.c . . . . . . . . . . . . . . 266
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1 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
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1.1 Rear Cross Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
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1.2 Tail Lamp Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
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1.3 End Crossmember . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
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1.4 Luggage Compartment Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
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1.5 Rear Longitudinal Member, Partial Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
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1.6 Side Panel, Vehicles with 4-Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
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1.7 Side Panel, Vehicles with 2-Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
1.8 Outer Wheel Housing Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
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2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
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3 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
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ii Contents
Golf 2009 ➤
00 – General, Technical Data

1 General Information
(Edition 10.2011)
⇒ “1.1 Safety Precautions”, page 1
⇒ “1.2 Vehicle Data”, page 1
1.1 Safety Precautions
WARNING
Before starting any repair work, always follow safety precau‐

tions in ⇒ General Information; Body Repairs, Body Collision
Repair .
1.2 Vehicle Data

⇒ “1.2.1 VIN”, page 1
⇒ “1.2.2 Type Plate”, page 3
⇒ “1.2.3 Vehicle Data Label”, page 4
1.2.1 VIN agen

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1. General Information 1
Golf 2009 ➤
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The VIN -arrow- is located on right side of vehicle in fender bolt

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area (upper wheel housing longitudinal member).

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If the fender mounts (wheel housing upper longitudinal member) must be replaced because of damage, service
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must be documented according to market-specific legal requirements.

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2 Rep. Gr.00 - General, Technical Data

Golf 2009 ➤
1.2.2 Type Plate
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The type plate -arrow- located on the left B-pillar on 2-door and
4-door vehicles.
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1. General Information 3
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Vehicle data label -arrow- is secured in spare wheel well on left

side in direction of travel.

Golf 2009 ➤
2 Description and Operation

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⇒ “2.2 Portal Gauge”,
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⇒ “2.3 Molded Foam
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⇒ “2.5 Laser Welds”, page 15
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2.1 Alignment Bracket Set
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Special tools and workshop equipment required
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♦ Alignment Bracket Set For Touran - VAS6240-
♦ Straightening Bracket Set Supplement For Golf, MY 2004 -
rrectne
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2. Description and Operation 5

Golf 2009 ➤
Note
Refer to assembly plan supplied with alignment bracket set for

detailed information on the assembly.
Assembly of complete Straightening Bracket Set For Touran -

VAS6240- with Straightening Bracket Set Supplement For Golf,
MY 2004 - VAS6240/2- and Straightening Bracket Set Supple‐
ment For Golf, MY 2009 - VAS6240/13- .
2.2 Portal Gauge

♦ Portal Gauge - VAS5007-
♦ Portal Gauge Supplement Golf MY 2004 - VAS5007/18-
⇒ “2.2.1 2-Door Vehicle”, page 6
2.2.1 2-Door Vehicle
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Golf 2009 ➤

Front Doors
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Rear Doors
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Golf 2009 ➤
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2.3 Molded Foam Inserts

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Various hollow body areas are equipped with molded foam parts
in this vehicle.
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The transfer of driving noises into the passenger compartment

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Exact positions of molded foam parts are depicted at the begin‐

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⇒ “2.4.1 Structure”, page 8 Prote AG.

2.4.1 Structure
General information apply to all work on higher-strength body
panels. Refer to ⇒ General Information; Body Repairs, Body Col‐
lision Repair .

Golf 2009 ➤
Vehicle construction is predominantly manufactured from galvan‐

ized steel panels.
The steel panels, which are made of high strength to hot formed
steel, are shown in color in the following illustrations (see Table).
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Color Type of steel Tensile strength / minimum yield point in Mpa

1 Gray Normal < 140
2 Light blue Soft 220 - 260
3 Yellow High-strength 280 - 340
4 Magenta Higher-strength 360 - 420
5 Blue Highest-strength 800 - 1000
6 Green Hot-formed / special quality 1200 - 1800

Golf 2009 ➤
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cial p
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To illustrate the body more clearly, the outer side panel and the gh ht
yri by
roof are not shown in the illustration. These parts are likewise
op Vo
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made from »standard« body steel.
cted agen
Prote AG.

Golf 2009 ➤
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spec
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cial p
f i
To illustrate the body more clearly, the outer side panel and the
nform
mer

atio
om
n
c
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or
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pr
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t.
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Cop py
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gh ht
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Vo
co lksw
by
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Prote AG.

Golf 2009 ➤
lkswage es n
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d ran
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u or
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nl
pt
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es, in part or in w
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roof are not shown in the illustration. These parts are likewise C py
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made from »standard« body steel. gh ht
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by
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Prote AG.

AG. Volkswagen AG d
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h
Golf 2009 ➤
ra
s c
s Body Repairs - Edition 10.2011
ce
le
un
pt
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d
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rm
ab
pe
ility
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es, in part or in w
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a
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tion in
r
te o
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do
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rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
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y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
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spec
es, in part or in w
t to the co
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nform
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at
om
ion
c
in t
or
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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.

Golf 2009 ➤
lkswage es n
o ot g
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d ran
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u or
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nl
pt
du
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ility
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spec
es, in part or in w
2.5 Laser Welds

t to the co
On this vehicle, roof and body are partially welded by laser.

rrectness of i
In laser welding, a high energy light beam is directed onto the

weld points via optical lenses or fiber optics.
l purpos
During the welding process, the upper plate is melted through and
the lower plate is partially melted, thereby forming a weld without
nform
ercia
using any additional materials.

m
at
om
During repairs (except roof repairs), laser weld seams are re‐
on
c
in t
placed by SG plug weld seams or RP spot weld seams.

or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2009 ➤
3 Specifications
⇒ “3.1 Body Gap Dimensions”, page 16
⇒ “3.2 Body Panel Dimensions”, page 20
3.1 Body Gap Dimensions

⇒ “3.1.1 Body, Front”, page 16
⇒ “3.1.2 Body, Center”, page 18
⇒ “3.1.3 Body, Rear”, page 19
Note
♦ Use the Adjustment Gauge - 3371- for adjusting or checking.

♦ Panel gaps are always indicated in mm.
AG. Volkswagen AG d
agen oes
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ara
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ris nte
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3.1.1 Body, Front
ce
le
un
pt
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d
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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.

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
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V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
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s
iva
do
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rp
cum
fo
en
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t.
yi Co
Cop py
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gh ht
pyri by
Vo
o
by c lksw
17
cted agen
Prote
3. Specifications
AG.
Golf 2009 ➤
Dimension -a- = 4.5 mm +/- 0.5 mm

Dimension -b- = 3.5 mm +/- 0.5 mm
Dimension -c- = 0.5 mm +/- 0.5 mm
Dimension -d- = 3.5 mm +/- 0.5 mm
Dimension -e- = 5.0 mm +/- 0.5 mm
3.1.2 Body, Center
AG. Volkswagen AG d
agen oes
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y V gu
d b ara
rise nte
tho eo
au ra
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ce
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un
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ility
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is n
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ole,
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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.

Golf 2009 ➤
On a 2-Door Vehicle, the Gap Dimension Between the Door and

Side Panel is 3.5 mm +/- 0.5 mm
On a 2-Door Vehicle, the Gap Dimension Between the Door and
Side Window is 4.0 mm +/- 0.5 mm
Dimension -b- = 0.0 mm - 1.0 mm
Dimension -e- = 0.0 mm -1.0 mm
Dimension -f- = 3.5 mm +/- 0.5 mm
3.1.3 Body, Rear
AG. Volkswagen AG d
agen oes
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V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
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f
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
3. Specifications 19
Golf 2009 ➤

Dimension -b- = 5.0 mm +/- 0.5 mm
Dimension -e- = 1.0 mm +/- 0.5 mm
Dimension -f- = 4.5 mm +/- 1.0 mm
3.2 Body Panel Dimensions

⇒ “3.2.1 Body, Front”, page 20
⇒ “3.2.2 Body, Center”, page 25
⇒ “3.2.3 Body, Rear”, page 33
⇒ “3.2.4 Front Floor Assembly”, page 36
⇒ “3.2.5 Center Floor Assembly”, page 38
AG. Volkswagen AG d
agen
⇒ “3.2.6 Rear Floor Assembly”, page 39 Volksw
oes
not
gu
by ara
d
rise nte
tho eo
Note ss au ra
c
ce
e
nl
pt
♦ The body dimensions serve only for inspection. The Alignment
du
an
itte
Bracket Set is standard.
y li
erm
ab
ility
♦ Bolts, plugs, trim and attachments must be removed before
ot p
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the measuring procedure.
, is n
h re
hole
♦ Use the Telescoping Measuring Device - VAS5159- or the
spec
Telescoping Measuring Device - VAS5160- to determine body
es, in part or in w
t to the co
dimensions.
♦ Ensure measuring points are always the same length to avoid
inaccuracy when measuring.
rrectness of i
l purpos
3.2.1 Body, Front

Front Bumper Mount
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.

Golf 2009 ➤
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
Dimension -a- = 988 mm +/- 2.0 mm

ion
c
in t
or
Front Upper Longitudinal Member

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.
Golf 2009 ➤
lkswage es n
o ot g
byV ua
d ran
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tho
u or
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ss
ce
e
nl
Dimension -a- = 1,290 mm +/- 2.0 mm

pt
du
an
itte
y li
Suspension Strut Mounting

erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
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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.

Golf 2009 ➤
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.

Engine Compartment Diagonal Dimension
Upper Longitudinal Member
Golf 2009 ➤
AG. Volkswagen AG d
agen oes
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y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2009 ➤

Dimension -b- = 488 mm +/- 2.0 mm
3.2.2 Body, Center

Windshield Opening
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co

rrectness of i
Dimension -b- = 1,448 mm +/- 2.0 mm

l purpos
2-Door Vehicle
Dimension between A-pillars
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.
Golf 2009 ➤
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
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ab
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ility
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wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
This dimension is the same in 2- and 4-door vehicles.

rrectness of i

l purpos
Door Opening
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.

Golf 2009 ➤
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.

Dimension between B-pillars
Golf 2009 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
Dimension -a- = 1,426 mm +/- 2.0 mm an

itte
y li
erm
ab
4-Door Vehicle ility
ot p
wit
, is n
Dimension between A-pillars, refer to ⇒ page 25

h re
hole
spec
Front Door Opening

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.

Golf 2009 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
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ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Dimension between B-pillars
Golf 2009 ➤
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.
Dimension -a-= 1,438 mm +/- 2.0 mm

Rear Door Opening

Golf 2009 ➤
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.

Dimension between C-pillars
Golf 2009 ➤
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.

Golf 2009 ➤

n AG. Volkswagen A age G do
lksw es n
3.2.3 Body,
ed
by
Vo Rear ot g
ua
ran
is tee
or
Rear Longitudinal
au
th Member or
ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Rear Lid Opening
Golf 2009 ➤
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
Roof Edge
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.

Golf 2009 ➤
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
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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.
Golf 2009 ➤
Dimension -a- = 950 +/- 1.0 mm
3.2.4 Front Floor Assembly

Front Longitudinal Member and Lower Front Left Longitudinal
Member
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
Dimension -a- = 1164 +/- 2.0 mm

t to the co
Dimension -b- = 620 +/- 2.0 mm

Front Assembly Mount
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.

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Golf 2009 ➤
Dimension -a- = 874 +/- 2.0 mm

Dimension -b- = 835 +/- 2.0 mm
3.2.5 Center Floor Assembly

Underbody (B-Pillar Height)
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
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
Note
do
priv
cum
for
en
g
Is measured on inner side of body flange.

n
t.
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Cop py
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Golf 2009 ➤
3.2.6 Rear Floor Assembly

Rear Axle Trailing Link Mount
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Dimension -a- = 1002 +/- 1.5 mm

Dimension -b- =1326 +/- 1.5 mm
Rear Longitudinal Member Diagonal
Golf 2009 ➤
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ate
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Dimension -a- = 1190 +/- 2.0 mm

Golf 2009 ➤
4 Special Tools
♦ Alignment Bracket Set For Touran - VAS6240-
VAS6240/2-
VAS6240/13-
♦ Portal Gauge - VAS5007-
♦ Portal Gauge Supplement Golf MY 2004 - VAS5007/18-
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4. Special Tools 41
Golf 2009 ➤ lkswage es n
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Body Repairs - Edition 10.2011 byV ua
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50 – Body Front
ce
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1 Removal and Installation
ility
ot p
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⇒ “1.1 Right Console”, page 42
h re
hole
spec
⇒ “1.2 Left Console”, page 45
es, in part or in w
t to the co
⇒ “1.3 Subframe Mounting Bracket”, page 50
⇒ “1.4 Front Bumper Bracket”, page 53
rrectness of i
⇒ “1.5 Upper Wheel Housing Longitudinal Member”, page 55 l purpos
⇒ “1.6 Front Wheel Housing”, page 63

⇒ “1.7 Subframe Mount Thread, Servicing”, page 74
nform
ercia
⇒ “1.8 Front Longitudinal”, page 79

m
at
om
io
⇒ “1.9 Front Longitudinal Member, Partial Section, Removing and
n
c
in t
or
Installing”, page 86
his
ate
do
riv
1.1 Right Console

p
cum
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WARNING t. C rig
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by
Observe safety precautions. Refer to ⇒ General Information; cted agen
Prote AG.
Body Repairs, Body Collision Repair

♦ Spot Welder (Inverter) - VAS6239-
♦ Welding Unit With C-Grips - VAS6366-
♦ Welding Unit With X-Grips - VAS6376-
♦ Programmable Welding Unit With C-Grips - VAS6377-
Removing
42 Rep. Gr.50 - Body Front

Golf 2009 ➤
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– Separate the original connection.
1. Removal and Installation 43

Golf 2009 ➤
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– Remove residual material. ss
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pt
Installation
an
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Note
wit
is n
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ole,
When using different types of steel and materials of different

spec
strengths, one of the inverters listed under the special tools sec‐
t to the co
tion of this repair manual are required to perform repair work

correctly.
rrectne
Welding In
Replacement Part
ss o
cial p
♦ Right console
inform
mer
– Fit new part to vehicle standing on Alignment Bracket Set and

atio
m
secure.
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Prote AG.

Golf 2009 ➤
AG. Volkswagen AG d
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– Weld in console, Straight-line spot weld seam.
fo
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1.2 Left Console Cop py
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WARNING
cted agen
Prote AG.
Observe safety precautions, Refer to ⇒ General Information;


Golf 2009 ➤
1 - Console
2 - Wheel Housing
3 - Longitudinal Member
AG. Volkswagen AG d
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nform
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m
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n
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ate
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um
for
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♦ Gas-Shielded Welder 250A - VAS6045A-
yi Co
Cop py
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Removing
gh ht
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Prote AG.

Golf 2009 ➤
AG. Volkswagen AG d
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Cop py
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Prote AG.

Golf 2009 ➤
AG. Volkswagen AG d
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spec
t to the co
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ss o
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mer
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te
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fo
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Cop py
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Prote AG.

Golf 2009 ➤
AG. Volkswagen AG d
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spec
– Remove residual material.

t to the co
Installation
rrectne
Note
s

s o
cial p
f in

form
mer
correctly.
atio
om
n
c
Preparing New Parts

or
n thi
te
sd
va
Replacement Part
i
o
pr
cum
r
fo
♦ Left console
en
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t.
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op py
– Drill holes for gas-shielded arc plug weld seam.
t. C rig
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Welding In
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Prote AG.
secure.

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Golf h2009
oris ➤ tee
t or
Bodyau Repairs - Edition 10.2011 ac
ss
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es, in part or in w
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tion in
r
te o
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en
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Cop py
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by
cted agen
Prote AG.
– Weld in console, Gas-shielded arc plug weld seam and

straight-line spot weld seam.
1.3 Subframe Mounting Bracket
WARNING
Observe safety precautions. Refer to ⇒ General Information;

Body Repairs, Body Collision Repair ; Safety precautions
Note
In the example, replacement of retaining bracket for subframe is

described for left front retaining bracket on this vehicle. The work
procedure is performed in a similar manner for the other 3 retain‐
ing brackets.


Golf 2009 ➤

Removing
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do
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en
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C py
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Prote AG.

Golf 2009 ➤

Installation
Note

correctly.
Preparing New Parts AG. Volkswagen AG d

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Replacement Part by Vo gu
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♦ Front retaining bracket uthofor
r
subframe (replacement part identi‐ eo
fication: retaining bracket
ss a mounting frame) ra
c
ce
le
un
pt
– Drill holes with an 8 mm diameter for a gas shielded arc plug
an
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weld seam
erm
ab
ility
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Welding In
wit
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secure.
spec
t to the co
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cial p
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mer
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Cop py
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Vo
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by
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Prote AG.

Golf 2009 ➤
AG. Volkswagen AG d
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es, in part or in w
t to the co
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l purpos
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mercia
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tion in
r
te o
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fo
en
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Weld in new part; Gas-shielded arc plug weld seam.
1.4 Front Bumper Bracket
WARNING


Removing

Golf 2009 ➤
1 - Longitudinal Member Cover

Plate
2 - Bumper Bracket
– Separate the original
connection.
AG. Volkswagen AG d
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Installation
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Note
es, in part or in w
t to the co

rrectness of i

correctly.
l purpos
Welding In
nf
ercia
Replacement part
rm
m
atio
m
♦ Front bumper bracket

o
n in
or c
thi

te
sd
iva
secure.
o
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o
m
f
en
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t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
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Prote AG.

Golf 2009 ➤
– Weld in bumper bracket, gas-shielded arc continuous weld

seam.
– Weld in bumper bracket, gas-shielded arc continuous weld

seam.
lkswage es n
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1.5 Upper Wheel Housing Longitudinal utho tee
or
a ac
Member ss
ce
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nl
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WARNING
erm
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ility
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es, in part or in w
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rrectness of i
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nf
ercia
orm
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om
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or c
thi
te
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o
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t.
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Prote AG.

Golf 2009 ➤
1 - Upper Wheel Housing Lon‐

gitudinal Member
2 - Bonded Area
3 - A-Pillar
4 - Wheel Housing
5 - Water Deflector (Installed in
the Outer Wheel Housing Lon‐
gitudinal Member)
AG. Volkswagen AG d
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es, in part or in w
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nf
ercia
orm
m
atio
om
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or c
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e

t
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♦ Welding Unit With X-Grips - VAS6376- cted agen
Prote AG.

Removing

Golf 2009 ➤
AG. Volkswagen AG d
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ility
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ole,
spec
– Disconnect the original joint between outer upper longitudinal

t to the co
member and inner upper longitudinal member, as well as to

the A-pillar.
– Disconnect the original joint on the water deflector -1- leading
rrectne
to the inner upper longitudinal member.

ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
en
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t.
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Cop py
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by
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Prote AG.

Golf 2009 ➤
AG. Volkswagen AG d
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Disconnect original joint between inner upper longitudinal

member, wheel housing and plenum chamber.
l purpos
nform
mercia
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com
tion in
r
te o
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en
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t.
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Cop py
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by lksw
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Prote AG.

Golf 2009 ➤
AG. Volkswagen AG d Body Repairs - Edition 10.2011
agen oes
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or eo
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es, in part or in w
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nf
ercia
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m
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or c
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Prote AG.
– Remove remaining material

– Completely remove adhesive remains and grind bonding sur‐
faces down to bare metal.
Installation
Note

correctly.
Preparing New Parts

Replacement Part
♦ Upper, inside wheel housing longitudinal member
♦ Upper, outside wheel housing longitudinal member
♦ 2K Body Adhesive - D 180 KD3 A2-

Golf 2009 ➤
AG. Volkswagen AG d
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du
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ab
ility
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spec
es, in part or in w
t to the co
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l purpos
nform
mercia
– Drill a 7 mm hole in the inner upper wheel housing longitudinal

at
om
io
member and the outer upper wheel housing longitudinal mem‐

n
c
in t
ber.
or
his
ate
do
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Welding In
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cum
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t.
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secure.
Co
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– Check fit with attachments. yri
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Golf 2009 ➤
AG. Volkswagen AG d
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un
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wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
– Weld the inner upper wheel housing longitudinal member to
com
tio
the wheel housing with a straight-line spot weld seam and gas-
n in
r
te o
shielded arc plug weld seam. thi

s
iva
do
– Weld the inner upper wheel housing longitudinal member to

r
rp
cum
fo
the suspension strut tower mount with a gas-shielded arc con‐

en
ng
t.
tinuous weld seam (staggered).
yi Co
Cop py
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Vo
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by c lksw
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Prote AG.

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
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d by ara
ise nte
or eo
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aut ra
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le
un
pt
an
d
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
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cum
fo
en
ng
t.
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Cop py
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Vo
o
by c lksw
cted agen
Prote AG.
Note
New part must be installed within 90 minutes, otherwise bonding properties of adhesive will be impaired.
– Apply 2K Body Adhesive - D 180 KD3 A2- in area of adhesive

that was applied during production.

Golf 2009 ➤
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un
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an
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ab
ility
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is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
– Weld in longitudinal member for upper outside wheel housing,
cted agen
Prote AG.
Gas-shielded arc plug weld seam and straight-line spot weld
seam.
1.6 Front Wheel Housing
WARNING

• Longitudinal member for upper wheel housing already re‐

moved. Refer to

Golf 2009 ➤
1 - Suspension Strut Mounting

2 - Wheel Housing AG. Volkswagen AG d
agen oes
olksw not
yV gu
3 - Front Longitudinal
ed b Member ara
nte
ris
ho eo
4 - Cover Plate
aut for Longitudinal ra
c
Member s s
ce
le
un
pt
an
d
itte
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erm
ab
ility
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wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
en
ng
t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.

♦ Gas-Shielded Welder 250aA - VAS6045A-
Removing

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
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d by ara
ise nte
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le
un
pt
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
– Original joint to front longitudinal member cover plate, loosen

from wheel housing side to inside and to plenum chamber.
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.

Golf 2009 ➤
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.
– Loosen remaining joint to plenum chamber.

Golf 2009 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co

rrectne
Installation
ss o
cial p
f i
Note
nform
mer
atio

om
n
c
i
or

thi
te
sd
a
correctly.
iv
o
pr
cum
r
fo
en
ng
Preparing New Parts

t.
yi Co
Cop py
♦ Wheel housing
t. rig
gh ht
pyri by
Vo
co
♦ Suspension strut mounting
by lksw
cted agen
Prote AG.
♦ Suspension strut mounting reinforcement

Golf 2009 ➤
– Drill 8 mm holes into suspension strut mounting reinforcement

for the for gas-shielded arc plug weld seam.
– Drill holes for gas-shielded arc plug weld seam in suspension

strut mount, 8 mm diameter.
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.

Golf 2009 ➤
AG. Volkswagen AG d
lksw
agen oes
not Body Repairs - Edition 10.2011
Vo 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.
Note
Distance between the holes: approximately 25 - 30 mm.
– Drill holes for gas-shielded arc plug weld seam in wheel hous‐
ing, 8 mm diameter.

Golf 2009 ➤
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,
– Position and secure new parts with using the alignment brack‐ spec
et mountings -15-, -17-, -18- and -19- from the Alignment
Bracket Set - VAS6240/2- .

t to the co
– Check fit with neighboring components.

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.

Golf 2009 ➤
Welding In
– Weld suspension strut mounting -green- with reinforcement
-gray-, gas-shielded arc plug weld.
– Drill holes -1- with a 10 mm diameter for bolting the suspension

strut and secure the suspension strut mounting with the rein‐
forcement to the alignment bracket mount -2- with screws.
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
71
Prote AG.
1. Removal and Installation
Golf 2009 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
– Weld in wheel
ss housing with suspension strut mounting, gas-
shielded arc plug weld seam and straight-line spot weld seam.
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
72
Prote AG.
Rep. Gr.50 - Body Front
Golf 2009 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Restore joint between wheel housing and plenum chamber,
rrectne
gas shielded arc plug weld seam.
– Restore original joint between suspension strut mounting -1-
s
and suspension strut mounting reinforcement -2-, straight line
s o
cial p
spot weld seam.

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.

Golf 2009 ➤
– Enlarge holes for suspension strut mounting cover cap.

AG. Volkswagen AG d
Dimension -a- = 34 mm ksw
agen oes
not
Vol
by gu
d ara
ise nte
or eo
Note aut
h
ra
ss c
ce
le
Use item 19 from the Straightening Bracket Set Supplement For
un
pt
an
d
Golf, MY 2004 - VAS6240/2- to check dimension -a-.
itte
y li
erm
ab
ility
ot p
– Install upper longitudinal member for wheel housing.
wit
is n
h re
ole,
spec
t to the co
1.7 Subframe Mount Thread, Servicing
rrectne
WARNING
ss o
cial p
f inform
mer
atio
m
• Subframe is already removed. Refer to ⇒ Suspension,

o
n
c
Wheels and Steering; Rep. Gr. 40 ; Removal and Installation
i
or
n thi
te
sd
iva
o
pr
cum
Note
r
fo
en
ng
t.
yi Co
op
In the example, thread repair on this vehicle is described for left
C py
t. rig
gh
front retaining bracket for subframe and is to be employed at the
ht
pyri by
Vo
other 3 retaining brackets accordingly as necessary.
o
by c lksw
cted agen
Prote AG.

♦ Thread Repair Set M 12x1.5 - VAS6058-
♦ Drill - VAS6267-

Golf 2009 ➤
1 - Threaded Plate (in Retain‐

ing Bracket for Subframe)
Note
♦ The threaded plate is not a re‐

placement part and can be serv‐
iced only one time if damaged.
♦ If damaged again, replace the re‐
taining bracket. Refer to
⇒ “1.3 Subframe Mounting
Bracket”, page 50 .
2 - Helicoil Thread Insert
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
Contentsthof
o Thread Repair Set
r 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
yri by
75
op Vo
by c lksw
Prote
cted AG.
agen 1. Removal and Installation
Golf 2009 ➤
1 - Spiral Drill 12.5 mm Diam‐

eter
2 - Tap M 12 x 1.5
3 - Installing Spindle
4 - Thread Insert M 12 x 1.5 x
24 ( -VAS6058/1- )
5 - Peg Breaker with Magnetic
Tips
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
Threads, Repairing
nform
ercia
Threads, Drilling
m
at
om
ion
c
in t
r
Caution
o
his
ate
do
riv
Wear protective eyewear when drilling out the threads.

p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Golf 2009 ➤
– Drill out the threads with the spiral drill.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
Note
un
pt
an
d
itte
y li
erm
♦ Use the Drill - VAS6267- for drilling and grinding.
ab
ility
ot p
♦ While drilling, drill must be held by a second person using an
wit
is n
additional handle.
h re
ole,
spec
♦ Do not angle the drill.
Threads, Cutting t to the co

rrectne
Caution
ss
Wear protective eyewear when cutting the thread and when

o
cial p
cleaning the threaded bushing with compressed air.

inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
r
– Cut the threads with the thread tap.

p
cum
r
fo
en
ng
– Clean threaded bushing (blow with pressurized air).

t.
yi Co
Cop py
t. rig
Thread Inserts, Inserting opyri
gh by
Vo
ht
c by lksw
cted agen
Prote AG.

Golf 2009 ➤ AG. Volkswagen AG d
agen
Body Repairs - Edition 10.2011 Volksw
oes
not
by gu
d ara
ise nte
– Turn the threaded insert -3- onto the spindle until the drive peg
ut
hor eo
-2- makes contact on drive tab -1- of installing spindle. ss a ra
c
ce
e
nl
pt
du
an
itte
Note
y li
erm
ab
ility
ot p
Thread insert must be able to be turned easily.
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
e
– Screw the threaded insert into the threaded plate until the
t
sd
iva
o
threaded insert is seated flush with the outer edge of the threa‐
r
rp
cu
o
m
ded plate (check visually).
f
en
ng
t.
yi Co
op
– Then screw the threaded insert in 1/4 turn. C py
t. rig
gh ht
pyri by
– Remove the spindle.
o Vo
by c lksw
cted agen
Prote AG.
– Break off thread insert driver tang using tang breaker.

– Install the subframe (tightening specification). Refer to ⇒ Sus‐
pension, Wheels and Steering; Rep. Gr. 40 ; Removal and
Installation .

Golf 2009 ➤
1.8 Front Longitudinal
WARNING

1 - Wheel Housing
3 - Separation Cut, Cover Plate
and Longitudinal Member
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
op
C py
t. rig
gh ht
yri by
♦ Spot Welder (Inverter) - VAS6239- cop Vo
by lksw
cted agen
Prote AG.
♦ MIGSoldering And Welding Units - VAS6382-
Removing

Golf 2009 ➤
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.
– Separate original joint to wheel housing.

Golf 2009 ➤
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
Note
rrectness of i
Do not damage mounts for subframe -3-.

l purpos
The offset between separating cuts -1- and -2- should be approx‐
nform
ercia
imately 50 mm.
m
Dimension -a- = 50 mm
a
com
tion in
– Perform the separating cuts -1- and -2- as illustrated.

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.

Golf 2009 ➤

Installation
Note

correctly.
Preparing New Parts

Replacement Part
♦ Longitudinal member
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
op py
– Transfer separating cuts onto new part and cut to shape.
. C rig
ht ht
rig by
opy Vo
– Drill holes with an 7 mm diameter for a gas shielded arc plug by c lksw
cted agen
weld seam Prote AG.

Golf 2009 ➤
Welding In
secure.
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
– Make the wheel housing joint, straight-line spot weld seam and
m
atio
m
gas-shielded arc plug weld seam.

o
n in
or c
thi
– Weld the longitudinal member separating cut along the cir‐

te
sd
a
cumference, gas shielded arc continuous seam.

iv
o
r
rp
cu
o
– Weld cover plate separating cut, gas shielded arc continuous

f
en
ng
t.
yi
seam.
Co
Cop py
t. rig
Shortening New Longitudinal Member with Cover Plate
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2009 ➤
1 - Longitudinal Member Cover

Plate
AG. Volkswagen AG d
Note lksw
agen oes
not
Vo gu
d by ara
Longitudinal membero-2- ris with cover
e nte
eo
plate -1- (replacement
aut part identifi‐
h
ra
cation: longitudinal
s member) is too
s c
ce
e
long in front area -shaded area- and

nl
pt
du
must be shortened to fit and weld
an
itte
y li
partition plate for front longitudinal
erm
ab
member.
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.

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
– Assemble alignment bracket for front longitudinal member
Prote AG.
-RW 1- with spacer plate -RW 3- and from below, hold at lon‐
gitudinal member as shown.
– Transfer scribe dimension plus 2 mm excess -a- onto longitu‐
dinal member and cover plate and cut off.

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
Note
nl
pt
du
an
itte
y li
There must be 1-2 mm of space between the longitudinal member -2- with cover plate -3- and the bumper
erm
ab
carrier -1-.
ility
ot p
wit
, is n
h re
– Secure front bumper bracket -1- using -RW 1- and -RW 3- in

hole
spec
front of longitudinal member -2-.

es, in part or in w
t to the co
– Install the front bumper bracket.
1.9 Front Longitudinal Member, Partial Sec‐

rrectness of i
tion, Removing and Installing

l purpos
WARNING
nf
ercia
orm
Follow all safety precautions.

m
atio
om
n in
or c
thi
e
Refer to ⇒ General Information; Body Repairs, Body Collision

t
sd
iva
Repair ; Safety Precautions

r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
86
cted agen
Prote AG.
Rep. Gr.50 - Body Front
Golf 2009 ➤
1 - Cover Plate
2 - Bumper Bracket
3 - Longitudinal Member End
Plate
❑ Available in replace‐
ment part
❑ Always installed in the
longitudinal member on lkswage es n
the left side of the vehi‐ d byV
o ot g
ua
cle o
ir se
ran
tee
th or
❑ Installed in the longitudi‐
au ac
ss
nal member on the right
ce
le
side of the vehicle only

un
pt
an
d
for “NAR” vehicles (ve‐

itte
y li
hicles for the North
rm
ab
pe
ility
American region)
ot
wit
, is n
4 - Laser Seam
h re
hole
spec
5 - Longitudinal Member Sep‐
es, in part or in w
arating Cut
t to the co
Note
rrectness of i
♦ The separation cut of cover plate
l purpos
-1- and of longitudinal member

-5- must be arranged with an off‐
set of 50 mm.
nform
ercia
♦ The longitudinal member sepa‐

m
a
com
t
ration cut -5- cen be 50 mm
ion in
-dimension a- in front of the laser
r
te o
thi
seam -4- or 60 mm
s
iva
-dimension b- after the laser do

r
rp
seam -4-.
um
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Tools
Note
Due to the different types of steel and material strength, use only
welding equipment approved by Volkswagen AG to perform any
service work.
Removing
Note
♦ The following describes removing and installing the longitudinal member on the left side of the vehicle. An
end plate is installed in the left longitudinal member on all vehicles world-wide.
♦ The end plate is installed in the longitudinal member on the right side of the vehicle only for “NAR” vehicles
(vehicles for the North American region)
♦ Removing and installing the right longitudinal member for “NAR” vehicles is the same.

Golf 2009 ➤

aration Cut -1-
❑ If the separation cut -1-
is selected, then the
weld points -3 and 4-
must be drilled out.
2 - Laser Seam
Note
The laser seam -2- must not be cut

or welded in the area 50 mm in front
of -dimension a- or 60 mm behind
-dimension b-
3 - Outer Weld Point for Longi‐

tudinal Member End Plate
4 - Inner Weld Point for Longi‐
tudinal Member End Plate
aration Cut -5-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
Note
ce
le
un
pt
an
d
itte
y li
♦ The cover plate -1- and longitudinal member -2- separation cuts must be arranged with an offset.
erm
ab
ility
ot p
♦ These separation cuts are permissible only in the specified area on the longitudinal member. If the longitu‐
wit
dinal member is damaged further, then it must be completely replaced.

is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
88
by lksw
cted agen
Rep. Gr.50 - Body Front Prote AG.
Golf 2009 ➤
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
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
– Label and perform separation cuts as shown.

te o
thi
s
iva
do
50 mm in Front of the Laser Seam

r
rp
cum
fo
en
– Separate the original joint.

ng
t.
yi Co
op py
– Remove residual material. t. C rig
gh ht
pyri by
– Completely remove any remaining adhesive and grind the ad‐
co Vo
by lksw
cted agen
hesive surfaces down to bare metal. Prote AG.
Installing
Note
Use only welding equipment approved by Volkswagen AG.
Preparing New Parts

Replacement Part
♦ Longitudinal member (sub-part)
♦ Cover plate for longitudinal member

Golf 2009 ➤
– Transfer separating cuts to new parts and cut.

Welding
– Fit new part to vehicle standing on Straightening Bracket Set
and secure.
– Weld longitudinal member separating cut along circumfer‐
ence, gas shielded arc continuous seam.
olksw
– Weld in longitudinal member end plate with sawgas-shielded
agen
AG. V arc
agen AG
does
plug weld seam. by
Volk not
gu
ara
ed nte
ris
tho e or
au ac
Note ss
ce
e
nl
pt
du
New part must be installed within 90 minutes, otherwise bonding
an
itte
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properties of adhesive will be impaired.
erm
ab
ility
ot p
wit
– Before fitting and welding the longitudinal member cover plate,
, is n
h re
apply 2K Body Adhesive - D 180 KD3 A2- in area of adhesive
hole
spec
applied during production.
es, in part or in w
t to the co
Note
rrectness of i
Distance between welding points -a-: approximately 35 - 40 mm.
l purpos
– Weld in longitudinal member cover plate, straight-line spot

nform
ercia
weld seam.
m
at
– Weld cover plate separating cut, gas shielded arc continuous

om
ion
seam.
c
in t
or
his
te
Shortening New Longitudinal Member with Cover Plate

a
do
priv
cum
or
– Shorten longitudinal member with cover plate. Refer to

f
en
ng
⇒ page 83 .
t.
yi Co
Cop py
. rig
– Weld in front bumper bracket. Refer to
t
gh ht
yri by
⇒ “1.4 Front Bumper Bracket”, page 53 . cop Vo
by lksw
cted agen
Prote AG.

Golf 2009 ➤
2 Special Tools
♦ Thread Repair Set M 12x1.5 - VAS6058-
♦ Drill - VAS6267-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Special Tools 91
Golf 2009 ➤
51 – Body Center, Chassis, Roof

⇒ “1.1 Roof, Vehicles without Sunroof”, page 92
⇒ “1.2 Roof, Vehicle with Sunroof”, page 107
⇒ “1.3 Roof Pillar”, page 123
⇒ “1.4 Front Roof Crossmember”, page 141
⇒ “1.5 Roof Reinforcement, Vehicles without Sunroof”,
page 145
⇒ “1.6 Rear Roof Cross Member”, page 149
⇒ “1.7 A-Pillar”, page 154
⇒ “1.8 A-Pillar Reinforcement”, page 164
⇒ “1.9 B-Pillar, 4-Door Vehicle”, page 172
⇒ “1.10 B-Pillar Reinforcement, 4-Door Vehicle”, page 183
⇒ “1.11 B-Pillar Reinforcement, 2-Door Vehicle”, page 198
⇒ “1.12 Outer Sill Panel, 4-Door Vehicle”, page 211
⇒ “1.13 Outer Sill Panel, 2-Door Vehicle”, page 220
⇒ “1.14 Outer Seat Cross Member Mount”, page 227
⇒ “1.15 Inner Seat Cross Member Mount”, page 232
⇒ “1.16 Sill Panel Front Reinforcement, Vehicles with 4-Doors”, AG. Volkswagen AG d
agen oes
ksw
page 237 byV
ol not
gu
ara
ed
is nte
⇒ “1.17 Sill Panel Front Reinforcement, Vehicles with 2-Doors”, hor eo
ut
page 242 ss a ra
c
ce
e
⇒ “1.18 Sill Panel Rear Reinforcement, Vehicles with 4-Doors”,

nl
pt
du
an
page 248
itte
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erm
ab
⇒ “1.19 Sill Panel Rear Reinforcement, Vehicles with 2-Doors”,
ility
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page 253
wit
, is n
h re
⇒ “1.20 Center Seat Cross Member”, page 258
hole
spec
1.1 Roof, Vehicles without Sunroof
es, in part or in w
DANGER! t to the co
rrectness of i

l purpos

nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
92 Rep. Gr.51 - Body Center, Chassis, Roof

Golf 2009 ➤
1 - Roof
2 - Laser Brazed Seam
3 - Bonded Area
AG. Volkswagen AG d
agen oes
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y V gu
d b ara
rise nte
tho eo
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le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
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cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Compressed Air Gun - V.A.G 1761/1-

Golf 2009 ➤
♦ Cartridge Heater - V.A.G 1939 A-
♦ Double Cartridge Gun - VAS 5237-
♦ Adjustment Gauge - 3371-
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
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erm
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ility
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hole
spec
es, in part or in w
♦ Tensioning Strap - T10038-

t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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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.

Golf 2009 ➤
♦ Suction Lifter - VAG1344-
Removing
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
95
Prote AG.
Golf 2009 ➤
wage es n
Note yV
olks ot g
ua
d b ran
ir se tee
♦ Apply fabric adhesive tape on the left and right roof pillars
utho
so that it is parallel to the laser brazed seam. or This
will prevent damage to the roof pillars and contaminants from getting in.
a ac
ss
ce
e
nl
♦ Maintain a distance of approximately 15 mm to the roof pillar -1- so that the roof pillar does not get damaged.
pt
du
an
itte
y li
♦ The roof reinforcement is not removed.
erm
ab
ility
ot p
wit
, is n
– Cut the original joint at the front of the roof crossmember.
h re
hole
– Cut the original joint inside the rear lid opening.
spec
es, in part or in w
t to the co
– Loosen the bonded joints on the front and rear roof cross‐
members -3- and on the roof reinforcement from the inside.
– Roughly cut out the roof parallel to the laser brazed seams
rrectness of i
-2-.
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.

Golf 2009 ➤
Note
♦ When removing the remaining roof material -1-, do not damage the side panel -2-.
♦ Do not use separating- or roughing blades; use a Lamellar disc instead.

– Remove any adhesive and sealant still remaining on the front
and rear roof crossmembers and on the roof reinforcement.
– Remove any remaining adhesive on the left and right roof pil‐
lars.
– Touch up any paint damage using the paint repair manual.
Installation
Note

correctly. swa
gen AG
. Volkswagen AG
does
k not
Vol gu
d by ara
Preparing New Parts ris
e nte
utho eo
ra
Replacement part ss
a c
ce
e
nl
♦ Roof
pt
du
an
itte
♦ 1K Assembly Adhesive - D 190 MKD A3- (3 cartridges) y li

erm
ab
ility
ot p
♦ 2K-Body Adhesive - D 180 KD3 A2- (2 cartridge sets) wit

, is n
h re
♦ Primer - ALN 002 003 04-
hole
spec
♦ Adhesive Sealant - AKD 476 KD5 05-

es, in part or in w
t to the co
♦ Felt - 533 867 910 B-

♦ Cavity Sealant - AKR 321 M15 4-
rrectness of i
l purpos
Note
nform
ercia
♦ In order to guarantee problem-free and long lasting roof repair,

the following work procedure must always be followed.
m
at
om
ion
♦ Be sure to follow the work procedure exactly to prevent making

c
in t
or
any mistakes.
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.

Golf 2009 ➤
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
– Sand the left and right adhesive areas on the roof down to the
r
te o
bare metal.
thi
s
iva
do
This ensures that 2k Body Adhesive - D 180 KD3 A2- can achieve
r
rp
cum
fo
a good bond with the adhesion area.

en
ng
t.
yi Co
op
– Position the Suction Lifter - VAG1344- on the outer side of the C py
ht. rig
roof. rig ht
py by
co Vo
by lksw
– Mount the roof onto the roof frame. cted agen
Prote AG.
– Make sure the roof fits correctly with the rear lid and the wind‐
shield.
Roof Depth Dimension, Adjusting

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op py
Note
t. C rig
gh ht
pyri by
Vo
o
by c lksw
♦ The tension straps prevent roof from lifting off the roof frame and sliding during the adhesive procedure.
cted agen
Prote AG.
♦ To prevent damage, do not overtighten the tensioning straps.

♦ If the side windows on a 2-door vehicle are already installed, then position the tensioning strap around the
entire vehicle.
– Tension the Tensioning Straps - T10038- across the roof in

the areas shown -arrows- to adjust the roof height.

Golf 2009 ➤
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
Note
nform
mercia
♦ Dimension -a- is determined by tightening or loosening the tension straps so that the roof is lower than the
a
com
ti
side panels.
on in
r
te o
thi
♦ Use the Adjustment Gauge - 3371- to check dimension -a-.

s
iva
do
r
rp
♦ If dimension -a- is exceeded, insert Felt - 533 867 910 B- into the roof fame to even it out.
um
fo
en
ng
t.
♦ If rear dimension -a- cannot be adjusted, it may be necessary to remove the rear roof crossmember, to add
yi Co
op
adhesive and to weld it again. Refer to ⇒ “1.6 Rear Roof Cross Member”, page 149 .
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
– Check the roof alignment to the side panels. cted agen
Prote AG.
Dimension -a- = 3.5 +/- 0.5 mm.

Roof, Bonding
– Remove the roof.
– Apply corrosion protection. Refer to Paint Repair Manual.
– Clean the adhesive areas on the roof and on the vehicles with
Silicone Remover - LSE 020 100 A3- .

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
yV gu
Note ised b ara
nte
or eo
h
ut ra
♦ Adhesive materials must be applied
ss a
very quickly. c
ce
e
nl
♦ Pay close attention to the processing time (working life).
pt
du
an
itte
y li
♦ To apply the adhesive materials, use a compressed air gun or
erm
ab
electric cartridge pistol.
ility
ot p
wit
, is n
h re
– For the corresponding bead geometry, cut off approx. 2 cm
hole
spec
from the tube -B-.
es, in part or in w
t to the co
Note
rrectness of i
l purpos

nf
ercia
any mistakes.
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.

Golf 2009 ➤
– Apply 1K Assembly Adhesive - D190 MKD A3- using the

Pneumatic Cartridge Gun - V.A.G 1761/1- on the front -1- and
rear -3- roof crossmember and on the roof reinforcement -2-
near the adhesive applied at the factory.
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.
– Apply 1K Assembly Adhesive - D190 MKD A3- -1- in the room

side member area using the Compressed Air Gun -
V.A.G 1761/1- .
Dimension -a- = approximately 12 mm
Dimension -b- = approximately 14 mm

Golf 2009 ➤
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
– Apply 1K Assembly Adhesive - D190 MKD A3- -1- to the inside by c lksw
cted agen
of the roof parallel to the left and right roof flange using the
Prote AG.
Compressed Air Gun - V.A.G 1761/1- .

Note
♦ Processing time (time on pot) for 2K Body Adhesive - D 180

KD3 A2- is approx. 90 minutes.
♦ An assistant is required for the following work steps.
♦ Remove any 2K Body Adhesive - D 180 KD3 A2- that leaks
out immediately. 2K Body Adhesive - D 180 KD3 A2- can only
be removed mechanically once it has hardened.

Golf 2009 ➤
– Cut off the first section of the static mixer -A- to get the correct
bead diameter.
– Operate the Double Cartridge Gun - VAS 5237- without mixer
until adhesive extrudes evenly out of both chambers of car‐
tridge union.
– Attach the mixer to the cartridge union.
– Apply the first 100 mm of adhesive onto a piece of cardboard
and only then begin the application on the vehicle.
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.
– Fill area -1- with 2K Body Adhesive - D 180 KD3 A2- using the
Double Cartridge Gun - VAS 5237- .
– Apply 2K Body Adhesive - D 180 KD3 A2- on the rear roof
crossmember near the adhesive applied at the factory.

Golf 2009 ➤
Note

any mistakes.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Coat the roof flange with 2K Body Adhesive - D 180 KD3 A2-
-1-.
– Mount the roof and align it.
– Secure the roof to the openings for the front window and the
rear lid as well as to the center area with the tensioning straps
using locking pliers.
– Check the roof depth dimension -a- and adjust the roof if nec‐
essary.
– Remove any 2K Body Adhesive - D 180 KD3 A2- that leaks
out using a cloth soaked in Silicone Remover - LSE 020 100
A3- .

Golf 2009 ➤

out of the holes for the hinges in the rear lid opening. AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
Note thor eo
au ra
ss c
♦ After adhering, vehicle must stand on a level surface at room
ce
e
nl
pt
temperature (at least 15 ° C) for 8 to 10 hours so the adhesive
du
an
itte
components can cure.
y li
erm
ab
ility
♦ Only after “minimum curing time” has elapsed can further work
ot p
be performed on the vehicle.
wit
, is n
h re
hole
spec
Welding in
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Weld the roof to the windshield opening and to the rear lid
opening using a straight-line spot weld seam.

Golf 2009 ➤
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
– Apply a fine-sealing of adhesive seam -1- to the seam between

rrectness of i
the roof and the roof pillar with Adhesive - AKD 476 KD5 05- .
l purpos
– After painting, protect hollow roof spaces -arrow- with Cavity

Sealant - AKR 321 M15 4- .
nf
ercia
1.2 Roof, Vehicle with Sunroof

rm
m
atio
om
n in
or c
DANGER!
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.

Golf 2009 ➤
1 - Roof
2 - Laser Brazed Seam
3 - Bonded Area
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
yri by
Special tools and workshop equipment required cop Vo
by lksw
cted agen
Prote
AG.

♦ Compressed Air Gun - V.A.G 1761/1-

Golf 2009 ➤
♦ Double Cartridge Gun - VAS 5237-

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

Golf 2009 ➤
Removing
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
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o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2009 ➤
Note
♦ Apply fabric adhesive tape on the left and right roof pillars so that it is parallel to the laser brazed seam. This
will prevent damage to the roof pillars and contaminants from getting in.
♦ Maintain a distance of approximately 15 mm to the roof pillar -1- so that the roof pillar does not get damaged.
♦ The roof reinforcement on the sunroof opening is also removed.
– Cut the original joint at the front of the roof crossmember.

– Cut the bonded joints on the front and rear roof crossmembers
-3- from the inside.
– Roughly cut out the roof parallel to the laser brazed seams
-2-.
lkswage es n
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byV ua
d ran
ir se tee
tho
u or
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
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m
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om
n in
or c
Note
thi
te
sd
iva
o
r
rp
cu
If the vehicle has a sunroof, then it is necessary to separate the sunroof reinforcement -1- from the roof frame
o
m
f
en
ng
-2- in order to remove the roof. It must welded back on again later.
t.
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Cop py
t. rig
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pyri by
111
co Vo
by lksw
cted 1. Removal and Installation
agen
Prote AG.
Golf 2009 ➤
. Volkswagen AG
a gen AG does
– Separate the joint between the sunroof reinforcementVol -1- and
ksw not
gu
the roof frame -2-. ed
by ara
nte
ris
utho eo
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ce
e
nl
pt
du
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itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
♦ When removing the remaining roof material -1-, do not damage the side panel -2-.
♦ Do not use separating- or roughing blades; use a Lamellar disc instead.

– Remove any excess adhesive and sealant on the front and
rear roof crossmembers.
– Remove any remaining adhesive on the left and right roof pil‐
lars.
– Touch up any paint damage using the paint repair manual.

Golf 2009 ➤
Installation
Note

correctly.
Preparing New Parts

Replacement part
♦ Roof
AG. Volkswagen AG d
agen oes
♦ 1K Assembly Adhesive - D 190 MKD A3-
yV
o(3
lkswcartridges) not
gu
b ara
ed
♦ 2K-Body Adhesive - D 180 KD3 A2-horis (2 cartridge sets) nte
eo
t
au ra
♦ Primer - ALN 002 003 04- ss c
ce
e
nl
pt
♦ Adhesive Sealant - AKD 476 KD5 05-
du
an
itte
y li
♦ Felt - 533 867 910 B-
erm
ab
ility
ot p
♦ Cavity Sealant - AKR 321 M15 4-
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
rrectness of i
l purpos
any mistakes.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Golf 2009 ➤
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.
– Sand the left and right adhesive areas on the roof down to the
bare metal.
This ensures that 2K Body Adhesive - D 180 KD3 A2- can achieve
a good bond with the adhesion area.
– Position the Suction Lifter - VAG1344- on the outer side of the
roof.
– Mount the roof onto the roof frame.
– Make sure the roof fits correctly with the rear lid and the wind‐
shield.
Roof Depth Dimension, Adjusting

Golf 2009 ➤
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
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rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
♦ The Tensioning Strap - T10038- prevent roof from lifting off the roof frame and sliding during the adhesive
procedure.
♦ To prevent damage, do not overtighten the Tensioning Strap - T10038- .
♦ If the side windows on a 2-door vehicle are already installed, then position the Tensioning Strap - T10038-
around the entire vehicle.
– Tension the Tensioning Strap - T10038- across the roof in the

areas shown -arrows- to adjust the roof height.

Golf 2009 ➤
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
Note
nform
ercia
♦ Dimension -a- is determined by tightening or loosening the Tensioning Strap - T10038- so that the roof is
m
at
lower than the side panels.

om
ion
c
in t
♦ Use the Adjustment Gauge - 3371- to check dimension -a-.

or
his
ate
do
riv
♦ If dimension -a- is exceeded, insert Felt - 533 867 910 B- into the roof fame to even it out.
p
cum
for
♦ If rear dimension -a- cannot be adjusted, it may be necessary to remove the rear roof crossmember, to add
en
ng
t.
yi
adhesive and to weld it again. Refer to ⇒ “1.6 Rear Roof Cross Member”, page 149 .
Co
Cop py
t. rig
gh ht
pyri by
– Check the roof alignment to the side panels.
co Vo
by lksw
cted agen
Prote AG.
Dimension -a- = 3.5 +/- 0.5 mm.
Roof, Bonding
– Remove the roof.
– Apply corrosion protection.
– Clean the adhesive areas on the roof and on the vehicles with
Silicone Remover - LSE 020 100 A3- .

Golf 2009 ➤
Note
♦ Adhesive materials must be applied very quickly.

♦ Pay close attention to the processing time (working life).
♦ To apply the adhesive materials, use a compressed air gun or
electric cartridge pistol.
– For the corresponding bead geometry, cut off approx. 2 cm

from the tube -B-.
Note

any mistakes.
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
117
cted agen
Prote AG.
Golf 2009 ➤
– Apply the 1K Assembly Adhesive - D190 MKD A3- to the front

roof crossmember -1- and rear cross member -2- in the area
where it was bonded at the factory using the Compressed Air
Gun - V.A.G 1761/1- .
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
– Apply 1K Assembly Adhesive - D190 MKD A3- -1- in the room

h re
side member area using the Compressed Air Gun -

ole,
spec
V.A.G 1761/1- .
t to the co

rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
118
agen
Prote AG.
Rep. Gr.51 - Body Center, Chassis, Roof
Golf 2009 ➤
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
– Apply 1K Assembly Adhesive - D190 MKD A3- -1- to the inside

itte
y li
erm
of the roof parallel to the left and right roof flange using the
ab
ility
Compressed Air Gun - V.A.G 1761/1- .

ot p
wit
, is n

h re
hole
spec

es, in part or in w
t to the co
Note
rrectness of i
♦ Processing time (time on pot) for 2K Body Adhesive - D 180

l purpos
KD3 A2- is approx. 90 minutes.

♦ An assistant is required for the following work steps.
nform
ercia
♦ Remove any 2K Body Adhesive - D 180 KD3 A2- that leaks

m
at
out immediately. 2K Body Adhesive - D 180 KD3 A2- can only

om
ion
be removed mechanically once it has hardened.

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.

Golf 2009 ➤
– Cut off the first section of the static mixer -A- to get the correct
bead diameter.
– Operate the Double Cartridge Gun - VAS 5237- without mixer
until adhesive extrudes evenly out of both chambers of car‐
tridge union.
– Attach the mixer to the cartridge union.
– Apply the first 100 mm of adhesive onto a piece of cardboard
and only then begin the application on the vehicle.
Note

any mistakes.
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.
– Fill area -1- with 2K Body Adhesive - D 180 KD3 A2- using the
Double Cartridge Gun - VAS 5237- .

Golf 2009 ➤
– Apply 2K Body Adhesive - D 180 KD3 A2- on the rear roof

crossmember near the adhesive applied at the factory.
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
– Coat the roof flange with 2K Body Adhesive - D 180 KD3 A2-
ility
ot p
-1-.
wit
, is n
h re
– Mount the roof and align it.

hole
spec
– Secure the roof to the openings for the front window and the
es, in part or in w
t to the co
rear lid as well as to the center area with the tensioning straps
using locking pliers.
– Check the roof depth dimension -a- and adjust the roof if nec‐
rrectness of i
essary.
l purpos

out using a cloth soaked in Silicone Remover - LSE 020 100
nform
ercia
A3- .
m
at

om
io
out of the holes for the hinges in the rear lid opening.
n
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
121
Prote AG.
Golf 2009 ➤
Note
♦ After adhering, vehicle must stand on a level surface at room

temperature (at least 60 ° F (15 ° C)) for 8 to 10 hours so the
adhesive components can cure.
♦ Only after “minimum curing time” has elapsed can further work
be performed on the vehicle.
Welding in
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
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.
– Weld the roof to the windshield opening and to the rear lid
opening using a straight-line spot weld seam.
– Weld the joint between the sunroof reinforcement and the roof
frame from inside the vehicle, gas-shielded arc continuous
weld seam.

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
– Apply a fine-sealing of adhesive seam -1- to the seam between

inform
the roof and the roof pillar with adhesive - AKD 476 KD5 05- .
mer
atio
– After painting, protect hollow roof spaces -arrow- with Cavity

om
Sealant - AKR 321 M15 4- .

c
i
or
n thi
te
sd
1.3 Roof Pillar

iva
o
pr
cum
r
fo
en
ng
t.
yi
WARNING
Co
Cop py
ht. rig
rig ht
py by
Observe safety precautions. Refer to ⇒ General Information; co Vo
by lksw
Body Repairs, Body Collision Repair . cted agen
Prote AG.
If welding or cutting with spark-producing devices/tools or

when plating in foamed areas where hazardous gases are pro‐
duced that are harmful to humans and the environment, these
procedures are to be omitted in each case.
Note
The process is almost identical for a 2-door and 4-door vehicle.

Any specific information will be given in the individual steps.

Golf 2009 ➤
1 - Roof Pillar
2 - Bonded Area
3 - Separating Cut on the Roof
4 - Roof
5 - Molded Foam Part
6 - Side Panel
7 - Separation Cuts on the A, B
and C Pillars
8 - A-Pillar
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
op
♦ Spot Welder (Inverter) - VAS6238 A-
C py
t. rig
gh ht
yri by
♦ Accessory Kit for spot welder - VAS6238/1 A- cop Vo
by lksw
cted agen
Prote AG.
♦ Sheet Metal Tool - VAS6249 L-
♦ MIG Soldering and Welding Units - VAS6382-
Removing

AG. Volkswagen AG d
agen oes
ksw
by
Vol not
Golf
gu 2009 ➤
d ara
orise Body Repairs - Edition 10.2011
nte
h eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
Be careful not to cut into the plates behind it when making the separation cuts.
– Make the separating cut -5- according to the damage, however

according to dimension -a- minimum.
– Make the separating cut -2- according to dimension -b- parallel
to the roof.
– Make the separating cut -3- according to dimension -d-.
– Make the separating cut -4- according to dimension -c-.
– Separate the original joint inside the front door opening and
inside the side window opening on a 2-door vehicle or inside
the rear door opening on a 4-door vehicle.
– Separate the bonded joints -1- near the reinforcements for the
roof rack.

Golf 2009 ➤
Dimension -b- = 15 mm
Dimension -c- = 100 mm
Dimension -d- = 100 mm
4-Door Vehicles
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.
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op py
Note
. C rig
ht ht
rig by
copy Vo
by lksw
Outer panel on roof pillar is shown removed in close up to provide a better illustration.
cted agen
Prote AG.
– Loosen welded seam to support panel -1-.

wage es n
yV
olks ot g Golf 2009 ➤
b ua
ir se
d ran
tee Body Repairs - Edition 10.2011
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.

Installation
Note

correctly.

Golf 2009 ➤
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
Note
nf
ercia
orm
m
atio
MIG soldered seams are permitted on the separating cuts shown in the illustration.
om
n in
or c
thi
e
Preparing New Parts

t
sd
iva
o
r
rp
cu
Replacement part
o
m
f
en
ng
t.
yi
♦ Side panel
Co
Cop py
t. rig
gh
ht
pyri by
Vo
co lksw
by
♦ Internally Threaded Pop Rivet
cted agen
Prote AG.
♦ Repair Kit for Roof Pillar Foam Filling (a set for front and rear)

Golf 2009 ➤
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
Note pt
an
d
itte
y li
erm
ab
When transferring and making the separation cut on the roof -1- do not forget excess material for overlapping.
ility
ot p
wit
is n
h re
– Transfer separating cuts to new part and cut off

ole,
spec
-shaded area-.
t to the co
– Position the new part in the roof area -1-.

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.

Golf 2009 ➤
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
Note
l purpos
♦ Structure foam should not bond with outer panel of roof pillar. Changing the volume of the structure foam
could result in ripples in the roof pillar.
nform
ercia
♦ The fabric adhesive tape is a component of the roof pillar foam filling repair kit.
m
at
om
ion
c
– Apply cloth reinforced adhesive tape to the large area near the
in t
or
his
e
foam filling pieces -1-.

at
do
priv
4-door vehicles
um
for
en
ng
t.
yi
– Drill 7 mm holes for the gas-shielded arc plug weld seam near
Co
op py
the rear foam filling piece.
. C rig
ht ht
rig by
py
Molded Foam Inserts
co Vo
by lksw
cted agen
Prote AG.

Golf 2009 ➤
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.
Observe repair notes.

Molded foam parts, refer to
Welding in
Note
Place the straight line weld points as far as possible from the outer
edge of the weld flange to provide strength.
4-Door Vehicles

Golf 2009 ➤
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.
– Drill holes for foam filler piece in support panel, 12 mm diam‐

eter.

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
e
Note
t
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
– Apply a 4 mm bead of 2K Body Adhesive - D 180 KD3 A2- in
ht. rig
rig ht
by
the front door opening and in the side window openings on a copy Vo
by lksw
2-door vehicle and in the rear door opening on a 4-door vehi‐ cted agen
Prote AG.
cle.
– Fit in roof pillar and secure.
– Check fit with attachments.

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Weld the separation cuts, either MIG-L stitch weld seam or a
gas-shielded arc continuous weld seam rrectness
Note
o
cial p
f inform
mer
♦ Both weld symbols are shown in the illustration.

atio
m
♦ Use a »heat shield« to avoid damage to the roof paint when welding the roof pillar.
o
n
c
i
or
n thi
te
sd
a
4-Door Vehicles
iv
o
pr
cum
r
fo
– Weld the connection for the support plate in the rear door
en
ng
t.
yi
opening, gas-shielded arc plug weld seam.
Co
Cop py
t. rig
gh
Roof pillar, filing with foam
ht
pyri by
Vo
o
by c lksw
Front structure foam, applying
cted agen
Prote AG.
– Warm structure foam cartridges for 20 minutes in an approx.

60 °C water bath.

Golf 2009 ➤
1 - 2K Structure Foam Car‐

tridges
– Lock open.
2 - Static Mixer
– Only cut off first stage on
tip.
3 - Extension Hose
4 - Fabric Adhesive Tape
Note
Bonded in replacement part so that

structure foam cannot bond with
outer panel.
5 - Adapter
Note
AG. Volkswagen AG d
agen oes
ksw
Adapter -5- and extension bhose -3-
ol not
yV gu
ara
are not needed to apply risefront struc‐
d
nte
ture foam. autho eo
ra
ss c
ce
le
6 - Union nut
un
pt
an
d
itte
y li
– Screw onto 2K structure
erm
ab
foam cartridge -1- with
ility
ot p
static mixer -2-.
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2009 ➤
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
– Using Compressed Air Gun - VAG1761/1- , apply structure

foam via static mixer through pop rivet nut opening to secure
roof base carrier -arrow-. 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.

Golf 2009 ➤
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
– Install an internally threaded pop rivet -arrow-.
wit
is n
h re
Rear Structure Foam, Applying
ole,
spec
– Warm structure foam cartridges for 20 minutes in an approx.

t to the co
60 °C (140 °F) water bath.
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.

Golf 2009 ➤
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
– Open 2K structure foam cartridge -1-.
r
rp
cum
fo
en
g
– Cut off the tip -shaded area- on the static mixer -2-.
n
t.
yi Co
op py
– Install adapter -5- and extension hose -3-.
t. C rig
gh ht
pyri by
Vo
o
– Fasten static mixer -2- to 2K structure foam cartridge using
c by lksw
cted agen
union nut -6-. Prote AG.
– Install extension hose

-3-
with adapter -5- in static mixer.
2-door vehicles

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Guide the connecting hose through the opening -arrow- inside

the roof pillar from the inside straight upward.
– Fill half the 2K Foam Cartridge with the Pneumatic Cartridge
Gun - VAG1761/1- .
– Pull the 2K Foam Cartridge and the Pneumatic Cartridge Gun
- VAG1761/1- back approximately 50 mm.
– Fill the rest of the 2K Foam Cartridge with the Pneumatic Car‐
tridge Gun - VAG1761/1- .
4-Door Vehicles

Golf 2009 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
Holes in support panel must be drilled before welding roof pillar ⇒ page 131 .
– Drill hole in roof pillar from inside to apply foam, 20 mm diam‐

eter.
4-Door Vehicles

Golf 2009 ➤
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
Note
ot
wit
, is n
h re
hole
Correct extension hose position is checked via neighboring hole in roof pillar.
spec
es, in part or in w
t to the co
– Using the Compressed Air Gun - VAG1761/1- , apply the con‐

tents of the 2K structure foam cartridge with the static mixer
and extension hose though the openings in the roof pillar -1-
rrectness of i
and in the support panel -arrow-.

l purpos
1.4 Front Roof Crossmember

nform
ercia
WARNING
m
a
com
tio

n in
r
te o

thi
s
iva
do
r
rp
cum
fo
en
g
• Roof already removed:

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

Golf 2009 ➤
1 - Front Roof Cross Member

2 - Left and Right Roof Pillar
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
♦ Spot Welder (Inverter) - VAS6249- yri
p by
o Vo
by c lksw
cted
agen
Prote AG.

Removing

Golf 2009 ➤
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.

Golf 2009 ➤
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
– Remove remaining material on crossover to left and right roof

rm
m
atio
pillars.
om
n in
c
Installation
or
thi
te
sd
iva
o
r
rp
cu
o
Note
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
p by
co Vo
lksw
by
cted agen
Prote
correctly.
AG.
Welding in
Replacement part
♦ Front roof cross member
– Align the new part and fix it in place.
– Check fit with roof.

Golf 2009 ➤
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.
– Weld in front roof crossmember; Straight-line spot weld seam

and gas-shielded arc plug weld seam.
– install the roof.
1.5 Roof Reinforcement, Vehicles without

Sunroof
DANGER!


Golf 2009 ➤
1 - Roof Reinforcement
2 - Left and Right Roof Pillar
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

m
at
om

on
c
in t
or

his
ate
do
riv

p
cum
for
en
ng
t.
Removing
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2009 ➤
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.

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
– Remove remaining material on crossover to left and right roof

f in
pillars.
form
mer
atio
Installation
om
n
c
i
or
n thi
te
sd
a
Note
iv
o
pr
cum
r
fo
en
ng

t.
yi Co
strengths, one of the inverters listed under the special tools sec‐ Cop py
t. rig
tion of this repair manual are required to perform repair work gh ht
yri by
correctly. cop Vo
by lksw
cted agen
Prote AG.
Welding in
Replacement part
♦ Roof reinforcement

Golf 2009 ➤
agen
AG. Volkswagen AG d
oes Body Repairs - Edition 10.2011
olksw not
y V gua
b
ed ran
oris tee
th or
au 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
o
by c lksw
cted agen
Prote AG.
– Weld the roof reinforcement with a gas-shielded arc continu‐

ous weld seam.
1.6 Rear Roof Cross Member
WARNING



Golf 2009 ➤
1 - Left and Right Roof Frame

2 - Rear Roof Cross Member
3 - Bonded Area
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p

wit
, is n
h re

hole
spec
es, in part or in w

t to the co

rrectness of i

l purpos

nform
ercia
Removing
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.

Golf 2009 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia

m
a
com
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.

Golf 2009 ➤
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
m
– Remove remaining material on the transition to left and right

o
n in
c
roof frames.
or
thi
te
sd
a
– Completely remove adhesive remains and grind bonding

iv
o
r
rp
cu
areas down to bare metal.

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

correctly.
Welding In
Replacement part
♦ Rear roof cross member

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
Note hor eo
aut ra
ss c
♦ Check the body dimensions before installing the roof cross‐
ce
le
un
pt
member. Refer to ⇒ page 34 .
an
d
itte
y li
♦ New part must be installed within 90 minutes, otherwise bond‐
rm
ab
pe
ility
ing properties of adhesive will be impaired.
ot
wit
, is n
♦ The holes for the hinge mount must be cleaned after applying
h re
hole
the adhesive.
spec
es, in part or in w
t to the co
– Apply 2K Body Adhesive - D 180 KD3 A2- in the areas where
it was bonded during production; adhesive bead: approx. 4
mm.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Weld in the new part, straight-line spot weld seam and gas-
shielded arc continuous weld seam.

Golf 2009 ➤
1.7 A-Pillar
WARNING

when plating in foamed areas where hazardous
agen
AG. Volkswgases
agen AGare pro‐
does
duced that are harmful to humansVolkswand the environment, these not
gu
procedures are to be omitted
se
d b in each case.
y ara
n ri tee
ho
aut or
ac
ss
ce
e
nl
pt
du
1 - A-pillar
an
itte
y li
erm
ab
2 - Upper Separating Cut
ility
ot p
wit
, is n
h re
hole
4 - Separating Cut for Sill Pan‐
spec
el
es, in part or in w
t to the co
Depending on the extent of the
damage, if the A-pillar rein‐
forcement must also be re‐
rrectness of i
placed, then minimum 290 mm
from the front edge of the A-
l purpos
pillar.
nf
ercia
5 - Separating Cut (Partial Re‐

placement) orm
m
atio
m
Partial renewal
o
n in
or c
With this separating cut, a par‐

thi
e
tial replacement of the A-pillar

t
sd
iva
is possible.
r
rp
cu
o
m
f
en
ng
t.
6 - Bonded Area
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Accessory kit for spot welder - VAS6238/1 A-

Golf 2009 ➤

♦ Laser Weld Seam Drill - VAS6319-
Removing
Note
lkswage es n
o ot g
♦ Only use Body Repair Saw - VAG1523- to make separating
ed
byV ua
ran
cuts. horis tee
ut or
Be sure not to damage the metal panels behind
ss it when making
a ac
♦
the separating cut.
ce
e
nl
pt
du
an
♦ If the A-pillar reinforcement is damaged, then is must always
itte
y li
erm
be replaced.
ab
ility
ot p
♦ A-pillar reinforcement must not be re-welding for safety rea‐
wit
, is n
sons »crash safety«!
h re
hole
spec
♦ Foam residue must be removed as much as possible before
es, in part or in w
sanding work.
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.

Golf 2009 ➤
Note
If the A-pillar reinforcement is being replaced, then the separation cut -2- must be made at least 290 mm from
the front edge of the A-pillar.
– Make a separating cut -1- according to the damage.

– Make a separating cut -2- according to the damage.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Continue making the separation cut -1- on the bottom of the

sill panel.
– Open the joint on the sill panel reinforcement.

Golf 2009 ➤
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
Installation
nf
ercia
Note
orm
m
atio
m

o
n in
or c
thi
e

t
sd
iva
correctly.
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.

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
l purpos
nf
ercia
Preparing New Parts

orm
m
atio
Replacement part
om
n in
c
♦ Sub-part, front side panel (replacement part identification:

or
thi
e
sub-part A-pillar with sill panel)

t
sd
iva
o
r
rp
cu
♦ Sill panel end plate

o
m
f
en
ng
t.
yi
Co
Cop py
t. rig
gh
♦ Butyl sealing cord - AKD 497 010 04 R10-
ht
pyri by
Vo
co lksw
by
♦ Molded foam part
cted agen
Prote AG.

Golf 2009 ➤
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
tio
n in
r
te o
– Drill a 7 mm hole in the new part for the transition to the upper thi
s
iva
do
longitudinal member and to the front wheel housing.

r
rp
cum
fo
en
– Drill a 7 mm hole in the sill panel end panel on the transition

ng
t.
yi Co
to the front wheel housing. t. Cop py
rig
gh ht
– Apply a 4 mm bead of 2K Body Adhesive - D 180 KD3 A2- to pyri by
Vo
o
by c
the sill panel end plate near the A-pillar -1-.
lksw
cted agen
Prote AG.
– Secure the sill panel end plate to the A-pillar.
– Weld the sill panel end plate to the A-pill with a straight-line
spot weld seam.
Molded Foam Inserts

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Observe Repair Notes.

Molded foam parts:
Welding In

Golf 2009 ➤
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
♦ New part must be installed within 90 minutes, otherwise bonding properties of adhesive will be impaired.
♦ The holes for the hinge mount must be cleaned after applying the adhesive.
– Position a butyl sealing cord - AKD 497 010 04 R10- in area

-1-.
– Apply a 4 mm diameter bead of 2K Body Adhesive - D 180
KD3 A2- near the door opening and the door hinges.

Golf 2009 ➤
Note
– Install new part with vehicle standing on its wheels or on the

alignment bracket set and affix it in place.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
o Vo
by c lksw
cted
gas-shielded arc continuous weld seam
agen
Prote AG.
Note
Both weld symbols are shown in the illustration.
– Weld the door opening, windshield opening and the sill panel
end plate with a straight-line spot weld seam.

Golf 2009 ➤
– Weld the A-pillar to the A-pillar reinforcement with a gas-shiel‐

ded arc plug weld seam.
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
ercia
Note
m
at
om
ion
c
in t
r

o
his
ate
do
priv
– Weld the joint to sill panel reinforcement with a gas-shielded

um
for
en
g
arc continuous weld seam (staggered).

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

Golf 2009 ➤
1.8 A-Pillar Reinforcement
WARNING

• A-pillar already removed. Refer to

• Upper outer longitudinal member for wheel housing is already
removed. Refer to
⇒ “1.5 Upper Wheel Housing Longitudinal Member”,
page 55 .
1 - A-Pillar Reinforcement
Note
Foam residue must be removed as

much as possible before sanding
work.
3 - Outer Sill Panel agen

AG. Volkswagen AG d
oes
olksw not
4 - Sill Panel Reinforcement d by V gu
ara
rise nte
5 - Bonded Area utho eo
ra
s a c
s
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
Special tools and workshop equipment required cted agen
Prote AG.


Golf 2009 ➤

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
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
– Separate original joint of A-pillar reinforcement.
AG.

Golf 2009 ➤
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
– Loosen upper hinge reinforcement weld seam from inside. 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.

Golf 2009 ➤
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.

Installation
Note

correctly.
Preparing New Parts

Replacement part
♦ A-pillar reinforcement

Golf 2009 ➤
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.

weld seam
Molded Foam Inserts

Golf 2009 ➤
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,
Observe Repair Notes.
spec
Molded foam parts:
t to the co
Welding In
rrectne
Note
ss o
cial p
f in

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

Golf 2009 ➤
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
Note
hole
spec
es, in part or in w
t to the co
– Apply 2K Body Adhesive - D 180 KD3 A2- near the reinforce‐

rrectness of i
ment for the hinge and near the door opening.

– Install new part with vehicle standing on the alignment bracket
l purpos
set and affix it in place.

nform
ercia
– Check fit to A-pillar.

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

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
– Weld in A-pillar reinforcement, straight-line spot weld seam
mer
and gas-shielded arc plug weld seam.
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.

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Weld the connection for the upper hinge reinforcement from

the inside with a gas-shielded arc plug weld seam.
– Install A-pillar.
– Install upper outer wheel housing longitudinal member.
1.9 B-Pillar, 4-Door Vehicle
DANGER!


Golf 2009 ➤
AG. Volkswagen AG d Body Repairs - Edition 10.2011
agen oes
olksw not
V gu
by ara
1 - B-Pillar rised
nte
ho eo
ut
2 - Bonded Area ss a ra
c
ce
le
3 - Rear Longitudinal Member
un
pt
an
d
itte
y li
erm
ab
ility
ot p
Note
wit
is n
h re
ole,
spec
t to the co
work.
5 - Front Longitudinal Member
rrectne
6 - Expanded Repair Area
ss o
Note
cial p
f inform
mer
♦ If B-pillar reinforcement must be
atio
replaced, it must be cut out out‐
om
n
side of area -6- when cutting out
c
i
or
n
B-pillar.
thi
te
sd
iva
o
♦ Do not damage original joint to
pr
cum
r
fo
roof.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Removing

Golf 2009 ➤
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
♦ Only use Body Repair Saw - VAG1523- to make separating cuts.

♦ Be careful not to cut into the plates behind it when making the separation cuts.
♦ Observe replacement part separating cut at separating cut -2-.
– Make the separating cut -1- according to dimension -a-.

– Perform the separating cut -2-.
– Make separating cut -3- on the sill panel depending on the
damage.
Partial renewal
The separation cut -4- makes a partial replacement of the B-pillar
possible.

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Continue the separation cuts on the underside of the sill panel.

– Separate original joint to sill panel reinforcement.

Golf 2009 ➤
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
Installation by c lksw
cted agen
Prote AG.
Note

correctly.
Preparing New Parts

Replacement part
♦ B-pillar (replacement part identification: A-pillar subpart with
side member)

Golf 2009 ➤
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.

Marking Zones That Must Not Be Welded

Golf 2009 ➤
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
Note
do
priv
cum
for
en
g
Dimensions given must be maintained due to safety reasons.

n
t.
yi Co
Cop py
t. rig
gh ht
– Mark the areas on the outer B-pillar where welding is not per‐ yri
p by
o Vo
mitted.
c by lksw
cted agen
Prote AG.
Molded Foam Inserts

AG. Volkswagen AG d
agen oes
olksw not
d by
V
Golf 2009gu ➤
ara
e nte
horis Body Repairs - Edition 10.2011 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
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Molded foam part:
Welding in

Golf 2009 ➤
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
m
Note
o
n in
or c
thi
e
t
sd
iva
o
r
rp
cu
♦ Screw holes must remain free of adhesive in hinge reinforcement area.

o
m
f
en
ng
t.
yi Co
op py
– Apply a bead of 2K Body Adhesive - D 180 KD3 A2- that is
. C rig
ht ht
rig
approximately 4 mm thick in area -1-. py by
co Vo
by lksw
cted agen
– Apply a 4 mm bead of 2K Body Adhesive - D 180 KD3 A2- in Prote AG.
area -2-.
secure.

Golf 2009 ➤
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

– Weld in B-pillar, straight-line spot weld seam.
nform
mercia
at
om
io
Note
n
c
in t
or
his
ate

do
priv
cum
or
♦ Pay attention to areas -1- in which welding must not be performed.

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

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
o eo
– Weld the separation cuts, either MIG-Laut stitch weld seam or a
h
ra
ss c
ce
le
un
pt
– Reproduce remainder of joint to sill panel reinforcement, SG

an
d
itte
stepped seam.
y li
erm
ab
ility
ot p
wit
is n
Note
h re
ole,
spec

t to the co
– Remove escaped adhesive.

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
182
c by lksw
cted agen
Rep. Gr.51 - Body Center, Chassis, Roof Prote AG.
Golf 2009 ➤
1.10 B-Pillar Reinforcement, 4-Door Vehicle

Front sill panel reinforcement (partial section) and rear sill panel
reinforcement (partial section)
DANGER!

when plating in foamed areas where hazardous AG. Vogases are
lkswagen AG pro‐
agen does
duced that are harmful to humans Voand
lksw the environment, these not
procedures are to be omittededinb each case.
y gu
ara
ris nte
utho eo
ra
a c
ss
• Outer B-pillar already removed:
ce
le
un
⇒ “1.9 B-Pillar, 4-Door Vehicle”, page 172
pt
an
d
itte
y li
• Sill panel already removed:
erm
ab
ility
ot p
wit
is n
1 - B-Pillar Reinforcement
h re
ole,
spec
Note
t to the co
When replacing B-pillar reinforce‐
ment, front sidemember reinforce‐
rrectne
ment and inner B-pillar with rear
sidemember reinforcement must al‐
so be replaced.
ss o
cial p
f in
2 - Bonded Area
form
mer
3 - Molded Foam Part atio

om
n
c
i
or
n thi
Note
te
sd
iva
o
pr
cum

r
fo
en
ng

t.
yi Co
work. Cop py
t. rig
gh ht
pyri by
Vo
o
4 - Rear Sill Panel Reinforce‐
c by lksw
cted agen
ment Separating Cut Prote AG.
5 - Rear Sidemember Rein‐

forcement (Belongs to Inner
Side Panel)
6 - Front Sill Panel Reinforce‐
ment Separating Cut
7 - Front Outer Longitudinal
Member


Golf 2009 ➤

♦ Mechanical door tensioner - VAG1438- AG. Volkswagen AG d
agen oes
lksw not
♦ Laser Weld Seam Drill - VAS6319- by Vo gu
ara
d
ise nte
Removing uthor eo
a ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
When performing separating cut be careful not to damage the roof pillar reinforcement underneath.
– Make the separation cut on the roof joint as illustrated.

– Separate the weld points.

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
Note
nl
pt
du
an
itte
y li
♦ Before the following procedures are performed, the mechanical door tensioner - VAG1438- must be inserted
erm
ab
ility
in front and rear door openings. This prevents roof from shifting its position.
ot p
wit
, is n
♦ When performing separating cuts -1- and -2-, ensure flange area below is not separated.
h re
hole
spec
♦ Use the Laser Weld Seam Drill - VAS6319- to separate the laser weld seams.
es, in part or in w
t to the co
– Make a separating cut -1- according to dimension -a- and -2-

(behind the partition plate that is behind).
rrectness of i

l purpos
– Loosen original joint to inner sidemember.

– Loosen remaining joint in door openings.
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
185
agen
Prote AG.
Golf 2009 ➤
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
Note
rrectness of i
Make the separation cuts with the single hand angle grinder - VAS5167- .
l purpos
– Separate the inner B-pillar at the top according to dimension

nform
ercia
-a- and -b-.

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.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
rise
d b
Golf 2009ara ➤
nte
autho
Body Repairs - Edition 10.2011 eo
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.
– Separate the joint on the inner B-pillar to the sill panel.

Golf 2009 ➤
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
Installation
l purpos
Note
nf
ercia
orm
m

atio
m
o
n in
c

or
thi
e
correctly.
t
sd
iva
o
r
rp
cu
o
m
f
Preparing New Parts

en
ng
t.
yi Co
op py
Replacement part . C rig
ht ht
rig by
py
♦ B-pillar reinforcement
co Vo
by lksw
cted agen
Prote AG.
♦ Front side member reinforcement (replacement part identifi‐
cation: side member fillet plate)
♦ Inner side panel (includes: inner B-pillar and rear side member
reinforcement)

Golf 2009 ➤
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
Note
es, in part or in w
t to the co
To drill holes for gas-shielded arc plug weld seam, use weld point drill for BTR steels. HSS drills are not suitable
because they do not have a sufficient standing time.
rrectness of i
– Transfer separating cut to B-pillar reinforcement and make

l purpos
cut.
nf
ercia
weld seam
rm
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.

Golf 2009 ➤
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
– Transfer separation cuts on front sidemember reinforcement
r
rp
cu
o
and inner side panel and make cuts. m

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

Golf 2009 ➤
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
erm
ab
ility
ot p
– Mark the areas on the B-pillar reinforcement and inside the B-

wit
is n
pillar where welding is not permitted.

h re
ole,
spec
– Apply 2K Body Adhesive - D 180 KD3 A2- to inner B-pillar

-marked area- in contact point to B-pillar reinforcement.

t to the co
– Connect and secure the inside of the B-pillar -2- and the B-
pillar reinforcement -1- before installing into the vehicle.
rrectne
– Clamp panels in bonded area until 2K Body Adhesive -

D 180 KD3 A2- has hardened.
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
191
by lksw
cted agen
Prote 1. Removal and Installation
AG.
Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
Note
un
pt
an
d
itte
y li
rm
ab
Sill panel reinforcements and B-pillar reinforcement must only be tack welded as depicted for upper and lower
pe
ility
sides -magnified areas-, otherwise toughness of B-pillar reinforcement will be impaired. Also, welding on outer
ot
wit
, is n
rounded areas weakens the construction.

h re
hole
spec
– Fit new parts to vehicle standing on Alignment Bracket Set and

es, in part or in w
t to the co
secure.
– Check the fit with the B-pillar.
rrectness of i
– Tack weld front sill panel reinforcement -1- to B-pillar rein‐

forcement -3- on upper -2- and lower side -5-, gas-shielded
l purpos
arc continuous weld seam for each tack weld point.

– Tack weld rear sill panel reinforcement -4- to B-pillar rein‐
nform
ercia

m

a
com
tion in
– Remove new parts from vehicle.

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
192
Prote AG.
Golf 2009 ➤
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
Note
om
ion
c
in t
or
Pay attention to the areas -hatched- that must not be welded.

his
ate
do
priv
cum
or
– In -shaded- areas, which must not be welded,, panels should

f
en
ng
be clamped until 2K Body Adhesive - D 180 KD3 A2- has

t.
yi Co
op
hardened. C py
t. rig
gh ht
yri by
– Weld above and under the areas, where welding is not per‐ cop Vo
by lksw
mitted, straight-line spot weld seam. cted agen
Prote AG.
– Weld front sill panel reinforcement -2- to B-pillar reinforcement

-3-, straight-line spot weld seam (2 straight-line spot weld
seams each on upper and lower side and 8 straight-line spot
weld seams in double row on outer side).
– Weld rear sidemember reinforcement -1- with B-pillar rein‐
forcement -3- from inside, gas-shielded arc plug weld and
continuous weld seam (see separated pillars).

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Note
It is not permitted to weld in the areas marked in the illustration for safety reasons.
rrectne
Molded Foam Inserts

ss o
cial p

inform
mer
Molded foam part:

atio
om
Welding in
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.

Golf 2009 ➤
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
– Apply one 4 mm bead of 2K Body Adhesive - D 180 KD3 A2-

to the areas -1- and -2-.
– Fit and secure B-pillar reinforcement while vehicle is on Align‐
ment Bracket Set .

Golf 2009 ➤
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
o
Note
c by lksw
cted agen
Prote AG.
♦ Pay attention to the areas -2- that must not be welded.

♦ Clamps in areas -2- must remain until 2K Body Adhesive - D 180 KD3 A2- on B-pillar reinforcement hardens.
– Replace original joint to sidemember and roof pillar, spot weld.

– Weld B-pillar reinforcement with front -1- and rear -3- side‐
member reinforcements, gas-shielded continuous weld seam.

Golf 2009 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Weld separating cut of B-pillar reinforcement, gas-shielded arc

continuous weld seam.
– Weld in B-pillar reinforcement, SG plug weld seam.

Golf 2009 ➤
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
– Weld separating cut on upper part of inner B-pillar, gas-shiel‐

erm
ab
ded arc continuous weld seam.

ility
ot p
wit
, is n
– Weld connection from inner B-pillar to sidemember, gas-shiel‐

h re
ded arc continuous weld seam.

hole
spec
es, in part or in w
– Weld in outer B-pillar.

t to the co
– Weld in side member.
1.11 B-Pillar Reinforcement, 2-Door Vehicle

rrectness of i
l purpos
Includes: front sill panel reinforcement (partial section) and rear

sill panel reinforcement
nf
ercia
orm
WARNING
m
atio
om
n in
c

or
thi
e

t
sd
iva
o
r
rp
cu

o
m
f
en
ng

t.
yi Co
duced that are harmful to humans and the environment, these Cop py
. rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
• Side panel already removed:

Golf 2009 ➤
• Sill panel already removed:
1 - Roof Pillar Reinforcement

2 - Inner Side Panel
3 - Rear Sill Panel Reinforce‐
ment
4 - Front Sill Panel Reinforce‐
ment
6 - B-Pillar Reinforcement
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

rm
m
atio
m
Removing
o
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.

Golf 2009 ➤
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.
Note
♦ Install the Mechanical Door Tensioner - VAG1438- before separating the B-pillar reinforcement. This will
prevent the roof from changing its position.
♦ The B-pillar reinforcement and the front sill panel reinforcement may be separated only at the points shown
-1- and -3-.
♦ For reasons of safety, it is not permitted to separate and weld at a points other than the ones indicated.
♦ The roof pillar reinforcement must not be damaged. For »crash safety« is it not permitted to weld the roof
pillar reinforcement again.
♦ Be careful not to damage the panel behind it when making the separation cuts.
– Perform the separating cut -1- as illustrated.

– Separate the joint between the B-pillar reinforcement and the
inner side panel -2-.

Golf 2009 ➤
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.
– Loosen original joint to inner roof frame.

– Separate remaining joint between inner B-pillar -1- and inner
sidemember -2-.

Golf 2009 ➤
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
tio
n in
r
te o
thi
s
iva
do
r
rp
cum
fo
Installation
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
by
Note copy Vo
by lksw
cted agen
Prote AG.
correctly.
Preparing New Parts

Replacement part
♦ B-pillar reinforcement
♦ Inner B-pillar
cation: side member fillet plate)
♦ Rear side member reinforcement (replacement part identifi‐
cation: inner side panel)

Golf 2009 ➤

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
op py
Note t. C rig
gh ht
pyri by
Vo
co lksw
by
To drill holes for gas-shielded arc plug weld seam, use weld point drill for BTR steels. HSS drills are not suitable
cted agen
Prote AG.
because they do not have a sufficient standing time.
– Transfer separating cut to B-pillar reinforcement and cut off

-shaded area-.
– Transfer the separation cut onto the sill panel front reinforce‐
ments and separate -shaded areas-.
– Separate the sill panel rear reinforcement from the inner side
panel.
weld seam

Golf 2009 ➤
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.
Note
Sill panel reinforcements and B-pillar reinforcement must only be tack welded as depicted for upper and lower
sides -magnified areas-, otherwise toughness of B-pillar reinforcement will be impaired. Also, welding on outer
rounded areas weakens the construction.
– Fit new parts to vehicle standing on Alignment Bracket Set and

secure.
– Check fit with side panel.
– Tack weld front sill panel reinforcement -1- to B-pillar rein‐
– Tack weld rear sill panel reinforcement -4- to B-pillar rein‐
– Remove new parts from vehicle.

Golf 2009 ➤
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.
– Weld front sill panel reinforcement -1- to B-pillar reinforcement

-2-, straight-line spot weld seam (2 straight-line spot weld
seams each on upper and lower side and 4 straight-line spot
weld seams on outer side).
– Weld the rear sill panel reinforcement -3- to the B-pillar rein‐
forcement -2- from the inside, gas-shielded arc plug weld
seam.

Golf 2009 ➤
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
♦ B-pillar reinforcement -1- and inner B-pillar -2- must be welded within 90 minutes, otherwise adhesive bond‐
ing properties will be affected.
♦ Pay attention to the areas where welding is not permitted -3- and -4-.
– Mark the areas where welding is not permitted due to safety

reasons.
– Apply 2K Body Adhesive - D 180 KD3 A2- in entire contact
area between B-pillar reinforcement -1- and inner B-pillar -2-
(1 bead, 4 mm diameter).
– Fit and secure inner B-pillar -2- and B-pillar reinforcement
-1-.
– Weld B-pillar reinforcement -1- with inner B-pillar -2-, straight-
line spot weld seam.

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
♦ Mark the areas where welding is not permitted due to safety reasons.
♦ Transfer dimension to inner B-pillar before welding B-pillar reinforcement and inner B-pillar.
Molded Foam Inserts

Golf 2009 ➤
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un
pt
an
d
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ility
ot p
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
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i
o
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r
fo
Molded foam parts:

en
ng
t.
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op py
Welding in t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2009 ➤
AG. Volkswagen ABody
G do Repairs - Edition 10.2011
agen es n
olksw ot g
y V ua
d b ran
e
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
o
by c lksw
cted agen
Prote AG.
Note
– Apply 2K Body Adhesive - D 180 KD3 A2- to roof joint area

-1- (1 bead, 4 mm diameter).
– Fit and fasten the new part with vehicle standing on wheels or
on alignment bracket set using the side panel and the outer
sill panel.

Golf 2009 ➤
Note
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
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au ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
– Weld in B-pillar reinforcement, straight-line spot weld seam.
co lksw
by
cted agen
Prote AG.
– Weld the joint on the inner side panel, straight-line spot weld
seam.
– Weld separating cuts, gas-shielded arc continuous weld
seam.

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
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ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
– Well inner B-pillar -1- with inner roof connection -3-, gas-shiel‐
– Weld remaining joint between inner B-pillar -1- and inner side‐
rrectness of i
member -2-, gas-shielded arc continuous weld seam, stag‐

l purpos
gered.
– Install the side panel.
nf
ercia
– Install sill panel.

rm
m
atio
m
1.12 Outer Sill Panel, 4-Door Vehicle

o
n in
or c
thi
te
sd
iva
WARNING
r
rp
cu
o
m
f
en
ng
t.
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Co
op py
t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Golf 2009 ➤
Note

work.
2 - Separation Cut on the Side

Panel
3 - Bonded Area
4 - B-Pillar Separating Cut
5 - Longitudinal Panel
6 - A-Pillar Separating Cut
AG. Volkswagen AG d
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d by ara
ise nte
or eo
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aut ra
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ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w

t to the co

rrectness of i

l purpos

nf
ercia

orm
m
atio

om
n in
or c

thi
te
sd
iva

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

Golf 2009 ➤
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

♦ Be careful not to damage the panel behind it when making the separation cuts.
– Make separating cut -1- depending on the damage.

– Perform separating cut -2- over lower door hinge mount of rear
door.
– Make separating cut -4- depending on the damage.
– Sand through the outer edge -3- at the wheel well.

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Clean flanged area on wheel housing (it must be free of dust
and grease).
Installation
Note

correctly.
Preparing New Parts

Replacement part
♦ Side panel
♦ Sill panel end plate

n AG. Volkswagen AG do Golf 2009 ➤
lkswage es n
d byV
o ot g
ua Body Repairs - Edition 10.2011
ran
ir se tee
ho
♦ 2K Body Adhesiveaut- D 180 KD3 A2- or
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.

– Apply 2K Body Adhesive - D 180 KD3 A2- to the sill panel end
plate -2-.
– Fit and secure the sill panel end plate -2- in the sill panel -1-.
– Weld the sill panel end plate -2- to the sill panel -1- with a
straight-line spot weld seam.
Molded Foam Inserts

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
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ss c
ce
e
nl
pt
du
an
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erm
ab
ility
ot p
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, is n
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hole
spec
es, in part or in w
t to the co
Molded foam part:
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Golf 2009 ➤
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
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rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
♦ Mark the areas on the outer B-pillar where welding is not permitted due to safety reason.
♦ It is important to maintain the indicated dimensions.
Welding in

Golf 2009 ➤ n AG. Volkswagen AG do
lkswage es n
Body Repairs - Edition 10.2011 d byV
o ot g
ua
ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
– Apply 2K Body Adhesive - D 180 KD3 A2- in the areas -1- (2

beads of adhesive, approximately 4 mm diameter) and -2- (1
bead of adhesive, approximately 4 mm diameter).
secure.

Golf 2009 ➤
lkswage es n
o ot g
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d ran
ir se tee
tho
u or
a ac
ss
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un
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an
d
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo

en
ng
t.
yi
Co
Cop py
t. rig
gh
– Reproduce original joint, straight-line spot weld and gas-shiel‐
ht
pyri by
Vo
o
c by lksw
cted agen
Prote AG.
Note

♦ Pay attention to the areas -1- that must not be welded.

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Make the remainder of the joint for the sill panel reinforcement,
gas-shielded arc continuous weld seam (staggered).
l purpos
– Reform wheel housing flange.

nform
ercia
– Wipe off escaping adhesive and seal wheel housing.

m
1.13 Outer Sill Panel, 2-Door Vehicle

com
tion in
r
te o
thi
s
iva
do
WARNING
r
rp
cum
fo
en
ng

t.
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op
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2009 ➤
1 - Longitudinal Panel
2 - Side Panel
Separating Cut
Note
Make separating cut based on ex‐

tent of damage.
4 - Front Longitudinal Member

Separating Cut
AG. Volkswagen AG d
agen oes
Note Volksw not
gu
by ara
d
ise nte
Make separating cut based on ex‐ thor eo
tent of damage. au ra
ss c
ce
le
un
pt
5 - A-Pillar
an
d
itte
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erm
ab
Note
ility
ot p
wit
is n
A part of the A-pillar can also be re‐
h re
ole,
placed depending on the scope of
spec
the damage. Refer to
t to the co
⇒ “1.7 A-Pillar”, page 154 .
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.
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op py
t. C rig
gh ht
pyri by
Vo
o
♦ Accessory Kit for Spot Welder - VAS6238/1 A-
c by lksw
cted agen
Prote AG.
Removing

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
Note

ss o
cial p
♦ Pay attention to the replacement part separation when making the separation cut -2-.
inform
mer
atio

om
n
c
i
or
– Mark and make separating cuts -1- and -2- according to the
thi
te
degree of damage.
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.

Golf 2009 ➤
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.

Installation
Note

correctly.
Preparing New Parts

Replacement part
♦ Sill panel (replacement part identification: sub-part A-pillar
with sill panel)

Golf 2009 ➤
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.
– Transfer separating cut to new part and cut new part.

Welding in

Golf 2009 ➤
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.
Note

Golf 2009 ➤
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
Note
do
r
rp
cum
fo
en
g
n
t.
yi Co
Cop py
t. rig
gh ht
– Apply 2K Body Adhesive - D 180 KD3 A2- on the flange of the yri
p by
o Vo
door opening, adhesive bead approximately 4 mm diameter.
c by lksw
cted agen
Prote AG.
– Align and secure new part with vehicle standing on wheels or
alignment bracket set.
– Check door close function.

lkswage es n Golf 2009 ➤
o ot g
byV uBody
ara Repairs - Edition 10.2011
d
ir se nte
tho eo
au ra
c
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.
– Weld the separting cuts -1-, either MIG-L stitch weld seam or
a gas-shielded arc continuous weld seam.
– Weld the sill panel, straight-line spot weld seam.
– Weld the joint to sill panel reinforcement with a gas-shielded
arc continuous weld seam (staggered).
Note
1.14 Outer Seat Cross Member Mount
WARNING


Golf 2009 ➤
Note
♦ If a thread in the outer seat cross member mount is damaged,

then it must be replaced.
♦ If the outer seat cross member mount (with the VIN) must be
replaced, then be sure to document the service according to
all market specific legal requirements.
♦ The vehicle identification must be noted prior to welding the
outer seat cross member mount.
1 - Outer Seat Cross Member

Mount
2 - VIN; on the Right Side of the
Vehicle Only
3 - Inner Side Member Panel
4 - Inner Sill Panel
5 - Seat Cross Member
6 - Floor Panel
AG. Volkswagen AG d
agen oes
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V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

nform
ercia

m
a
com
tion in

r
te o
thi
s
iva

do
r
rp
cum
fo

en
ng
t.
yi Co
op
♦ Sheet Metal Tool - VAS6249 L- C py
t. rig
gh ht
yri
p by
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by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
ut
ho Golf 2009 ➤e or
a a
ss Body Repairs - Edition 10.2011 c
ce
le
un
pt
an
Removing
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
When loosening the weld seams, be sure not to damage the plates behind it.
– Separate the original connection to the seat crossmember

-1-, to the floor panel -2- and to the sill panel -3-.

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n

h re
hole
spec
Installation
es, in part or in w
t to the co
Note
rrectness of i

l purpos
correctly.
nform
mercia
Preparing New Parts

com
tion in
Replacement Part
r
te o
thi
s
iva
do
♦ Outer seat cross member mount (replacement part identifica‐

r
rp
cum
tion: seat bracket)

fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Golf 2009 ➤
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
Note
thi
te
sd
iva
o
r
If necessary, apply the vehicle identification number (VIN) before installing.

rp
cu
o
m
f
en
ng
t.
yi Co
op
C py
t. rig
weld seam.
gh ht
pyri by
Vo
co lksw
by
Welding in Prote
cted AG.
agen

– Check the fit with the seat.

Golf 2009 ➤
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
– Weld the outer seat cross member mount to the floor panel
nf
ercia
-1-, to the seat cross member -2- and to the inner sill panel
or
-3- with a gas-shielded arc plug weld seam.

m
m
atio
om
1.15 Inner Seat Cross Member Mount

n in
or c
thi
te
sd
iva
o
r
rp
cu
WARNING
o
m
f
en
ng
t.
yi Co
Observe safety precautions. Refer to ⇒ General Information; Cop py
t. rig
Body Repairs, Body Collision Repair opyri
gh by
Vo
ht
by c lksw
cted agen
Prote AG.
• Mount for outer seat cross member already removed. Refer to
• Seat cross member already removed. Refer to
Note
If a thread in mount of seat cross member is damaged, compo‐

nent must be replaced.

Golf 2009 ➤
1 - Inner Seat Cross Member

Mount
2 - Center Tunnel
3 - Floor Panel
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
Special tools and workshop equipment required opyri
gh by
Vo
ht
c
by lksw
cted agen
Prote AG.
Removing

Golf 2009 ➤
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
Note
om
ion
c
in t
or
♦ When loosening the weld seams, be sure not to damage the plates behind it.
his
ate
do
riv
♦ The weld points on the center tunnel reinforcement near -1- must be drilled out because the mount for the
p
cum
or
seat crossmember is installed there.

f
en
ng
t.
yi Co
Cop py
t. rig
– Separate the original connection to the center tunnel -1- and gh ht
yri by
to the floor panel -2-. cop Vo
by lksw
cted agen
Prote AG.

Golf 2009 ➤
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

um
for
en
ng
t.
yi
Installation
Co
Cop py
t. rig
gh ht
pyri by
Vo
co
Note
by lksw
cted agen
Prote AG.

correctly.
Preparing New Parts

Replacement part
♦ Inner seat cross member mount (replacement part identifica‐
tion: bracket)

Golf 2009 ➤
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
– Drill holes with a 7 mm diameter for a gas shielded arc plug
nf
ercia
o
weld seam
rm
m
atio
m
Welding in
o
n in
or c
– Align the new parts and secure them.

thi
te
sd
iva
– Make sure the outer seat crossmember mount, the seat cross‐
r
rp
cu
o
member and the seat fit correctly.

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

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
– Weld the inner seat cross member mount to the center tunnel
atio
m
-1- and to the floor panel -2-, gas-shielded arc plug weld and
o
n
c
gas-shielded arc continuous weld seam (staggered).

or
n thi
te
sd
va
1.16 Sill Panel Front Reinforcement, Vehi‐

i
o
pr
cum
r
fo
cles with 4-Doors

en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
WARNING p by
co Vo
by lksw
cted agen
Prote AG.
• Sill panel already removed. Refer to

Golf 2009 ➤
1 - Sill Panel Reinforcement

2 - Remainder of the Sill Panel
Reinforcement (Not Removed)
4 - Outer A-Pillar
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
Special tools and workshop equipmentut required
ho eo
ra
s a c
s
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
ht. rig
rig ht
py by
238
co Vo
by lksw
cted
agen
Prote AG.
Golf 2009 ➤
AG. Volkswagen AG d
ksw
agen oes
not
Vol
by gu
ara
ed nte
oris eo
th
au ra
c
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Make the separation cut according to dimension -a- (in front

of the partition plate).
– Open the joint for the fillet plate inside the sill panel -1- from
the top.

Golf 2009 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
– Remove remaining material t. Cop py
rig
gh ht
– Completely remove adhesive remains and grind bonding sur‐ pyri by
Vo
co
by lksw
cted agen
Prote AG.
Installation
Note

correctly.
Preparing New Parts

Replacement part
cation: front side member fillet plate)

Golf 2009 ➤
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.
– Transfer separating cut onto new part and cut to shape.

– Drill 10 mm diameter holes for the gas-shielded arc plug weld
seam according to the welds made at the factory.
seam from the top -1-.
Welding in
secure.

Golf 2009 ➤
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
– Weld original joint, SG plug weld seam and RP spot weld cted agen
Prote AG.
seam.
– Weld connection to fillet plate, gas-shielded arc plug weld
seam.
– Weld the separating cut, Gas-shielded arc continuous weld
seam.
– Install the sill panel.
1.17 Sill Panel Front Reinforcement, Vehi‐

cles with 2-Doors
WARNING

• Outer sill panel already removed. Refer to

Golf 2009 ➤
1 - Sill Panel Reinforcement

2 - Side Panel
Reinforcement (Not Removed)
4 - Separating Cut
6 - Remainder Front Sill Panel
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
riv

p
cum
for

en
ng
t.
yi Co
op py
♦ Spot Welder (Inverter) - VAS6239- t. C rig
gh ht
pyri by
co Vo
by lksw
cted agen
Prote AG.
Removing

Golf 2009 ➤
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
– Make the separation cut according to dimension -a-. p by
o Vo
by c lksw
cted agen
– Separate the original joint. Prote AG.
– Open the joint for the fillet plate inside the sill panel -1- from
the top.

Golf 2009 ➤
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.
Installation
Note

correctly.
Preparing New Parts

Replacement part
♦ Sill panel reinforcement (replacement part identification: sill
panel fillet plate)

Golf 2009 ➤
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
– Transfer separating cut to new part and cut new part.

l purpos

seam according to the welds made at the factory.
nform
ercia

seam from the top -1-.
m
a
com
tio
Welding in
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
co lksw
by
cted agen
Prote AG.

Golf 2009 ➤
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
ercia
Note
m
a
com
New part must be installed within 90 minutes, otherwise bonding properties of adhesive will be impaired. tion in
r
te o
thi
– Apply 2K Body Adhesive - D 180 KD3 A2- inside the door

s
iva
do
r
opening, adhesive bead approximately 4 mm diameter.

rp
cum
fo
en
ng
– Install new part with vehicle standing on the alignment bracket

t.
yi Co
op
set and affix it in place. C py
t. rig
gh ht
yri by
– Check fit with the outer sill panel.
op Vo
by c lksw
cted agen
Prote AG.

Golf 2009 ➤
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.
– Weld in side member reinforcement, straight-line spot weld

and gas-shielded arc plug weld.
seam.
– Install the outer side member.
1.18 Sill Panel Rear Reinforcement, Vehicles

with 4-Doors
WARNING

• Sill panel already removed, refer to

Golf 2009 ➤

forcement
3 - Outer Side Panel
4 - Outer Wheel Housing
5 - Sill Panel Rear Reinforce‐
ment (Not Removed)
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

m

com
tion in
r

te o
thi
s
iva
do

r
rp
cum
fo
en

ng
t.
yi Co
op py
. C rig
ht ht
rig by
py
co Vo
by lksw
cted agen
Prote AG.
Removing

Golf 2009 ➤
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
– Perform the separating cuts -1 and 2- as illustrated.

itte
y li
erm
ab
– Separate original joint to inner sill panel and to wheel housing

ility
ot p
liner.
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.

Golf 2009 ➤
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
Installation
or
his
ate
do
priv
cum
or
Note
f
en
ng
t.
yi Co
op py
. C rig
ht ht
rig
strengths, one of the inverters listed under the special tools sec‐ py by
co Vo
by lksw
cted agen
Prote
correctly.
AG.
Preparing New Parts

Replacement Part

Golf 2009 ➤
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
Welding in
t to the co
– Fit new part to vehicle standing on its wheels or on Alignment

Bracket Set and secure.
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.

Golf 2009 ➤
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
– Reproduce original joint, RP spot weld seam.

l purpos
– Weld separating cuts, gas-shielded arc continuous weld

seam.
nform
ercia
– Install the sill panel.

m
a
com
ti
1.19 Sill Panel Rear Reinforcement, Vehicles

on in
r
te o
with 2-Doors
thi
s
iva
do
r
rp
cum
fo
en
g
WARNING
n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
co Vo
by lksw
cted agen
Prote AG.
• Side panel already removed. Refer to

Golf 2009 ➤

Rear Reinforcement (Not Re‐
moved)
forcement
4 - Wheel Housing Liner
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
♦ Welding Unit With C-Grips - VAS6366- 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
d by Golfgu 2009 ➤
ara
ise nte
thor Body Repairs - Edition 10.2011
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.

– Loosen original joint to inner sidemember, inner side panel
and wheel housing liner.

Golf 2009 ➤
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

um
fo
en
ng
t.
Installation
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
Note
by lksw
cted agen
Prote AG.

correctly.
Preparing New Parts

Replacement part

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Note
rrectne
Drill from inner side panel to avoid damaging sidemember reinforcement.

s
– Loosen sidemember reinforcement from inner side panel.

s o
cial p
f i
Welding in
nform
mer

atio
m

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.

Golf 2009 ➤
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.
– Reproduce original joint, RP spot weld seam.

seam.
1.20 Center Seat Cross Member
WARNING

• Mount for outer seat cross member already removed. Refer to

Golf 2009 ➤
1 - Seat Cross Member

2 - Assembly Carrier
3 - Floor Panel
4 - Inner Seat Cross Member
Mount
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
Special tools and workshop equipment required t to the co

rrectne

s

s o
cial p
f in

form
mer

atio
om
n
c

i
or
n thi
te
sd
a

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

Golf 2009 ➤
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
Note Prote AG.
When loosening the weld seams, be sure not to damage the plates behind it.
– Open the original joint for the inner seat crossmember mount
and for the floor panel.

Golf 2009 ➤
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.

Installation
Note

correctly.
Preparing New Parts

Replacement part
♦ Seat cross member

Golf 2009 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co

weld seam.
rrectne
Welding in
– Align the new parts and secure them.
ss o
– Make sure the outer seat crossmember mount and the seat fit
cial p
f in
correctly.
form
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2009 ➤
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
ercia
– Weld the seat crossmember to the inner seat crossmember

m
mount and to the floor panel with a gas-shielded arc plug weld
at
om
io
seam.
n
c
in t
or
his
e
– Install mount for outer seat cross member.

at
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.

Golf 2009 ➤
2 Special Tools
♦ Programmable Welding Unit With C-Grips - VAS6377- AG. Volkswagen AG d
agen oes
lksw not
♦ Compressed Air Gun - V.A.G 1761/1- d by
Vo gu
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
♦ Double Cartridge Gun - VAS 5237- Prote
cted AG.
agen

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
265
by c lksw
cted
2. Special Tools
agen
Prote AG.
Golf 2009 ➤
53 – Body Rear
⇒ “1.1 Rear Cross Panel”, page 266
⇒ “1.2 Tail Lamp Mount”, page 270
⇒ “1.3 End Crossmember”, page 275
⇒ “1.4 Luggage Compartment Floor”, page 280
⇒ “1.5 Rear Longitudinal Member, Partial Section”, page 286
⇒ “1.6 Side Panel, Vehicles with 4-Doors”, page 292
⇒ “1.7 Side Panel, Vehicles with 2-Doors”, page 303
⇒ “1.8 Outer Wheel Housing Liner”, page 314
1.1 Rear Cross Panel
WARNING

• End crossmember already removed:
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
266
cted agen
Prote AG.
Rep. Gr.53 - Body Rear
Golf 2009 ➤
1 - Cross Panel
2 - Right Corner Piece
3 - Left Corner Piece
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
♦ Welding Unit With C-Grips - VAS6366- . Cop py
rig
ht ht
rig
♦ Welding Unit With X-Grips - VAS6376- py by
co Vo
by lksw
cted agen
♦ Programmable Welding Unit With C-Grips - VAS6377- Prote AG.
Removing

Golf 2009 ➤
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
Note
spec
es, in part or in w
t to the co
The corner pieces must be separated and slightly bent -1- in order to remove the back plate.

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.
268 Rep. Gr.53 - Body Rear

Golf 2009 ➤
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
Installation
l purpos
Note nform
ercia

m
at
om
ion
c

in t
or
his
e
correctly.
at
do
priv
cum
or
Welding in
f
en
ng
t.
yi Co
op
Replacement part C py
t. rig
gh ht
yri by
♦ Cross panel
op Vo
by c lksw
cted agen
Prote
AG.
secure.
– Check rear lid closing function.

Golf 2009 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
Bend the corner pieces back to their original shaft and weld them to the back panel.
– Weld in the back panel, straight-line spot weld seam.

– Install end crossmember.
1.2 Tail Lamp Mount
DANGER!


Golf 2009 ➤
1 - Tail Lamp Mount

2 - Mounting Bracket
Note
When cutting out tail light mount

-1-, mounting bracket -2- must also
be replaced.
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
Special tools and workshop equipment required rig ht
py by
co Vo
by lksw
♦ Spot Welder (Inverter) - VAS6239- cted agen
Prote AG.

Removing

Golf 2009 ➤
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
– Separate the original joint. Prote AG.
– Separate the connection between the tail lamp assembly

mount and the side panel -1-.

Golf 2009 ➤
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.

– Drill a 7 mm diameter hole in the side panel -1- for the gas-
shielded arc plug weld seam.
Installation
Note

correctly.
Preparing New Parts

Replacement part
♦ Mount for tail lamp assembly
♦ Mounting bracket

Golf 2009 ➤
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
weld seam.
es, in part or in w
t to the co
Welding in
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.

Golf 2009 ➤
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
Note
hole
spec
es, in part or in w
Use a »heat shield« to avoid paint damage on side panel when welding it with tail light mount.
t to the co
– Weld the tail lamp assembly mount and bracket, straight-line

rrectness of i
spot weld seam and gas-shielded arc plug weld seam.

l purpos
1.3 End Crossmember

nf
ercia
orm
m
atio
m
DANGER!
o
n in
or c
thi
e

t
sd
iva

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.

Golf 2009 ➤
1 - End Crossmember
2 - Right Corner Piece
3 - Cross Panel
4 - Left Corner Piece
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
♦ Spot Welder (Inverter) - VAS6239- spec

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

l purpos

nform
ercia

m

com
tion in

r
te o
thi
s
iva
Removing
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.

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
is nte
– Separate the original
hor connection. 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
by
277
copy Vo
by lksw
cted agen 1. Removal and Installation
Prote AG.
Golf 2009 ➤
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
Installation
erm
ab
ility
ot p
wit
, is n
Note
h re
hole
spec
es, in part or in w

t to the co
correctly.
rrectness of i
Preparing New Parts

l purpos
Replacement part
nform
ercia
♦ End crossmember
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Golf 2009 ➤
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.

weld seam.

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Weld the new part, straight-line spot weld seam and gas-shiel‐
1.4 Luggage Compartment Floor
DANGER!


• Cross panel already removed:

Golf 2009 ➤
1 - Luggage Compartment
Floor
2 - Right Wheel Housing
4 - Left Wheel Housing
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
e

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.

Removing

Golf 2009 ➤
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
Note gh ht
pyri by
Vo
o
by c lksw
cted agen
Be careful not to damage the crossmember behind when making the separation cut.
Prote AG.
– Make the separation cut on the front floor panel as illustrated.

– Loosen original joint to longitudinal members and wheel hous‐
ings.

Golf 2009 ➤
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
by lksw
cted agen
Prote AG.
Installation
Note

correctly.
Preparing New Parts

Replacement part
♦ Luggage compartment floor (replacement part identification:
rear floor panel)

Golf 2009 ➤
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
When marking the separating cut, allow 10 mm excess material for overlapping.
h re
hole
spec

es, in part or in w
t to the co

weld seam.
rrectness of i
Welding in
l purpos
– Fit new parts to vehicle standing on its wheels or on Alignment

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.

Golf 2009 ➤
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
– Weld the luggage compartment floor, straight-line spot weld

and gas-shielded arc plug weld.
rrectness of i
– Weld the luggage compartment floor to the front floor panel,

l purpos
gas-shielded arc continuous weld seam (staggered)

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.

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Weld the luggage compartment floor to the crossmember,

gas-shielded arc continuous weld seam (staggered)
– Install the cross panel.
1.5 Rear Longitudinal Member, Partial Sec‐

tion
DANGER!


• Cross panel already removed:
• Luggage compartment floor already removed:

Golf 2009 ➤

2 - Rear Inner Wheel Housing agen
AG. Volkswagen AG d
oes
olksw not
3 - Remainder of the Rear Lon‐ ed by
V gu
ara
gitudinal Member (Not Re‐ horis nte
eo
moved) aut ra
c
ss
4 - Spare Wheel Well Rein‐
ce
le
un
pt
forcement
an
d
itte
y li
erm
ab
ility
ot p
6 - Separating Cut
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Removing

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
– Make the separation cuts according to dimension -a-.
op Vo
by c lksw
cted agen
Prote AG.
– Separate the original joint on the inner wheel housing and on
the side panel reinforcement.

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
– Make the separation cuts according to dimensions a-a-.
u ra
c
s ce
le
– Separate original joint to inner wheel housing.

un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
289
cted agen
Prote AG.
Golf 2009 ➤
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.

Installation
Note

correctly.
Preparing New Parts

Replacement part
♦ Rear longitudinal member

Golf 2009 ➤
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
Welding in
l purpos
– Align and secure the new part to the Alignment Bracket Set
which the vehicle standing on its wheels using the back panel
nf
ercia
and the luggage compartment floor.

rm
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.

Golf 2009 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Butt weld around separating cut; Gas-shielded arc continuous

weld seam.
– Re-create original joint to wheel housing, straight-line spot
weld seam.
– Weld new part with inner side panel reinforcement, gas-shiel‐
– Install luggage compartment floor.
– Install lower back panel.
1.6 Side Panel, Vehicles with 4-Doors
WARNING


Golf 2009 ➤
1 - Side Panel
2 - C-Pillar Separating Cut
3 - Bonded Area
5 - Wheel Housing Bonded
Area
el
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
C-pillar Cut-Out in Separating Cut Area
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.

Golf 2009 ➤

2 - Sealing Channel
4 - C-Pillar Reinforcement
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
a

iv
o
r
rp
cu
o

f
en
ng
t.
yi Co
op
♦ Spot Welder (Inverter) - VAS6249- C py
t. rig
gh ht
yri by
op Vo
by c lksw
cted agen
Prote
AG.

Removing

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
Note
nl
pt
du
an
itte
y li

erm
ab
ility
ot p
♦ Do not damage the panels behind when separating.

wit
, is n
h re
♦ Note cut identification: ⇒ page 293 .

hole
spec
es, in part or in w
♦ Observe replacement panel separating cut at separating cut -1-.

t to the co
– Perform the separating cut -1- as illustrated.

rrectness of i
– Make a separating cut on the C-pillar -2- according to dimen‐

sions -a- and -b-.
l purpos
nform
ercia

m
at
– Sand through the outer edge at the wheel well.

om
ion
c
in t
r

o
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
295
cted agen
Prote AG.
Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
ut ra
– Cut the original joint inside the
ss a rear lid opening. 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
296
cted agen
Prote AG.
Rep. Gr.53 - Body Rear
Golf 2009 ➤
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
– Completely remove adhesive remains and grind bonding sur‐ C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
– Clean flanged area on wheel housing (it must be free of dust cted agen
Prote AG.
and grease).
Installation
Note

correctly.
Preparing New Parts

Replacement part
♦ Side panel sub-part

Golf 2009 ➤
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
– Drill holes in the side panel for a gas-shielded arc plug weld
seam, 7 mm diameter.
rrectness of i
Molded Foam Inserts

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.

Golf 2009 ➤
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.

Molded foam part:
Welding in

Golf 2009 ➤
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
Note
om
n in
or c
thi
te
sd
iva
o
r
♦ Apply 2K Body Adhesive - D 180 KD3 A2- around the tank filler neck before welding the right side panel.
rp
cu
o
m
f
en
ng
t.
yi Co
op
– Apply 1K Assembly Adhesive - D 190 MKD A3- in the adhesion C py
t. rig
area -1-, triangular bead cross section, 12 mm high. gh ht
pyri by
Vo
co lksw
by
– Apply 2 4 mm diameter beads of 2K Body Adhesive - D 180 Prote
cted AG.
agen
KD3 A2- in area -2-.

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
– Weld in side panel, Straight-line spot weld seam.

du
an
itte
y li

erm
ab
ility

ot p
wit
, is n
h re
hole
spec
Note
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.

Golf 2009 ➤
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
yri by
– Make the original joint inside the rear lid opening, MIG-L stitch cop Vo
by lksw
weld seam or gas-shielded arc continuous weld seam are cted agen
Prote AG.
possible.
Note
– Weld the connection tail lamp assembly mount, gas-shielded

arc plug weld seam.

Golf 2009 ➤
1.7 Side Panel, Vehicles with 2-Doors
WARNING

1 - Side Panel
2 - C-Pillar Separating Cut
3 - Bonded Area
4 - Separating Cut (Partial Re‐
placement)
el
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
C-Pillar Cut-Out in Separating Cut Area

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
303
Prote AG.
Golf 2009 ➤

2 - Sealing Channel
4 - C-Pillar Reinforcement
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot

wit
, is n
h re
hole
spec
es, in part or in w

t to the co

rrectness of i

l purpos

nform
ercia

m
a
com

tion in
r
te o
Removing
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.

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note

♦ Do not damage the panels behind when separating.
♦ Note cut identification: ⇒ page 303 .
♦ Pay attention to the replacement part separation cut.
– Perform the separating cuts -1- and -2- and -3- as illustrated.

Golf 2009 ➤
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.

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co

rrectne
– Clean flanged area on wheel housing (it must be free of dust

and grease).
s
Installation
s o
cial p
f inform
mer
Note
atio
om
n
c

or
n thi
e
t
sd
va

i
o
pr
cum
r
correctly.
fo
en
ng
t.
yi Co
Cop py
Preparing New Parts
t. rig
gh ht
pyri by
Vo
o
Replacement part by c lksw
cted agen
Prote AG.
♦ Side panel sub-part

Golf 2009 ➤
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
– Drill holes in the side panel for a gas-shielded arc plug weld
seam, 7 mm diameter.
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.

Golf 2009 ➤
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
ercia
– Make the side panel where welding is not permitted due to

m
a
com
crash safety reasons.

tion in
r
te o
thi
s
iva
do

r
rp
cum
fo
en
g
Molded Foam Inserts

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

Golf 2009 ➤
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.

Molded foam part:⇒ General Information; Body Repairs, Body
Collision Repair
Welding in

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
l purpos
♦ Apply 2K Body Adhesive - D 180 KD3 A2- around the tank filler neck before welding the right side panel.
– Apply a 4 mm diameter bead of 2K Body Adhesive - D 180

nf
ercia
KD3 A2- in area -2-.

rm
m
atio
m
– Apply 1K Assembly Adhesive - D 190 MKD A3- in the adhesion

o
n in
c
area -2-, triangular bead cross section, 12 mm high.

or
thi
te
sd
a

iv
o
r
rp
cu

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

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n

h re

ole,
spec
t to the co
Note

rrectne
♦ Pay attention to the areas where welding is not permitted.

ss o
cial p
– Weld in side panel, Straight-line spot weld seam.

inform
mer
– Weld transition to sidemember reinforcement, gas-shielded

atio
m
arc continuous seam, staggered.

o
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.

Golf 2009 ➤
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
– Make the original joint inside the rear lid opening, MIG-L stitch
weld seam or gas-shielded arc continuous weld seam are t to the co
possible.
rrectne

ss o
cial p
f i
Note
nform
mer
atio

om
n
c
i
or
n thi
e
– Weld the connection tail lamp assembly mount, gas-shielded

t
sd
va
arc plug weld seam.

i
o
pr
cum
r
fo
en
ng

t.
yi Co
op py
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2009 ➤
1.8 Outer Wheel Housing Liner
DANGER!

Note
Removing and installing the outer wheel housing liner on a 2-door

vehicle does not differ much from removing and installing the out‐
er wheel housing liner on a 4-door vehicle.
• Side panel in 2-door vehicle already removed:

• Side panel in 4-door vehicle already removed:
1 - Outer Wheel Housing n AG. Volkswagen AG do

kswage es n
2 - C-Pillar Reinforcement byV
ol ot g
ua
d ran
ir se
3 - Rear Inner Side Panel tho tee
or
au ac
4 - Rear Sill Panel Reinforce‐ ss
ce
le
ment
un
pt
an
d
itte
y li
5 - Front Inner Side Panel
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.


Golf 2009 ➤

Removing
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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
– Make the separation cut parallel to the inner side panel. t. C rig
gh ht
pyri by
– Separate the joint for the sill panel reinforcement, for the C-
co Vo
by lksw
cted
pillar reinforcement and for the tail lamp assembly mount.
agen
Prote AG.

Golf 2009 ➤
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
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Installation
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♦ Outer wheel housing liner

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When marking the separating cut, allow 10 mm excess material for overlapping. Prote AG.
– Transfer separating cut onto new part and cut to shape.

– Check fit with side panel.

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– Weld the outer wheel housing liner to the inner wheel housing
liner from above and below, gas-shielded arc continuous weld
seam (staggered).
– Weld the outer wheel housing liner to the sill panel reinforce‐
ment and the C-pillar reinforcement, straight-line spot weld
seam.
– Make original joint for the tail lamp assembly mount, straight-
line spot weld seam.

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2 Special Tools
Edition 12/15/2014 - K0059050421 - FU - JY
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2. Special Tools 319

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Cautions & Warnings
Please read these WARNINGS and CAUTIONS before proceeding with maintenance
and repair work. You must answer that you have read and you understand these
WARNINGS and CAUTIONS before you will be allowed to view this information.
•= If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this manual, we
suggest you leave such repairs to an authorized Volkswagen retailer or other qualified shop. We especially urge
you to consult an authorized Volkswagen retailer beforeAGbeginning
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on any vehicle that may still be covered
wholly or in part by any of the extensive warranties w gen
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•= Disconnect the battery negative terminalhor (ground strap) whenever you work on the fuel
e o system or the electrical
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system. Do not smoke or work near ss aheaters or other fire hazards. Keep an approved fire
c extinguisher handy.
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•= Volkswagen is constantly improving its vehicles and sometimes these changes, both in parts and specifications,
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are made applicable to earlier models. Therefore, part numbers listed in this manual are for reference only. Always
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check with your authorized Volkswagen retailer parts department for the latest information.
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•= Any time the battery has been disconnected on an automatic transmission vehicle, it will be necessary to
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reestablish Transmission Control Module (TCM) basic settings using the VAG 1551 Scan Tool (ST).
es, in part or in w
t to the co
•= Never work under a lifted vehicle unless it is solidly supported on stands designed for the purpose. Do not support
a vehicle on cinder blocks, hollow tiles or other props that may crumble under continuous load. Never work under a
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vehicle that is supported solely by a jack. Never work under the vehicle while the engine is running.
l purpos
•= For vehicles equipped with an anti-theft radio, be sure of the correct radio activation code before disconnecting the
battery or removing the radio. If the wrong code is entered when the power is restored, the radio may lock up and
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become inoperable, even if the correct code is used in a later attempt.
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•= If you are going to work under a vehicle on the ground, make sure that the ground is level. Block the wheels to
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keep the vehicle from rolling. Disconnect the battery negative terminal (ground strap) to prevent others from
or
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starting the vehicle while you are under it.

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•= Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to yourself and
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others if you are tired, upset or have taken medicine or any other substances that may impair you or keep you from . Co py
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•= Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills. Prote AG.
•= Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid. Wear
goggles, gloves and other protective clothing whenever the job requires working with harmful substances.
•= Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near
machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery, severe
injury could result.
•= Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used
only once and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts,
washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners with
new parts where indicated, and any other time it is deemed necessary by inspection.
Page 1 of 3
© 2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0
Cautions & Warnings
•= Illuminate the work area adequately but safely. Use a portable safety light for working inside or under the vehicle.
Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled
fuel or oil.
•= Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not create dust by
grinding, sanding, or by cleaning with compressed air. Avoid breathing asbestos fibers and asbestos dust.
Breathing asbestos can cause serious diseases such as asbestosis or cancer, and may result in death.
•= Finger rings should be removed so that they cannot cause electrical shorts, get caught in running machinery, or be
crushed by heavy parts.
•= Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the
instructions thoroughly; do not attempt shortcuts. Use tools that are appropriate to the work and use only
replacement parts meeting Volkswagen specifications. Makeshift tools, parts and procedures will not make good
repairs.
•= Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or beverage containers that
might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills at
once, but do not store the oily rags, which can ignite and burn spontaneously.
•= Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten
fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque
listed.
olkswagen AG
ag does battery. If escaping hydrogen gas is en AG. V
•= Keep sparks, lighted matches, and open flame ksw away from the top of thenot
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ignited, it will ignite gas trapped in theedcells
by and cause the battery to explode.ara
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•= Be mindful of the environmentssand ecology.
Before you drain the crankcase,
a the proper way to dispose of find outc
the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local ordinances that
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govern the disposal of wastes.
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•=
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The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C system should be
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serviced only by trained automotive service technicians using approved refrigerant recovery/recycling equipment,
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trained in related safety precautions, and familiar with regulations governing the discharging and disposal of
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automotive chemical refrigerants.

t to the co
•= Before doing any electrical welding on vehicles equipped with anti-lock brakes (ABS), disconnect the battery
negative terminal (ground strap) and the ABS control module connector.
rrectne
•= Do not expose any part of the A/C system to high temperatures such as open flame. Excessive heat will increase
system pressure and may cause the system to burst.
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•= When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the Transmission
form
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Control Module (TCM), the ABS control module, and the trip computer. In cases where one or more of these
atio
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components is not separately fused, disconnect the control module connector(s).

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Some of the vehicles covered by this manual are equipped with a supplemental restraint system (SRS), that
sd
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automatically deploys an airbag in the event of a frontal impact. The airbag is operated by an explosive device.
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Handled improperly or without adequate safeguards, it can be accidentally activated and cause serious personal
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injury. To guard against personal injury or airbag system failure, only trained Volkswagen Service technicians . Cop py
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Page 2 of 3
Version 1.0
Cautions & Warnings
•= Do not quick-charge the battery (for boost starting) for longer than one minute, and do not exceed 16.5 volts at the
AG. Volkswagen AG d
swagenbefore boosting
battery with the boosting cables attached. Wait at least one ominute theoebattery
s no a second time.
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•= Never use a test light to conduct electrical tests of thehor airbag system. The system must only be tested
eo by trained
ut ra
Volkswagen Service technicians using the VAG 1551
ss a Scan Tool (ST) or an approved equivalent. The cairbag unit
must never be electrically tested while it is not installed in the vehicle.
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•= Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that may have been
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inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of ignition away from the tire repair
ility
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area. Inflate and deflate the tire at least four times before breaking the bead from the rim. Completely remove the
, is n
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tire from the rim before attempting any repair.
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•= When driving or riding in an airbag-equipped vehicle, never hold test equipment in your hands or lap while the
t to the co
vehicle is in motion. Objects between you and the airbag can increase the risk of injury in an accident.
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I have read and I understand these Cautions and Warnings.
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Page 3 of 3
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Service Department. Technical Information

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Copyright © 2014 Volkswagen AG, Wolfsburg D3E802237C9

00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.6 Front Wheel Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

1.7 Subframe Mount Thread, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

1.8 Front Longitudinal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

1.9 Front Longitudinal Member, Partial Section, Removing and Installing . . . . . . . . . . . . . . . . 86

1.2 Roof, Vehicle with Sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

1.4 Front Roof Crossmember . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

1.5 Roof Reinforcement, Vehicles without Sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

1.6 Rear Roof Cross Member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

1.7 A-Pillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

1.8 A-Pillar Reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

1.9 B-Pillar, 4-Door Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

1.6 Side Panel, Vehicles with 4-Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292

3 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320

00 – General, Technical Data

1.1 Safety Precautions

Before starting any repair work, always follow safety precau‐

1.2 Vehicle Data

1.2.1 VIN agen

The VIN -arrow- is located on right side of vehicle in fender bolt

area (upper wheel housing longitudinal member).

must be documented according to market-specific legal requirements.

2 Rep. Gr.00 - General, Technical Data

1.2.2 Type Plate

Vehicle data label -arrow- is secured in spare wheel well on left

4 Rep. Gr.00 - General, Technical Data

2 Description and Operation

Strength Hot Formed Body Panels”, page 8

2.1 Alignment Bracket Set

Special tools and workshop equipment required

2. Description and Operation 5

Refer to assembly plan supplied with alignment bracket set for

Assembly of complete Straightening Bracket Set For Touran -

2.2 Portal Gauge

2.2.1 2-Door Vehicle

6 Rep. Gr.00 - General, Technical Data

2.2.2 4-Door Vehicle

2. Description and Operation 7

2.3 Molded Foam Inserts

The transfer of driving noises into the passenger compartment

are reduced by molded foam parts.

Exact positions of molded foam parts are depicted at the begin‐

ning of the respective repair descriptions.

2.4 Galvanized Body Parts and High-

⇒ “2.4.2 2-Door Vehicle”, page 10

8 Rep. Gr.00 - General, Technical Data

Vehicle construction is predominantly manufactured from galvan‐

Color Type of steel Tensile strength / minimum yield point in Mpa

2. Description and Operation 9

2.4.2 2-Door Vehicle

10 Rep. Gr.00 - General, Technical Data

made from »standard« body steel.

2. Description and Operation 11

12 Rep. Gr.00 - General, Technical Data

2. Description and Operation 13

14 Rep. Gr.00 - General, Technical Data

made from »standard« body steel.

2.5 Laser Welds

On this vehicle, roof and body are partially welded by laser.

In laser welding, a high energy light beam is directed onto the