Body Repairs

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

GETtheMANUALS.org
Service
Repair Group overview for Body Repairs
Repair Group
00 - Technical data
50 - Body - front
51 - Body - centre
53 - Body - rear
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Technical information should always be available to the foremen and mechanics, because their
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careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and cted agen
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safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2010 Volkswagen AG, Wolfsburg D3E8027D416

GETtheMANUALS.org
Amarok 2011 ➤
Body Repairs - Edition 10.2010
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Key vehicle data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Identification plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Moulded foam elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 Galvanized body parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5 Body panel gaps/shut lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.1 Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.2 Body - centre, vehicles with double cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.3 Body - centre, vehicles with single cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.4 Body - rear, vehicles with double cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.5 Body - rear, vehicles with single cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.6 Body add-on parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6 Body dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.1 Double cab frame dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.2 Single cab frame dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.3 Double cab box dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.4 Single cab box dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.5 Double cab load surface dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.6 Single cab load surface dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7 Alignment jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.2 Alignment bracket fixture overview of complete vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.3 Alignment bracket fixture overview of vehicle chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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7.4 Alignment bracket fixture overview of vehiclelkcab gen AG
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7.5 Alignment bracket fixture overview of vehicle ed
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cab . . . . . . . . . . . . . . . . . . t.gu. a.ra. . . . . . . . . . . 39
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50 - Body - front . . . . . . . . . . . . . . . .s a.ut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .or .ac . . . . . 41
s
1 Renewing cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
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1.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
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1.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
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2 Renewing deformation element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

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

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

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

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

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

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

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

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3.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
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4 Renewing rear roof cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
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4.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
cted
125
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4.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
5 Renewing rear window frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
5.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
5.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
6 Renewing cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
6.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
6.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
7 Renewing hinge pillar (A-pillar) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
7.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
7.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
7.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
8 Renewing hinge pillar (A-pillar) reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
8.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
8.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
8.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
9 Renewing centre pillar (B-pillar) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
9.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
9.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
9.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
10 Renewing centre pillar (B-pillar) reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
10.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
10.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
10.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
11 Renewing lock pillar (C-pillar) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
11.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
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11.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

11.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
12 Renewing mounting bracket for front seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
12.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
12.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
53 - Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

1 Renewing rear cross panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
1.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
2 Renewing rear longitudinal member - part section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
2.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
2.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
3 Renewing rear side panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
3.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
3.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
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Contents iii
GETtheMANUALS.org
Amarok 2011 ➤
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iv Contents
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Amarok 2011 ➤
00 – Technical data
1 Key vehicle data
1.1 Vehicle identification number
Note
If components into which the vehicle ID number (chassis number) is stamped are renewed in the event of
damage, a surveyor must be involved prior to repair.
AG. Volkswagen AG d
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Vehicle identification number (chassis number) on the body:

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

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

frame:
The vehicle identification number (chassis number) is visibly
stamped into the right vehicle frame longitudinal member
AG. Volkswagen AG d
-arrow B-. ksw
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♦ According to the legislation in Brazil, Argentina and Mexico, a „shortened vehicle ID number (chassis num‐
nl
pt
du
an
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Additional, shortened vehicle identification number (chassis num‐

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

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AG. Volkswagen AG d
agen oes
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V
d by gu
ara Amarok 2011 ➤
ise nte
thor Body Repairs
eo - Edition 10.2010
au ra
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un
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to the right B-pillar -arrow B-.
an
d
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1.2 Identification plate
ab
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The identification plate -arrow- is stuck on the left B-pillar.
is n
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spec
t to the co
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mer
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n
c
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1.3 Vehicle data sticker
thi
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– The vehicle data sticker -arrow- is located in the footwell on
um
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1. Key vehicle data 3

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Amarok 2011 ➤
2 Safety instructions
WARNING
Before beginning any cutting, alignment or dent removal, refer

to safety notes in the binder General information, body repairs
and general body repairs.
AG. Volkswagen AG d
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Amarok 2011 ➤
3 Moulded foam elements
Note
♦ Various body cavities in the Amarok 2010 ► have been fitted

with moulded foam elements.
♦ The moulded foam elements reduce the amount of driving
noise that is transmitted into the interior.
♦ The moulded elements are fitted during body shell construc‐
tion and increase their volume in the paint shop drying oven
at approx.180°C, after priming.
♦ The exact locations of these moulded foam elements are ad‐
ditionally shown at the beginning of the respective repair de‐
scriptions.
1 - Upper A-pillar
❑ Moulded foam element
between A-pillar outer
skin and A-pillar rein‐
forcement.
❑ Moulded foam element AG. Volkswagen AG d
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Vol not
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nte
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nl
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du
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between C-pillar outer
erm
ab
skin and C-pillar rein‐
ility
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forcement.
wit
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hole
between C-pillar rein‐
spec
forcement and inner
es, in part or in w
t to the co
panel.
3 - Lower B-pillar
rrectness of i
between B-pillar outer
l purpos
skin and B-pillar rein‐

forcement.
nform
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between B-pillar rein‐
m
at
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forcement and inner

ion
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panel.
in t
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4 - Lower A-pillar
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❑ Moulded foam element by c lksw

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between A-pillar rein‐ Prote AG.
forcement and inner

panel.
As these temperatures cannot be achieved under normal work‐

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

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Amarok 2011 ➤
– Restore the paint work structure. If necessary, apply two coats

(wet in wet) of glass/paint primer -D 009 200 02- (apply the
second coat in the opposite direction) - flash-off time of about
10 minutes.
Prerequisites
– Before continuing with this procedure, ensure that the part for
replacement is correctly prepared e.g. cut and adapt to fit,
corrosion protection measures.
Renewing moulded foam element
– Wrap moulded foam element with sealing cord -AKD 497 010
04 R10- all round. gen AG
. Volkswagen AG
a does
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– Fix moulded foam element to vehicle.
db
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– Secure new part (e.g. A-pillar)ut in position. Apply gentle pres‐
ho eo
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sure to contact new part in sarea
sa of moulded foam element and c
weld in.
ce
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nl
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an
– Do not do perform shielded arc welding within 15 mm on either
itte
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erm
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– Carry out cavity preservation on repair area after painting ve‐
wit
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Amarok 2011 ➤
4 Galvanized body parts

The vehicle consists partly of body panels galvanized on one or
both sides!
Before carrying out body repairs observe the following information
⇒ General Information; Body Repairs, General Body Repairs .
AG. Volkswagen AG d
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4. Galvanized body parts 7

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Amarok 2011 ➤
5 Body panel gaps/shut lines
Note
Use setting gauge -3371- to set or check shut lines.
5.1 Body - front
A - 2.5 mm + 1.5 mm
B - 3.0 mm + 0.5 mm
C - 5.0 mm ± 0.5 mm
D - 2.0 mm ± 1.0 mm
E - 10.5 mm + 1.0 mm
F - 4.0 mm + 1.0 mm
G - 8.7 mm + 2.0 mm
AG. Volkswagen AG d
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Rep. gr.00 - Technical data Prote AG.
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Amarok 2011 ➤
5.2 Body - centre, vehicles with double cab
H - 0.5 mm ± 0.3 mm
I - 4.2 mm ± 0.5 mm
J - 5.0 mm ± 0.75 mm
K - 7.0 mm ± 1.0 mm
L - 34.5 mm ± 1.5 mm
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5. Body panel gaps/shut lines 9

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Amarok 2011 ➤
5.3 Body - centre, vehicles with single cab
J - 5.0 mm ± 0.75 mm
K - 7.0 mm ± 1.0 mm
M - 2.5 mm ± 0.3 mm
Q - 3.0 mm ± 0.3 mm
R - 35.0 mm ± 5.0 mm
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Amarok 2011 ➤
5.4 Body - rear, vehicles with double cab
B - 3.0 mm + 0.5 mm
M - 2.5 mm ± 0.3 mm
N - 20.0 mm ± 5.0 mm
O - 6.0 mm ± 1.0 mm agen
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R - 35.0 mm ± 5.0 mm aut
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V - 1.0 mm ± 0.3 mm
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GETtheMANUALS.org
Amarok 2011 ➤
5.5 Body - rear, vehicles with single cab
B - 3.0 mm + 0.5 mm
O - 6.0 mm ± 1.0 mm
P - 2.0 mm ± 0.5 mm
AG. Volkswagen AG d
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GETtheMANUALS.org
Amarok 2011 ➤
5.6 Body add-on parts
S - 1.0 mm + 0.5 mm / - 1.0 mm

❑ Shut line between wheel
cover and body part.
T - 3.0 mm ± 1.0 mm
❑ Height difference be‐
tween wheel cover and
drop sides.
AG. Volkswagen AG d
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cial p
f inform
mer
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i
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GETtheMANUALS.org
Amarok 2011 ➤
U - 10.5 mm ± 3.0 mm
❑ Shut line between rear
bumper and drop sides.
AG. Volkswagen AG d
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cial p
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Prote AG.

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Amarok 2011 ➤
6 Body dimensions
Note
♦ Dimensions only given for checking purposes. The alignment

bracket set is definitive. Bolts, screws, plugs, trim and attached
components must be removed before starting the measuring
process.
♦ Use Telescopic gauge -VAS 5159- or Telescopic gauge -VAS
5160- to determine body dimensions.
6.1 Double cab frame dimensions
6.1.1 Front frame dimensions

Frame dimensions between front frame longitudinal members
Maß a - 1,320 mm ± 4.0 mm

❑ Dimension between cab
mounting 2
Maß b - 1,015 mm ± 3.0 mm
❑ Dimension between
suspension strut mount‐
ings
Maß c - 660 mm ± 3.0 mm
❑ Dimension diagonally
between assembly swa
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Maß d - 645 mm ± 3.0 ris
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❑ Dimension sbetween
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sembly mountings
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Maß e - 1,040 mm ± 4.0 mm

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Maß f - 800 mm ± 3.0 mm

hole
spec
❑ Inner dimension be‐

es, in part or in w
tween frame longitudi‐

t to the co
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6. Body dimensions 15
GETtheMANUALS.org
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Amarok 2011 ➤ d by Vo ot g
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Body Repairs - hEdition
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10.2010 tee
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Maß a - 800 mm ± 3.0 mm
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Maß b - 815 mm ± 2.0 mm
, is n
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❑ Dimension between an‐
hole
spec
ti-roll bar bolting points
es, in part or in w
t to the co
Maß c - 840 mm ± 2.0 mm
front axle mountings
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Prote AG.

GETtheMANUALS.org
Amarok 2011 ➤
6.1.2 Centre frame dimensions

Lower centre frame dimensions
Maß a - 780 mm ± 2.0 mm

front axle rear mount‐
ings
Maß b - 810 mm ± 3.0 mm
gearbox mountings
Maß c - 490 mm ± 2.5 mm
❑ Dimension between re‐
bound strap bolting
points
AG. Volkswagen AG d
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Upper centre frame dimensions

or
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Prote AG.
GETtheMANUALS.org
Amarok 2011 ➤
Maß a - 1,340 mm ± 4.0 mm

mounting 3
Maß b - 1,100 mm ± 4.0 mm
❑ Dimension between AG. Volkswagen AG d
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Maß c - 1,100 mm ± 4.0 mm utho eo
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❑ Dimension between ss c
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load surface bolting
un
pt
point 2
an
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Maß d - 1,100 mm ± 4.0 mm
ility
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point 3
spec
Maß e - 910 mm ± 3.0 mm
t to the co
tween frame rear longi‐
rrectne
tudinal members
ss o
cial p
f inform
mer
atio
om
n
c
i
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Prote AG.

GETtheMANUALS.org
Amarok 2011 ➤
6.1.3 Rear frame dimensions

Upper centre frame dimensions
Maß a - 1,340 mm ± 4.0 mm

mounting 3
Maß b - 1,100 mm ± 4.0 mm
point 1
Maß c - 1,100 mm ± 4.0 mm
point 2
Maß d - 1,100 mm ± 4.0 mm
point 3
Maß e - 910 mm ± 3.0 mm
tween frame rear longi‐
tudinal members
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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aut ra
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ce
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pt
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erm
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es, in part or in w
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rrectness of i
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Rear diagonal frame dimensions

nf
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Prote AG.
GETtheMANUALS.org
Amarok 2011 ➤
Maß a - 1,345 mm ± 4.0 mm

between load surface
bolting point 1 on left
and load surface boltingwage
es n
point 2 on right y Volks ot g
u b ara
ed
Maß b - 1,658 mm ris± 4.0 mm nte
utho e or
❑ Dimension
ss
a diagonally ac
ce
e
nl
pt
bolting point 1 on right
du
an
itte
and load surface bolting
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erm
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point 3 on left
ility
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wit
Maß c - 1,195 mm ± 4.0 mm
, is n
h re
hole
spec
es, in part or in w
bolting point 2 on left
t to the co
and load surface bolting
point 3 on right
rrectness of i
Maß d - 1,488 mm ± 2.5 mm
l purpos
front leaf spring mount‐
ing and rear leaf spring
nform
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mounting
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GETtheMANUALS.org
Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
lksw not
6.2 Single cab frame dimensions
o
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6.2.1 Front frame dimensions
ce
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pt
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d
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Frame dimensions between front frame longitudinal members
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Maß a - 1,320 mm ± 4.0 mm
h re
hole
spec
mounting 2
es, in part or in w
t to the co
Maß b - 1,015 mm ± 3.0 mm
rrectness of i
suspension strut mount‐
ings
l purpos
Maß c - 660 mm ± 3.0 mm

nform
ercia
between assembly
m
mountings
a
com
tion in
Maß d - 645 mm ± 3.0 mm
r
te o
thi
❑ Dimension between as‐
s
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sembly mountings
rp
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Maß e - 1,040 mm ± 4.0 mm

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Maß f - 800 mm ± 3.0 mm Prote AG.

nal members
Front lower frame dimensions
GETtheMANUALS.org
Amarok 2011 ➤
Maß a - 800 mm ± 3.0 mm

nal members
Maß b - 815 mm ± 2.0 mm
❑ Dimension between an‐
ti-roll bar bolting points n AG. Volkswagen AG do
lkswage es n
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Maß c - 840 mm ± 2.0 mm ir se
d b ran
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❑ Dimension between auth or
ac
front axle mountings ss
ce
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nl
pt
du
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Prote AG.
6.2.2 Centre frame dimensions
Note
Centre frame dimensions were not yet available at time of going

to print!
6.2.3 Rear frame dimensions
Note
Rear frame dimensions were not yet available at time of going to

print!

GETtheMANUALS.org
Amarok 2011 ➤
6.3 Double cab box dimensions
6.3.1 Front box dimensions

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

ing flange
nf
ercia
orm
Maß - 1,742 mm ± 2.0 mm
m
atio
m
o
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or c
between left wing

thi
e
mounting flange at rear

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

Maß - 270 mm ± 2.0 mm
nf
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o
rm
m
ber to lamp carrier
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Prote AG.
Front end box dimensions

GETtheMANUALS.org
AG. Volkswagen AG d
agen oes
olksw not
yV gu
ed b ara
nte
Amarok 2011 ➤
ris
ut
ho eo
ra
s a c
s
Maß - 950 mm ± 3.0 mm
ce
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nl
pt
du
an
❑ Dimension between A-
itte
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pillar and front end
erm
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ility
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Maß - 1,067 mm ± 2.0 mm
wit
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hole
spec
es, in part or in w
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rrectness of i
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nf
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Prote AG.
GETtheMANUALS.org
Amarok 2011 ➤
6.3.2 Centre box dimensions

Centre box dimensions
Maß - 1,870 mm ± 3.0 mm

pillars
Maß - 1,870 mm ± 3.0 mm
❑ Dimension between B-
pillars
Maß - 420 mm ± 2.0 mm: Di‐
mension
❑ Upper door hinge to low‐
er door hinge on A-pillar
Maß - 445 mm ± 2.0 mm
❑ Upper door hinge to low‐
er door hinge on B-pillar
lkswage es n
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d ran
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ss
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nl
pt
du
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itte
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es, in part or in w
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Prote AG.

GETtheMANUALS.org
Amarok 2011 ➤
6.3.3 Rear box dimensions

Rear box dimensions
Maß - 1,195 mm ± 2.0 mm

roof side members
Maß - 1,465 mm ± 2.0 mm
❑ Dimension rear panel
aperture
Maß - 340 mm ± 2.0 mm

❑ Dimension rear window
aperture
Maß - 1,524 mm ± 3.0 mm
side members
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
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nl
pt
du
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itte
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erm
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ility
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hole
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es, in part or in w
t to the co
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nf
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Prote AG.
GETtheMANUALS.org
Amarok 2011 ➤
6.4 Single cab box dimensions
6.4.1 Front box dimensions

Front engine compartment box dimensions
Maß - 956 mm ± 1.0 mm

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

GETtheMANUALS.org
Amarok 2011 ➤
Maß - 1,500 mm ± 2.0 mm

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

nl
pt
du
an
itte
Maß - 270 mm ± 2.0 mm
y li
erm
ab
ility
ot p
ber to lamp carrier
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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Front end box dimensions Prote AG.
GETtheMANUALS.org
Amarok 2011 ➤
Maß - 950 mm ± 3.0 mm

Maß - 1,067 mm ± 2.0 mm
lkswage es n
o ot g
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d ran
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ss
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un
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an
d
itte
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6.4.2 Centre box dimensions

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

t to the co
print!
rrectne
6.4.3 Rear box dimensions

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

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

GETtheMANUALS.org
Amarok 2011 ➤
6.5 Double cab load surface dimensions
6.5.1 Upper load surface dimensions

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

agen oes
❑ Dimension inner side of Volksw not
gu
y
load area side panel d b ara
rise nte
ho eo
Maß - 1,810 mm ± 2.0 mm aut ra
c
ss
❑ Dimension outer side of
ce
le
un
load area side panel
pt
an
d
itte
y li
Maß - 2,122 mm ± 2.0 mm
rm
ab
pe
ility
❑ Diagonal dimension for
ot
wit
, is n
load surface
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
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s
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Cop py
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by
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Prote AG.
Lashing eye deviations
GETtheMANUALS.org
Amarok 2011 ➤
Maß - 1,574 mm ± 2.0 mm

lashing eyes
Maß - 1,656 mm ± 2.0 mm
❑ Diagonal dimension be‐
tween lashing eyes
lkswage es n
o ot g
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d ran
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u or
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ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
h re
hole
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es, in part or in w
t to the co
rrectness of i
l purpos
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Vo
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Prote AG.

GETtheMANUALS.org
Amarok 2011 ➤
6.5.2 Lower load surface dimensions

Lower load surface deviations
Maß - 1,663 mm ± 2.0 mm

front part of wheel hous‐
ings AG. Volkswagen AG d
agen oes
olksw not
yV gu
Maß - 1,653 mm ± 2.0 mm ed b ara
nte
ris
❑ Dimension between aut
ho eo
ra
rear part of wheel hous‐ ss c
ings
ce
e
nl
pt
du
an
itte
Maß - 1,420 mm ± 2.0 mm
y li
erm
ab
❑ Dimension lower part of
ility
ot p
tailboard aperture
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
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Cop py
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rig ht
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cted agen
Prote AG.
GETtheMANUALS.org
Amarok 2011 ➤
6.5.3 Rear load surface dimensions

Rear load surface deviations
Maß - 1,421 mm ± 2.0 mm

tailboard aperture
Maß - 1,362 mm ± 2.0 mm
❑ Dimension between D-
pillars
Maß - 1,421 mm ± 2.0 mm
❑ Dimension upper part of
tailboard aperture
Maß - 381mm ± 1.0 mm
❑ Dimension tail light
aperture
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
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erm
ab
ility
ot p
wit
, is n
h re
hole
6.6 Single cab load surface dimensions

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

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

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

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

GETtheMANUALS.org
Amarok 2011 ➤
6.6.3 Rear load surface dimensions

Rear load surface deviations
Maß - 1,421 mm ± 2.0 mm

tailboard aperture
Maß - 1,362 mm ± 2.0 mm
❑ Dimension between D-
pillars
Maß - 1,421 mm ± 2.0 mm
❑ Dimension upper part of
tailboard aperture
Maß - 381mm ± 1.0 mm
❑ Dimension tail light
aperture
lkswage es n
o ot g
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d ran
ir se tee
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ss
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e
nl
pt
du
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itte
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erm
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ility
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es, in part or in w
t to the co
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Prote AG.
GETtheMANUALS.org
Amarok 2011 ➤
7 Alignment jig
7.1 Tools
Special tools and workshop equipment required
♦ Alignment jig -V.A.G 1920/1-
♦ Measurement and alignment system -VAS 6526-Basis-
♦ Measurement and alignment system -VAS 6527-Profi-
♦ Measurement and alignment system -VAS 6527-Profi-Plus-
. Volkswage n AG n AG d
wage oes
♦ Alignment bracket set Amaroky-VAS
Vol
ks 6637- not
gu
b ara
ed
♦ Portal gauge supplement,
ho Amarok -VAS 5007/48-
ris nte
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au ra
7.2 Alignment bracket fixture overview of complete vehicle ss c
ce
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nl
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an
Alignment bracket fixture overview of complete vehicle with align‐
itte
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ment bracket set Amarok -VAS 6637-
erm
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ility
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es, in part or in w
t to the co
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.

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

Alignment bracket fixture overview of vehicle chassis with align‐
G. Volkswagen AG d
ment bracket set Amarok -VAS 6637- lkswagen A oes
n o ot g
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db ran
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es, in part or in w
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Prote AG.
Note
7. Alignment jig 37
GETtheMANUALS.org
Amarok 2011 ➤
7.4 Alignment bracket fixture overview of vehicle cab

Alignment bracket fixture overview of vehicle cab with alignment
bracket set Amarok -VAS 6637-
lkswage es n
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Cop py
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Prote AG.
Note

GETtheMANUALS.org
Amarok 2011 ➤
7.5 Alignment bracket fixture overview of vehicle cab

Alignment bracket fixture overview of front of vehicle cab with
alignment bracket set Amarok -VAS 5007/48-
lkswage es n
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d ran
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itte
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t to the co
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ercia
Alignment bracket fixture overview of rear of vehicle cab with

alignment bracket set Amarok -VAS 5007/48-
m
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Prote AG.
7. Alignment jig 39
GETtheMANUALS.org
AG. Volkswagen AG d
agen oes
olksw not
Amarok 2011 ➤ d by
V gu
ara
e nte
Body Repairs - Edition 10.2010 tho ris
eo
au ra
ss c
ce
le
un
pt
an
d
itte
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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
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by c lksw
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Prote AG.
Note
Detailed information on setting up the portal gauge supplementary set can be found in the installation plans
enclosed with the portal gauge set.

GETtheMANUALS.org
Amarok 2011 ➤
50 – Body - front
RO: 50 34 55 00
1 Renewing cross member
WARNING
Observe safety notes!
Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
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un
pt
an
d
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rm
ab
pe
ility
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Cop py
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by c lksw
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Prote AG.
1. Renewing cross member 41

GETtheMANUALS.org
Amarok 2011 ➤
1.1 Removing
Carry out the following work:
Note
♦ The bolt for the cross member support -1- was discontinued in production as of July 2010 ▶. Instead the
front cross member support was welded to the frame longitudinal member -2- in production.
♦ If a cross member with bolted support requires replacement, the support must be welded to the new cross
member when installing the cross member. The bolting point in the frame longitudinal member must be
closed with weld and the support is then welded in position.
AG. Volkswagen AG d
agen oes
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un
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Models ◀July 2010; undo bolt -1- of cross member support.

– Models July 2010 ▶: separate original joint of cross member
support.
– Separate original joint of cross member from front.
– Remove cross member from frame.
42 Rep. gr.50 - Body - front

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Amarok 2011 ➤
lkswage es n
o ot g
byV ua
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a ac
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove remaining material -1- on frame longitudinal mem‐

bers.
– Grind welding surfaces and welding edges down to bare met‐
al.
1.2 Installing
1.2.1 Preparing new part

Replacement part
♦ Cross member

GETtheMANUALS.org
Amarok 2011 ➤
Body Repairs - Edition 10.2010 n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
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tho
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a ac
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un
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Grind welding edges back to bare metal from inside.

– Grind support down to bare metal.

GETtheMANUALS.org
Amarok 2011 ➤
1.2.2 Welding in
Note
♦ It is no longer permissible to bolt the cross member support to the frame longitudinal member.
♦ If a cross member with bolted support was installed in the vehicle, the threaded connection in the frame
longitudinal member must be closed with weld before installing the new cross member.
♦ Then the support must be welded to the frame longitudinal member, SG continuous weld seam.
AG. Volkswagen AG d
agen oes
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nl
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es, in part or in w
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f
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Adapt new part using alignment bracket set and fix in place.
– Weld in cross member, SG continuous weld seam.
– Weld in support, SG continuous weld seam.

GETtheMANUALS.org
Amarok 2011 ➤
RO: 50 34 55 10
2 Renewing deformation element
WARNING

2.1 Tools
♦ Resistance spot welder -VAS 6239 A-
♦ Resistance spot welder -VAS 6535-
♦ Accessory pack -VAS 6535 /1-
2.2 Removing
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t to the co
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cial p
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mer
atio
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c
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or
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pr
cum
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

GETtheMANUALS.org
AG. Volkswagen AG d
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not
Amarok 2011 ➤
ol
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d ara
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– Separate original joint.
s aut ra
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– Remove deformation element from body.
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– Remove remaining material.
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– Grind welding edges back to bare metal. ot p
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is n
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2.3 Installing
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The use of different types and different thicknesses of steel re‐
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Co
op py
must be used for proper spot welding ⇒ „2.1 Tools“, page 46 .
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2.3.1 Preparing replacement part
agen
Prote AG.
Replacement part
♦ Deformation element
– Grind welding surfaces on both sides back to bare metal.
2. Renewing deformation element 47

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Amarok 2011 ➤
2.3.2 Welding in
AG. Volkswagen AG d
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es, in part or in w
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– Adapt new part on both sides according to -dimension a- and

nf
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fix in place.
orm
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Dimension a = 270 mm
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Cop py
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co lksw
by
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Prote AG.

GETtheMANUALS.org
Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
olksw not
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rise nte
tho eo
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du
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– Weld in deformation element, RP spot weld seam.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Renewing deformation element 49

GETtheMANUALS.org
Amarok 2011 ➤
RO: 50 60 55 00
3 Renewing headlight mounting
WARNING

3.1 Tools
3.2 Removing
• Deformation element already removed
⇒ „2 Renewing deformation element“, page 46 .
AG. Volkswagen AG d
agen oes
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es, in part or in w
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l purpos
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mercia
a
com
tion in
r
te o
thi
s
iva
do
r
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cum
fo
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
cted agen
Prote AG.

GETtheMANUALS.org
Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
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un
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d
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ab
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es, in part or in w
t to the co
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l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3. Renewing headlight mounting 51

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

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

GETtheMANUALS.org
Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
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un
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an
d
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ab
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.
– Grind bonding surface and welding surfaces on both sides
back to bare metal.
3.3 Installing
Note


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

GETtheMANUALS.org
Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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ris nte
ho eo
aut ra
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un
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– Drill specified holes in new part, ∅ 7.0 mm.

rrectness o
cial p
f inform
mer
atio
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n
c
i
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sd
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pr
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t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

GETtheMANUALS.org
Amarok 2011 ➤
3.3.2 Welding in
– Apply body adhesive 2K adhesive -D 180 KD3 A2- to bonding
surface.
Note
♦ Apply adhesive bead sufficiently thickly so that optimal bond‐

ing with the body is guaranteed.
♦ New part must be welded in within 90 minutes or adhesion
swa
geof
es
adhesive will be impaired. by
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Cop py
t. rig
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pyri by
Vo
co lksw
by
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Prote AG.

GETtheMANUALS.org
Amarok 2011 ➤
– Adapt new part with vehicle standing on its wheels or on align‐

ment bracket set and hold in position.
– Check fit with all add-on parts.
– Weld in headlight mounting, RP spot weld seam and SG plug
weld seam.
AG. Volkswagen AG d
agen oes
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– Install bolt -1- for cab mounting.

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

– Install deformation element ⇒ „2.3 Installing“, page 47 .
rrectness of i
l purpos
nform
mercia
a
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tion in
r
te o
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iva
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cum
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Cop py
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pyri by
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by c lksw
56
cted agen
Prote
Rep. gr.50 - Body - front
AG.
GETtheMANUALS.org
Amarok 2011 ➤
RO: 50 53 55 00
4 Renewing wing connecting plate
WARNING

1 - Bonded areas
2 - Cutting point
❑ The parting cut is per‐
mitted for other forms of
damage.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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aut ra
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nl
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du
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
4.1 Tools
Prote AG.

4. Renewing wing connecting plate 57

GETtheMANUALS.org
Amarok 2011 ➤
Body Repairs - Edition 10.2010 agen
AG. Volkswagen AG d
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4.2 Removing
d
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Carry out the following work: ss c
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mer
atio
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n
c
i
or
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te
sd
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pr
cum
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fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Bend up metal tab -1-.

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

GETtheMANUALS.org
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
c
Amarok 2011 ➤
s
s Body Repairs - Edition 10.2010
ce
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un
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an
d
itte
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erm
ab
ility
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is n
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spec
t to the co
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cial p
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mer
atio
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n
c
i
or
n thi
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sd
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pr
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fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

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


Replacement parts
♦ Wing connecting plate

GETtheMANUALS.org
Amarok 2011 ➤

4.3.2 Welding in
AG. Volkswagen AG d
agen oes
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byV gu
ara
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

surface.

GETtheMANUALS.org
Amarok 2011 ➤
Note
♦ Apply adhesive bead sufficiently thickly so that optimal bonding with the body is guaranteed.
♦ New part must be welded in within 90 minutes or adhesion of adhesive will be impaired.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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ce
le
un
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an
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wit
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es, in part or in w
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l purpos
nform
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ment bracket set and fix in position.

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

GETtheMANUALS.org
Amarok 2011 ➤
RO: 50 53 55 10
5 Renewing connection piece
WARNING
AG. Volkswagen AG d
agen oes
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Observe safety notes! by
Vol not
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Safety notes ⇒ General Information; Body Repairs, General Body ss c
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un
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5.1 Tools
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5.2 Removing
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Note
o
cial p
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mer
Make parting cuts with pneumatic jig-saw -V.A.G 1523- only. Do not damage inner reinforcements.
atio
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n
c
i
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pr
cum
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fo
en
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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.

GETtheMANUALS.org
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
rised
Amarok 2011 nte ➤
o eo
aut
h
Body Repairs - Edition 10.2010 ra
ss c
ce
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un
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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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Make parting cut.

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

GETtheMANUALS.org
Amarok 2011 ➤
5.3 Installing
Note


Replacement parts
♦ A-pillar reinforcement
– Transfer dimension for parting cut from body and carry out.
– Drill out connection piece from A-pillar reinforcement.
– Punch specified holes in new part, ∅ 7.0 mm.
AG. Volkswagen AG d
– Grind bonding surface back to bare metal. lksw
agen oes
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– Grind welding surfaces on both sides back to bare metal.ise d b ara
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es, in part or in w
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5.3.2 Welding in
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nf
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surface.
orm
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Note
or
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♦ Apply adhesive bead sufficiently thickly so that optimal bond‐

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

GETtheMANUALS.org
Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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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
o Vo
by c lksw
cted agen
Prote AG.
– Check fit with bolt-on parts.
– Weld in connection piece, RP spot weld seam, SG plug weld
seam and SG continuous weld seam.
– Seal cavity after welding work.
5. Renewing connection piece 65

GETtheMANUALS.org
Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
RO: 50 72 55 70 olksw not
y V gu
b ara
6 Renewing upper wheel housing lon‐
d
rise nte
tho eo
gitudinal member au ra
ss c
ce
le
un
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ility
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6.1 Tools
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s
s o
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f i
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mer
atio
om
n
c
6.2 Removing
i
or
n thi
te
sd
va

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

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

⇒ „5 Renewing connection piece“, page 62

GETtheMANUALS.org
Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
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nf
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sd
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f
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t.
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Cop py
ht. rig
rig ht
py by
– Separate original joint. co Vo
by lksw
cted agen
Prote
– Remove upper longitudinal member for wheel housing from
AG.
body.
6. Renewing upper wheel housing longitudinal member 67

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Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
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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
o
by c lksw
cted agen
Prote AG.

6.3 Installing
Note


Replacement part
♦ Upper longitudinal member for wheel housing

GETtheMANUALS.org
Amarok 2011 ➤

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o ot g
byV ua
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tho
u or
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an
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6.3.2 Welding in
ab
ility
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

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

GETtheMANUALS.org
Amarok 2011 ➤
• Install wing connecting plate ⇒ „4.3 Installing“, page 59 .

• Install connection piece ⇒ „5.3 Installing“, page 64 .
• Install headlight mounting ⇒ „3.3 Installing“, page 53 .
• Install deformation element ⇒ „2.3 Installing“, page 47 .
lkswage es n
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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.

GETtheMANUALS.org
lkswage es n
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d ran
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tho tee
or Amarok 2011 ➤
u
ss
a ac
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nl
pt
du
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RO: 50 74 55 00
erm
ab
ility
7 Renewing front wheel housing
ot p
wit
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hole
spec
WARNING
es, in part or in w
t to the co
rrectness of i
l purpos
7.1 Removing
nform
ercia

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

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

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

ility
ot p
– Remove front wheel housing from body.

wit
, is n
h re
hole

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

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

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

GETtheMANUALS.org
Amarok 2011 ➤

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

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

GETtheMANUALS.org
Amarok 2011 ➤
• Install upper longitudinal member for wheel housing

⇒ „6.3 Installing“, page 68 .
• Install wing connecting plate ⇒ „4.3 Installing“, page 59 .
• Install connection piece ⇒ „5.3 Installing“, page 64 .
• Install headlight mounting ⇒ „3.3 Installing“, page 53 .
• Install deformation element ⇒ „2.3 Installing“, page 47 .
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.

GETtheMANUALS.org
Amarok 2011 ➤
RO: 50 80 55 00
8 Renewing front part of longitudinal

member - part section 1-
WARNING

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

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

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

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

– Grind welding surface back to bare metal.
8.2 Installing

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

GETtheMANUALS.org
Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
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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
– Transfer parting cut -1- from body to new part.
l purpos
– Make parting cut -1-.

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

GETtheMANUALS.org
Amarok 2011 ➤
8.2.2 Welding in
AG. Volkswagen AG d
agen oes
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byV gu
ara
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pt
du
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erm
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nf
ercia
– Adapt new part to vehicle standing on alignment bracket set orm

m
atio
m
and fix in place.

o
n in
or c
– Check fit with adjacent parts.

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

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

f
en
ng
t.
seam.
yi Co
Cop py
ht. rig
Dimension a = 3.5 mm + 0.5 mm rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
♦ Adherence to -air gap dimension a- is vital to guarantee proper through-welding.

♦ Before welding longitudinal member, check welder settings; weld several „test seams“ and check roots of
„test weld seams“ (correct welding parameters if necessary).
♦ SG continuous weld seam must not be reworked (ground or smoothed)!
– Carry out cavity preservation on front longitudinal member.
8. Renewing front part of longitudinal member - part section 1- 79

GETtheMANUALS.org
Amarok 2011 ➤
– Install front cross member ⇒ „1.2 Installing“, page 43 .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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erm
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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.

GETtheMANUALS.org
Amarok 2011 ➤
RO: 50 79 55 02
9 Renewing longitudinal member - part

section 2-
WARNING

9.1 Removing
Note
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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aut ra
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nl
pt
du
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erm
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ot p
wit
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l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
9. Renewing longitudinal member - part section 2- 81

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

– Remove longitudinal member.

GETtheMANUALS.org
Amarok 2011 ➤
lkswage es n
o ot g
byV ua
d ran
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tho
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a ac
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– Remove remaining material. wit

, is n
h re
hole

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

l purpos
Replacement parts
nform

mercia
♦ Mounting bracket for front for cab mounting

a
com
tion in

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

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

GETtheMANUALS.org
Amarok 2011 ➤
9.2.2 Producing longitudinal member reinforcement

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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un
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an
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wit
is n
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cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Using in-house material, produce longitudinal member rein‐

forcement according to deviations -a-, -b- and -c-.
Dimension a = 90 mm
Dimension b = 40 mm
Dimension c = 60 mm
– Grind welding edges of longitudinal member reinforcement
back to bare metal.

GETtheMANUALS.org
Amarok 2011 ➤ agen
AG. Volkswagen AG d
oes
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by
Vol not
gu
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oris e
9.2.3 Welding in th or
au ac
ss
ce
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un
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d
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ot p
wit
is n
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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
o
by c lksw
cted agen
Prote AG.
– Adapt new part to vehicle standing on alignment bracket set

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


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

GETtheMANUALS.org
olkswagen AG
wag en AG. V
Amarok 2011 ➤ olks
does
not
yV gu
Body Repairs - Edition
se
d 10.2010
b ara
nte
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rm
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wit
, is n
h re
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Adapt mounting bracket -1- to fit and fix in position.

– Weld in mounting bracket, SG continuous weld seam.
– Carry out cavity preservation on front longitudinal member.

GETtheMANUALS.org
Amarok 2011 ➤
RO: 50 79 55 00
10 Renewing longitudinal member com‐

plete
WARNING

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

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

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

GETtheMANUALS.org
Amarok 2011 ➤
10 - Mounting for cross member for gearbox mounting

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

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

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

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

ility
ot p
and cross member.

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

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

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

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

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

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

GETtheMANUALS.org
lkswage es n
o ot g
byV ua
ir se
d ran
tee Amarok 2011 ➤
o
uth or Body Repairs - Edition 10.2010
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Separate original joints of reinforcement -1- and remove from

frame.
– Separate original joints of cross members -2- and -3- from be‐
low.
Note
♦ Ensure the weld edges of the cross member are not damaged when separating the SG continuous weld
seams.
♦ If the weld edges of the separated cross members do not lie on the longitudinal member when rewelding,
then replace these parts.

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

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

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

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

, is n
h re
middle part of frame.

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

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

m
at
om
– Grind welding surfaces back to bare metal.

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

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

GETtheMANUALS.org
Amarok 2011 ➤
♦ Bracket for hydraulic unit

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

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

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

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

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

GETtheMANUALS.org
Amarok 2011 ➤
– Grind welding edges of mounting for cross member for gear‐

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

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

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

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

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

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

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

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

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

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

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

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

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

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

GETtheMANUALS.org
Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness
– Adapt mounting bracket -1- and anti-roll bar mounting -3- us‐
o
cial p
f i
ing alignment bracket set and fix in place.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

ab
ility
to bare metal.
ot p
wit
is n

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

s
s o
cial p
f inform
mer

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

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

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

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

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

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

GETtheMANUALS.org
Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
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e
nl
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m
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– Set roof joint gap ⇒ Item L (page 9) on both sides with setting
or c
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thi
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rp
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– Weld in roof, RP spot weld seam.

t.
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Cop py
t. rig
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pyri by
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by c lksw
cted agen
Prote AG.

GETtheMANUALS.org
Amarok 2011 ➤
RO: 51 07 55 70
2 Renewing front cross member for

roof
WARNING

2.1 Removing olksw

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AG. Volkswagen AG d
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• Roof already removed ⇒ „1 Renewing roof“,
rise page 110 .
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Carry out the following work: ss au ra
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nl
pt
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sd
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f
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ng
t.
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Cop py
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pyri by
Vo
co lksw
by
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Prote AG.

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

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AG. Volkswagen AG d
agen oes
olksw not
V gu
Amarok 2011 ➤ d by ara
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r
Body Repairs - Edition 10.2010 ut
ho eo
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an
d
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cial p
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mer
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c
i
or
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t.
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Cop py
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

2.2 Installing

Replacement parts
♦ Front roof cross member

GETtheMANUALS.org
Amarok 2011 ➤

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

lkswage es n
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Carry outs athe
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s
ce
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un
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an
d
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erm
ab
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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
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o
pr
cum
r
fo
en
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t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Renewing front cross member for roof 119

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

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

l purpos
– Install roof ⇒ „1.3 Installing“, page 113 .

nf
ercia
orm
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thi
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

GETtheMANUALS.org
Amarok 2011 ➤
RO: 51 08 55 70
3 Renewing roof reinforcement
WARNING

3.1 Removing
• Roof already removed ⇒ „1 Renewing roof“, page 110 .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
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aut ra
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ce
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un
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an
d
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rm
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pe
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mercia
a
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tion in
r
te o
thi
s
iva
do
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cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c
lksw
cted agen
Prote AG.
– Remove roof reinforcing -1- from body.
3. Renewing roof reinforcement 121

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Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
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aut ra
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ce
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un
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d
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cial p
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mer
atio
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c
i
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te
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o
pr
cum
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fo
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

3.2 Installing

Replacement parts
♦ Roof reinforcement

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Amarok 2011 ➤

3.2.2 Welding in
Note

AG. Volkswagen AG d
agen oes
olksw not
V gu
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nl
pt
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Carry out the following work: ility
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nf
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t.
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Cop py
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pyri by
Vo
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by c lksw
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Prote AG.
3. Renewing roof reinforcement 123

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Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Adapt roof reinforcing -1- with vehicle standing on its wheels

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

GETtheMANUALS.org
Amarok 2011 ➤
RO: 51 09 55 70
4 Renewing rear roof cross member
WARNING

4.1 Removing AG. Volkswagen AG d

agen oes
olksw not
• Roof already removed ⇒ „1 Renewing roof“, d by page
V 110 . gu
ara
rise nte
Carry out the following work: utho eo
ra
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s
ce
e
nl
pt
du
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itte
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erm
ab
ility
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, is n
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
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or c
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f
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ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

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

GETtheMANUALS.org
AG. Volkswagen AG d
agen oes
Amarok 2011 ➤ olksw not
byV gu
ara
Body Repairs - Edition 10.2010 rised
nte
ho eo
aut ra
ss c
ce
le
un
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an
d
itte
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rm
ab
pe
ility
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rrectness of i
l purpos
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mercia
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r
te o
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cum
fo
en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

4.2 Installing

Replacement parts
♦ Rear roof cross member

GETtheMANUALS.org
Amarok 2011 ➤

4.2.2 Welding in
Note
To ensure sufficient sturdiness, the RP weld points must be set AG. Volkswagen AG d
as far as possible from the outer edge of the welding flange. olkswagen oes
no
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au ra
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rrectness of i
l purpos
nform
mercia
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tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.
4. Renewing rear roof cross member 127

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

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

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

1 - Rear window frame

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

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

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

GETtheMANUALS.org
Amarok 2011 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
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nl
pt
du
an
itte
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erm
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ility
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spec
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t to the co
rrectness of i
l purpos
nf
ercia
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m
atio
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n in
or c
thi
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sd
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rp
cu
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t.
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– Remove adhesive residues and grind bonding surfaces down
Co
op py
to bare metal. t. C rig
gh ht
pyri by
co Vo
by lksw
cted agen
Prote AG.
5.2 Installing

Replacement parts
♦ Rear window frame

GETtheMANUALS.org
Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
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nl
pt
du
an
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erm
ab
ility
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, is n
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es, in part or in w
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nf
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or c
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t
sd
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rp
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– Grind bonding surfaces down to bare metal on one side (from

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

GETtheMANUALS.org
Amarok 2011 ➤
5.2.2 Welding in
AG. Volkswagen AG d
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Apply 2K body adhesive -D 180 KD3 A2- to bonding surfaces.

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

GETtheMANUALS.org
Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
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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
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m
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t.
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Cop py
t. rig
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ment bracket set and fix in position. op Vo
by c lksw
cted agen
Prote
– Check fit with rear-view window.
AG.
– Weld in rear window frame, RP spot weld seam and SG plug

weld seam.

GETtheMANUALS.org
Amarok 2011 ➤
RO: 51 14 55 70
6 Renewing cross member

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

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

– Remove cross member -1- from body.

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

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

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

GETtheMANUALS.org
Amarok 2011 ➤

lkswage es n
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byV ua
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6.2.2 Welding in utho tee
or
a ac
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nl
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du
Note
an
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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
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

GETtheMANUALS.org
Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
olksw not
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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
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m
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n in
or c
thi
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sd
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rp
cu
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f
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– Adapt cross member -1- with vehicle standing on its wheels or

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

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

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

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

wage
n AG. Volksfor
wagother
en AG forms of damage.
doe
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♦ Description for other forms ofeddamage
by must be derived from this gaccordingly.
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Assembly overview for vehicles
ss
a with double cab c
ce
e
nl
pt
du
an
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1 - Upper parting cut
y li
erm
ab
❑ Carry out as per dimen‐
ility
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sion -a-.
wit
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spec
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2 - Parting cut for partial re‐

newal t to the co
rrectness of i
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nf
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rm

m
atio
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or c
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4 - Parting cut for side member

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Dimension b = 250 mm C py
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by c lksw
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Prote AG.
sion -c-.
Dimension c = 750 mm
6 - Moulded foam element

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

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

sion -a-.

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

sion -c-. n AG. Volkswagen AG do
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Dimension c = 750 mm sed b ua
ran
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an
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ility
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wit
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hole
⇒ page 5 .
spec
es, in part or in w
7 - Bonded area
t to the co
❑ Cannot be restored in event of repair.

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

l purpos
nf
ercia
7.1 Tools
rm
m
atio
m

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

t
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rp
cu

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

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

♦ Parting cuts must be straight.
♦ Do not damage inner reinforcements when carrying out part‐
ing cuts.
AG. Volkswagen AG d
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olksw not
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d b ara
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te
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pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Mark parting cut -1- as per ⇒ Item 1 (page 139) (400 mm from
top edge of windscreen aperture) and cut.
centre of hole) and cut.

GETtheMANUALS.org
Amarok 2011 ➤
– Release bonded joint ⇒ Item 7 (page 139) . To release, heat

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

t to the co

to bare metal.
rrectness of i

l purpos
– Prepare moulded foam elements -1- for installation

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

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

GETtheMANUALS.org
Amarok 2011 ➤
7.3.1 Preparing new part, vehicles with dou‐

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

cab
Replacement parts
♦ Side panel

GETtheMANUALS.org
Amarok 2011 ➤
♦ Wing retainer
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss ce
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un
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an
d
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ility
ot p
wit
is n
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ole,
spec
t to the co
rrectne

ss

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

form
mer
atio

om
n
c
i
or
n thi
te
sd
iva
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.

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

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

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

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Amarok 2011 ➤
– Optically process visible weld joints.

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

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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
– Position wing with wing retainer on body -1-.

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

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

GETtheMANUALS.org
Amarok 2011 ➤
– Remove wing.
– Weld in wing retainer, SG plug weld seam.
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.

GETtheMANUALS.org
Amarok 2011 ➤
RO: 51 38 55 70
8 Renewing hinge pillar (A-pillar) rein‐

forcement
WARNING


• Hinge pillar (A-pillar) already removed
⇒ „7 Renewing hinge pillar (A-pillar)“, page 139
1 - Upper moulded foam ele‐

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

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

wit
ment
, is n
h re
hole

spec

es, in part or in w

t to the co

rrectness of i

⇒ page 5 .
l purpos
3 - Bonded area
nform
mercia
at
om
ion
c
in t
or
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.

GETtheMANUALS.org
Amarok 2011 ➤
8.1 Tools AG. Volkswagen AG d

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

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

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AG. Volkswagen AG d
agen oes
olksw not
y V gu
Amarok 2011 ➤ rise d b ara
nte
Body Repairs - aEdition
ut
ho
10.2010 eo
ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
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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
Prote AG.

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


Replacement parts
♦ Hinge pillar (A-pillar) reinforcement

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

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

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

GETtheMANUALS.org
Amarok 2011 ➤

Note
♦ Apply adhesive beads sufficiently thickly so that optimal bond‐

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

for
en
g

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

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

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

sion -e-.
Dimension e = 520 mm

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


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

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

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

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

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

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

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


Replacement parts
♦ Side panel

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

om
n
c
i
or

thi
te
sd
va

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

the illustration.

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

weld seam and SG stitch weld seam.

GETtheMANUALS.org
Amarok 2011 ➤
RO: 51 42 55 70
10 Renewing centre pillar (B-pillar) rein‐

forcement
WARNING


• Centre pillar (B-pillar) already removed
⇒ „9 Renewing centre pillar (B-pillar)“, page 154
AG. Volkswagen AG d
agen oes
olksw not
y V gu
b
Note rise
d ara
nte
tho eo
au ra
♦ Specified parting cut -1- and scutting points -3- and -4- can be combined for otherc forms
s of damage.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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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.

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

nform
ercia

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

♦ Parting cut must be straight.
10. Renewing centre pillar (B-pillar) reinforcement 161

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

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

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

Replacement parts
♦ Middle pillar (B-pillar) reinforcement

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

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

es, in part or in w
t to the co

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

ion in

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

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

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

ole,

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

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

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

age.
sion -b-.

GETtheMANUALS.org
Amarok 2011 ➤
AG. VolkswBody
agen ARepairs - Edition 10.2010
agen G do
es n
olksw ot gu
yV
11.1 Tools rise
db ara
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ility
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hole
spec
♦ MIG brazing and welding system -VAS 6382- es, in part or in w
t to the co
11.2 Removing
rrectness of i
Note
l purpos
nf
ercia
o
rm
m
atio
m

o
n in
c
ing cuts.
or
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te
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ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
11. Renewing lock pillar (C-pillar) 167

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Amarok 2011 ➤
AG. Volkswagen AG d
agen oes
– Mark parting cut -1- and carry out. o lksw not
byV gu
ara
e d
– Parting cut -2- as per ⇒ Item 5 (pagehoris 166) . Mark (250 mm from nte
eo
reference edge) and cut. aut ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
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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
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Mark parting cut -1- and carry out.

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

GETtheMANUALS.org
Amarok 2011 ➤
lkswage es n
o ot g
byV ua
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tho
u or
a ac
ss
ce
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un
pt
an
d
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erm
ab
ility
ot p

wit
is n

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

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

GETtheMANUALS.org
Amarok 2011 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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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.

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


Replacement parts
♦ Side panel

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

the illustration.

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

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

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

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

GETtheMANUALS.org
Amarok 2011 ➤
RO: 51 70 55 20
12 Renewing mounting bracket for front

seat
WARNING

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

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

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

ility
ot p
– Grind welding surfaces down to bare metal.

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

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

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

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

or
thi
te
sd
a

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

GETtheMANUALS.org
Amarok 2011 ➤
12.2.2 Welding in
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
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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
– Adapt mounting bracket for front seat -1- to fit and fix in posi‐
thi
te
sd
a
tion.
iv
o
pr
cum
r
fo
– Weld in mounting bracket for front seat, SG plug weld seam.

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

GETtheMANUALS.org
Amarok 2011 ➤
53 – Body - rear
RO: 53 05 55 00
1 Renewing rear cross panel

gen AG
. Volkswagen AG
d a oes
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Vol gu
d by ara
WARNING ris
e nte
tho eo
au ra
c
Observe safety notes! ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
1 - Bonded areas
spec
es, in part or in w
t to the co
2 - Rear cross panel
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
178 Rep. gr.53 - Body - rear

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

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

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

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

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

to bare metal.
1.2 Installing

Replacement parts
♦ Rear cross panel

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

inside).

GETtheMANUALS.org
Amarok 2011 ➤
1.2.2 Welding in
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
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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
Note
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

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

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

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

GETtheMANUALS.org
Amarok 2011 ➤
RO: 53 48 55 70
2 Renewing rear longitudinal member -

part section
WARNING AG. Volkswagen AG d

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

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

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

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

2.2 Installing

Replacement part
♦ Rear longitudinal member complete
♦ Mounting bracket

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

nform
ercia

m
at
om
io
– Remove shaded area.

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

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

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

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

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


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

GETtheMANUALS.org
Amarok 2011 ➤
RO: 53 55 55 20
3 Renewing rear side panel
WARNING

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

GETtheMANUALS.org
Amarok 2011 ➤
3.1 Removing
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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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
op
– Separate original joint. C py
ht. rig
rig ht
py by
– Release bonded joints -1-, -2- and -3-. To release, heat bon‐ co Vo
by lksw
ded surfaces with hot air blower -V.A.G 1416- . cted agen
Prote AG.
3. Renewing rear side panel 191

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

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

form
mer
atio

om

n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
en
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GETtheMANUALS.org
Amarok 2011 ➤
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GETtheMANUALS.org
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seam and SG continuous weld seam.

GETtheMANUALS.org

Body Repairs

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Body Repairs

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Service

Service Department. Technical Information

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Copyright © 2010 Volkswagen AG, Wolfsburg D3E8027D416

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

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

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

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

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

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

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

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

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

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

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

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

1.1 Vehicle identification number

Vehicle identification number (chassis number) on the body:

1. Key vehicle data 1

Vehicle identification number (chassis number) on the vehicle

Additional, shortened vehicle identification number (chassis num‐

2 Rep. gr.00 - Technical data

1. Key vehicle data 3

Before beginning any cutting, alignment or dent removal, refer

4 Rep. gr.00 - Technical data

3 Moulded foam elements

♦ Various body cavities in the Amarok 2010 ► have been fitted

❑ Moulded foam element

between C-pillar rein‐

skin and B-pillar rein‐

❑ Moulded foam element

forcement and inner

❑ Moulded foam element

between A-pillar outer

❑ Moulded foam element by c lksw

forcement and inner

As these temperatures cannot be achieved under normal work‐

3. Moulded foam elements 5

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

– Carry out cavity preservation on repair area after painting ve‐

6 Rep. gr.00 - Technical data

4 Galvanized body parts

4. Galvanized body parts 7

5 Body panel gaps/shut lines

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

5.1 Body - front

5.2 Body - centre, vehicles with double cab

5. Body panel gaps/shut lines 9

5.3 Body - centre, vehicles with single cab

10 Rep. gr.00 - Technical data

5.4 Body - rear, vehicles with double cab

5. Body panel gaps/shut lines 11

5.5 Body - rear, vehicles with single cab

12 Rep. gr.00 - Technical data

5.6 Body add-on parts

S - 1.0 mm + 0.5 mm / - 1.0 mm

5. Body panel gaps/shut lines 13

14 Rep. gr.00 - Technical data

♦ Dimensions only given for checking purposes. The alignment

6.1 Double cab frame dimensions

6.1.1 Front frame dimensions

Maß a - 1,320 mm ± 4.0 mm

Maß e - 1,040 mm ± 4.0 mm

❑ Dimension between cab