SM 54

Service
Body Repairs
Sharan 1996 ➤
Edition 11.2004
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Service Department. Technical Information

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

No reproduction without prior agreement from publisher.
Copyright © 2010 Volkswagen AG, Wolfsburg SHA53201020

Sharan 1996 ➤
Body Repairs - Edition 11.2004
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Contents
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00 - Technical data . . . a.uth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . e.e .or a. . . . . . ........... 1
o t
ss c
1 Vehicle identification data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............. 1
ce
e
nl
1.1 Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
pt
du
an
itte
1.2 Identification plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
y li
erm
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1.3 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
ility
ot p
wit
2 Body dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
, is n
h re
2.1 Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
hole
spec
2.2 Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
es, in part or in w
t to the co
2.3 Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.4 Floor group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3 Body panel gaps/shut lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
rrectness of i
3.1 Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
l purpos
3.2 Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.3 Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
nf
ercia
o
4 Straightening jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
rm
m
atio
5 Galvanized body parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
om
n in
or c
thi
50 - Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
te
sd
iva
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r
1 Renewing engine bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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1.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
ng
t.
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op
2 Renewing gearbox bracket ▸ 05.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
C py
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2.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
p by
co Vo
by lksw
cted
3 Renewing gearbox bracket 06.00 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
agen
Prote AG.
3.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4 Renewing support ▸ 05.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5 Renewing support 06.00 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6 Renewing end plate 06.00 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7 Renewing upper wheel housing longitudinal member ▸ 05.00 . . . . . . . . . . . . . . . . . . . . . . 37
7.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8 Renewing upper wheel housing longitudinal member 06.00 ▸ . . . . . . . . . . . . . . . . . . . . . . 39
8.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
9 Renewing front wheel housing - partial renewal ▸ 05.00 . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
10 Renewing front wheel housing - partial renewal 06.00 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . 44
10.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
11 Renewing front part of longitudinal member - partial renewal . . . . . . . . . . . . . . . . . . . . . . 47
11.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
51 - Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1 Renewing roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2 Renewing front roof cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3 Renewing roof reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4 Renewing rear roof cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Contents i
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
o lksw not
4.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . .ed. b.y.V. . . . . . . . . . . . . . . . . . . . . . . . .gu.a.ra. . . . . . 59
ris nte
5 Renewing outer side panel - partial renewal ut
ho . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . e.o. . .
ra 61
a
5.1 Removing . . . . . . . . . . . . . . . . . . . . .ss. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .c . 61
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6 Renewing outer side panel - partial renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
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itte
6.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
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7 Renewing inner side panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
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7.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
, is n
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hole
8 Renewing A-pillar- partial renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
spec
8.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
es, in part or in w
t to the co
9 Renewing B-pillar- partial renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
9.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
rrectness of i
10 Renewing outer side member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
10.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
l purpos
11 Renewing inner side member - partial renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

11.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
nf
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12 Renewing floor panel - partial renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
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12.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
o
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53 - Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
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1 Renewing rear lock carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
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1.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
t.
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2 Renewing tail light mounting - partial renewal ▸ 05.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
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2.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
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3 Renewing tail light mounting - partial renewal 06.00 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
AG.
3.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4 Renewing rear cross member - partial renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
4.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5 Renewing luggage compartment floor, partial renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
6 Renewing bumper bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
6.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
7 Renewing rear cross panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
7.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
8 Renewing rear longitudinal member - partial renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
8.1 Includes: rear shock absorber mounting and extension arm . . . . . . . . . . . . . . . . . . . . . . . . 103
9 Renewing side panel - partial renewal ▸ 05.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
9.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
10 Renewing side panel - partial renewal 06.00 ▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
10.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
11 Renewing rear wheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
11.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
12 Renewing cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
12.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
ii Contents
Sharan 1996 ➤
00 – Technical data
1 Vehicle identification data
1.1 Vehicle identification number
The vehicle identification number (chassis number) is stamped
on the bulkhead of engine compartment.
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1.2 Identification plate
t to the co
The identification plate is located on the B-pillar of the left door.
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The storage recess is covered by a lid. Prote AG.
1. Vehicle identification data 1

Sharan 1996 ➤
2 Body dimensions
2.1 Body - front
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Distance between front longitudinal members

Distance between suspension strut mountings
2 Rep. Gr.00 - Technical data

Sharan 1996 ➤
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Distance between wheel housing corners
Dimension between brackets for bumper
Distance between front longitudinal members
2. Body dimensions 3
Sharan 1996 ➤
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Diagonal distance between bonnet hinge mounting and wheel

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Distance between bonnet hinge mounting and wheel housing p by
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Prote AG.

Sharan 1996 ➤
AG. Volkswagen AG d
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Prote AG.
olkswagen AG
en AG. V
Sharan 1996 ➤ olkswag does
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Body Repairse-d bEdition 11.2004 gu
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Diagonal distance
ss across
a windscreen aperture ra
c
ce
Distance plenum chamber flange - roof flange e
nl
pt
du
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2.2 Body - centre
erm
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ility
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es, in part or in w
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l purpos
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c
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Prote AG.
Front door aperture

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
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y V gu
d b ara
rise nte
o
Distance between aut A-pillars
h eo
ra
ss c
Distance between B-pillars
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
rrectness of i
l purpos
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at
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ion
c
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or
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Vo
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7
c by lksw
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Prote AG. 2. Body dimensions
AG. Volkswagen AG d
agen oes
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Sharan 1996 ➤ d byV gu
ara
e
Body Repairs - Editionhoris 11.2004 nte
eo
aut ra
ss c
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nl
pt
du
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erm
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ility
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hole
spec
es, in part or in w
t to the co
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l purpos
nf
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Prote AG.
Rear door aperture

AG. Volkswagen AG d Sharan 1996 ➤
agen oes Body Repairs - Edition 11.2004
olksw not
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aut ra
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un
pt
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d
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is n
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spec
t to the co
rrectness o
cial p
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mer
atio
om
n
c
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n thi
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Cop py
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by lksw
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Prote AG.
Sharan 1996 ➤
Distance between C-pillars
2.3 Body - rear
AG. Volkswagen AG d
agen oes
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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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erm
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spec
es, in part or in w
t to the co
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l purpos
Distance flange of cross panel - roof flange, centre of vehicle

nf
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Distance between inserts

rm
m
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n in
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by
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Prote AG.

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
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ara
ed
ris nte
ho eo
aut ra
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ce
e
nl
pt
du
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erm
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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
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n in
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t.
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Cop py
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by lksw
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Prote AG.
Sharan 1996 ➤
Distance between rear longitudinal members

Dimension between securing points for gas struts agen
AG. Volkswagen AG d
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V
2.4 Floor group by gu
d ara
rise nte
tho eo
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spec
t to the co
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cial p
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mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
r
fo
en
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
horis nte
eo Sharan 1996 ➤
aut r a Body Repairs - Edition 11.2004
ss c
ce
le
un
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d
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ab
pe
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hole
spec
es, in part or in w
t to the co
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l purpos
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mercia
a
com
tion in
r
te o
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s
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cum
fo
en
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t.
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by lksw
cted agen
Prote AG.
Sharan 1996 ➤
3 Body panel gaps/shut lines
3.1 Body - front

Use special tool 3371 for adjusting or checking.
A - 1 mm
C - 3 ±1 mm
D - 4 ±1 mm AG. Volkswagen AG d
agen oes
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G - 6.5 ±1 mm 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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itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
3.2 Body - centre
C - 3 ±1 mm
D - 4 ±1 mm
E - 5 ±1 mm
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wit
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es, in part or in w
t to the co
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l purpos
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com
tion in
r
te o
thi
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iva
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t.
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Cop py
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Vo
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by
cted agen
Prote AG.
3. Body panel gaps/shut lines 15

Sharan 1996 ➤
3.3 Body - rear
D - 4 ±1 mm
F - 6 ±1 mm
G - 6.5 ±1 mm
H - 9 ±1 mm
AG. Volkswagen AG d
agen oes
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ris nte
ho eo
aut ra
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ce
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un
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d
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rm
ab
pe
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
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en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
4 Straightening jig
Note
♦ The item numbers in the figure are identical with the end num‐
bers on the straightening bracket -V.A.G 1960- inserts.
♦ The required basic size is given for the alignment bracket
mounting.
2 - MZ 200
4 - MZ 142 and TV 400
6 - MZ 260 and TV 400 agen
AG. Volkswagen AG d
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8 - MZ 260, TV 400 and ed byV gu
ara
straightening bracket mount‐ horis nte
eo
ing -6- aut ra
c
ss
11 - MZ 260
ce
e
nl
pt
du
an
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12 - MZ 601
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erm
ab
ility
16 - MZ 260
ot p
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20 - MZ 140
h re
hole
spec
22 - MZ 080
es, in part or in w
t to the co
24 - MZ 140
25 - Distance piece, left and
right identical
rrectness of i
26 - MZ 260
l purpos
28 - MZ 200 and TV 400
nf
ercia
o
30 - MZ 140, TV 400 and
rm
m
straightening bracket mount‐
atio
m
ing -32-
o
n in
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by lksw
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Prote AG.
4. Straightening jig 17
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
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an
d
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Overview - front alignment bracket positions

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

Sharan 1996 ➤
2 - Longitudinal member end

plate
4 - Front longitudinal member
6 - Bumper bracket
8 - Upper wheel housing longi‐
tudinal member
11 - Engine bracket
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hole
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es, in part or in w
t to the co
rrectness of i
l purpos
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mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
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byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
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
nform
mercia
at
om
ion
c
in t
or
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e
Overview - middle alignment bracket positions

at
do
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for
en
ng
t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.

Sharan 1996 ➤
16 - Subframe mounting
12 - Suspension strut mount‐
ing
20 - Subframe mounting
22 - Drilling in longitudinal
member
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
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d
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
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mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
r
fo
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
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d by ara
ise nte
or eo
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aut ra
ss c
ce
le
un
pt
an
d
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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
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o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Overview - rear alignment bracket positions

Sharan 1996 ➤
24 - Rear axle mounting

AG. Volkswagen AG d
agen oes
Note olksw not
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d b ara
rise nte
The threaded
utho holes in the vehicle eo
ra
are offset
ss a 4° from a level plain. c
ce
e
nl
pt
du
25 - Distance piece, left and
an
itte
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right identical
erm
ab
ility
ot p
26 - Rear axle mounting
wit
, is n
h re
28 - Shock absorber mounting
hole
spec
30 - Rear longitudinal member
es, in part or in w
t to the co
32 - Bumper bracket
rrectness of i
l purpos
nf
ercia
orm
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n in
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Cop py
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Prote AG.
Sharan 1996 ➤
5 Galvanized body parts
1 - One side galvanized

2 - Both sides galvanized
AG. Volkswagen AG d
agen oes
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V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
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om
n in
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t.
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Cop py
t. rig
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Vo
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by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
50 – Body - front
AG. Volkswagen AG d
agen oes
lksw not
RO: 50 40 55 50 Vo gu
by ara
1 Renewing engine bracket ed
ris nte
ho eo
aut ra
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ce
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WARNING
nl
pt
du
an
itte
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Observe safety notes!
erm
ab
ility
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h re
⇒ General Information; Body Repairs, General Body Repairs ;
hole
spec
Chapter 1 - Safety notes
es, in part or in w
t to the co
1.1 Removing
rrectness of i
1.1.1 Cutting locations
l purpos
nform
mercia
at
om
ion
c
in t
or
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do
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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.
– Separate engine bracket from wheel housing with a grinder.

– Drill out SG plug weld seams on longitudinal member.
1. Renewing engine bracket 25

Sharan 1996 ➤ agen
AG. Volkswagen AG d
oes
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Body Repairs b-y Edition
Vol 11.2004 not
gu
ara
ed nte
oris
– Drill out spotawelds
ut
h on wheel housing. e or
ac
ss
– Drill out engine bracket on wheel housing and longitudinal
ce
le
un
pt
member.
an
d
itte
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– Remove remainder of joint with a grinder.
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
1.1.2 Replacement part
ss o
cial p
f
♦ Engine bracket
inform
mer
Preparing new part
atio
om
– Drill 7 mm ∅ holes for SG plug weld seam.
n
c
i
or
n thi
e
1.1.3 Welding in
t
sd
iva
o
pr
cum
r
fo
– Secure vehicle and new part to alignment bracket.

en
ng
t.
yi Co
op
– Weld new part in, SG continuous seam. C py
t. rig
gh ht
yri by
– Weld in bracket to wheel housing, RP spot weld seam. op Vo
by c lksw
cted agen
Prote AG.
– SG plug weld remainder of joint.

– Weld in new part, RP spot weld seam.
– Weld in longitudinal member, SG continuous weld seam.
26 Rep. Gr.50 - Body - front

Sharan 1996 ➤
RO: 50 40 55 53
2 Renewing gearbox bracket ▸ 05.00
WARNING

2.1 Removing
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
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Separate gearbox bracket from wheel housing and longitudi‐
nal member with a grinder.
2. Renewing gearbox bracket ▸ 05.00 27

Sharan 1996 ➤

– Remove remainder of joint with a grinder.

♦ Gearbox bracket
Preparing new part
2.1.3 Welding in
– Weld new part in, SG continuous seam.
lkswage es n
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d ran
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ss
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d
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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
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pr
cum
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fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
RO: 50 40 55 53 oris nte
h eo
3 ss aut ra
c Renewing gearbox bracket 06.00 ▸
ce
e
nl
pt
du
an
WARNING
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
3.1 Removing
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Separate gearbox bracket from wheel housing and longitudi‐

nal member with a grinder.
– Remove remaining material.
3. Renewing gearbox bracket 06.00 ▸ 29

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
Sharan o1996
ris
e ➤ nte
h eo
BodyaRepairs
ut - Edition 11.2004 ra
c
ss
ce
e
3.1.2 nl
Replacement part
pt
du
an
itte
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erm
ab
♦ Gearbox bracket
ility
ot p
Preparing new part
wit
, is n
h re
hole
spec
es, in part or in w
3.1.3 Welding in
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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r
rp
cu
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f
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
RO: 50 41 55 50
4 Renewing support ▸ 05.00
WARNING

4.1 Removing
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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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.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
4. Renewing support ▸ 05.00 31

Sharan 1996 ➤
– Cut-out cover plate and bracket for bumper.

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d ran
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ss
ce
e
nl
pt
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itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
♦ Bracket for bumper
es, in part or in w
t to the co
♦ Cover plate
Preparing new part
rrectness of i
l purpos
4.1.3 Welding in
nform
ercia
– Secure new part and check gaps and shut lines to attached
m
parts.
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Weld in console, SG plug weld seam.

– Weld in cover plate, RP spot weld seam.
– Weld remaining joint, SG plug weld seam.

Sharan 1996 ➤
RO: 50 41 55 50
5 Renewing support 06.00 ▸
WARNING

5.1 Removing
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
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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
– Cut-out cover plate and bracket for bumper.
ht
pyri by
Vo
o
by c lksw
– Drill out weld points above.
cted agen
Prote AG.
5. Renewing support 06.00 ▸ 33

Sharan 1996 ➤

– Drill out weld points below.
5.1.2 Replacement part agen

AG. Volkswagen AG d
oes
olksw not
♦ Bracket for bumper d byV gu
ara
ise nte
r
♦ Cover plate aut
ho eo
ra
ss c
Preparing new part
ce
e
nl
pt
du
an
itte
y li
erm
ab
5.1.3 Welding in
ility
ot p
wit
, is n
h re
hole
parts.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
m
– Weld in cover plate, SG plug weld seam.

o
n in
or c
– Weld in console, SG plug weld seam. 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.

Sharan 1996 ➤
RO: 50 53 55 50
6 Renewing end plate 06.00 ▸
WARNING

6.1 Removing AG. Volkswagen AG d

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

6. Renewing end plate 06.00 ▸ 35

Sharan 1996 ➤

♦ End plate
6.1.3 Welding in
parts.
– Spot weld upper wheel housing longitudinal member, RP spot
weld seam.
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.

Sharan 1996 ➤
RO: 50 72 55 50
7 Renewing upper wheel housing lon‐

gitudinal member ▸ 05.00
WARNING

7.1 Removing
7.1.1 Cutting slocations

wage
es
olk not
yV gu
edb ara
ris nte
tho eo
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Drill out spot welds.
7. Renewing upper wheel housing longitudinal member ▸ 05.00 37

Sharan 1996 ➤
– Cut out longitudinal member.

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
♦ Longitudinal member
pe
ility
ot
wit
, is n
Preparing new part
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
7.1.3 Welding in
thi
s
iva
do
r
rp

um
fo
en
g
weld seam.
n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Weld in longitudinal member, SG plug weld seam.
– Spot weld remaining joint in, RP spot weld seam.

Sharan 1996 ➤
RO: 50 72 55 50
8 Renewing upper wheel housing lon‐

gitudinal member 06.00 ▸
WARNING

wage es n
8.1 Removing olks 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.

– Cut out longitudinal member.
8. Renewing upper wheel housing longitudinal member 06.00 ▸ 39

Sharan 1996 ➤

Preparing new part
8.1.3 Welding in
weld seam.
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.

Sharan 1996 ➤
RO: 50 74 55 12
9 Renewing front wheel housing - par‐

tial renewal ▸ 05.00
WARNING

9.1 Removing
Note
If the damage goes beyond the prescribed cut line, the longitudi‐
nal member complete with wheel housing must be renewed.
• Longitudinal member for upper wheel housing already re‐

moved .
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.
9. Renewing front wheel housing - partial renewal ▸ 05.00 41

Sharan 1996 ➤

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

– Cut out wheel housing.

♦ Wheel housing
♦ Battery bracket (left side only)
♦ Cover support bracket (left side only)

Sharan 1996 ➤
Preparing new parts

– Transfer parting cut to new part and remove shaded area.
9.1.3 Welding in
– Weld in wheel housing, SG plug weld seam.
– Weld remaining joint in, SG stepped weld seam.

– Weld in battery bracket retainer, RP spot weld.
– Weld in cover support bracket RP spot weld.
– Weld in longitudinal member for wheel housing ⇒ page 38 .
. Volkswage n AG n AG d
wage oes
Volks not
gu
by ara
ed nte
oris eo
th
au ra
c
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
9. Renewing front wheel housing - partial renewal ▸ 05.00 43

Sharan 1996 ➤
RO: 50 74 55 12
10 Renewing front wheel housing - par‐

tial renewal 06.00 ▸
WARNING

10.1 Removing
Note
If the damage goes beyond the prescribed cut line, the longitudi‐
nal member complete with wheel housing must be renewed.
• Longitudinal member for upper wheel housing already re‐

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

Sharan 1996 ➤
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.

– Cut out wheel housing.
Preparing new part
– Transfer parting cut to new part.
10. Renewing front wheel housing - partial renewal 06.00 ▸ 45

Sharan 1996 ➤
10.1.2 Welding in
– Weld in wheel housing, SG plug weld seam.
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.

Sharan 1996 ➤
RO: 50 80 55 12
11 Renewing front part of longitudinal

member - partial renewal
WARNING

11.1 Removing
Note
AG. Volkswagen AG d
agen oes
lksw not
If the damage goes beyond the prescribed cut line,dtheby longitudi‐
Vo gu
ara
nal member complete with wheel housing must obe ris renewed.
e nte
h eo
aut ra
s c
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
11. Renewing front part of longitudinal member - partial renewal 47

Sharan 1996 ➤
– Separate longitudinal member and cover plate before engine

bracket or gearbox bracket.
– Parting cut when bumper support ids removed
11.1.2 Replacement parts

♦ Cover plate for longitudinal member
♦ End plate for longitudinal member
Preparing new parts
– Transfer parting cuts to new parts and cut out.
– Drill 10 mm ∅ holes for SG plug weld seam (cover plate and
end plate for longitudinal
swa
gmember).
en AG. V
olkswagen AG
does
k not
Vol gu
11.1.3 Welding in
ris
ed by ara
nte
utho eo
ra
a c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Secure longitudinal member to alignment bracket and butt

weld, SG continuous weld seam.
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.

Sharan 1996 ➤
– The weld points must run parallel with one another. It is es‐
sential that the prescribed distance is adhered to.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
– Weld in cover plate for longitudinal member, SG plug weld
an
d
itte
seam.
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
– Butt weld cutting point of cover plate, SG continuous weld
Co
op py
seam. t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
11. Renewing front part of longitudinal member - partial renewal 49

Sharan 1996 ➤
– Weld in end plate ▸ 05.00, SG plug weld seam.

– Weld in end plate 06.00 ▸, SG continuous seam.
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.

Sharan 1996 ➤
AG. Volkswagen AG d
agen
51 – Body - centre
oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
s c
RO: 51 03 55 00s
ce
e
nl
1 Renewing roof
pt
du
an
itte
y li
erm
ab
ility
ot p
WARNING
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
1.1 Removing
l purpos
Note
nform
mercia
at
Separate along with roof reinforcements.
om
ion
c
in t
or
his
e

at
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Renewing roof 51
Sharan 1996 ➤
– Roughly cut out roof.
– Remove remaining material. AG. Volkswagen AG d

agen oes
ksw
– Clean spot weld flange, from inside, to bright surface using ball by Vol not
gu
ara
milling tool. rise
d
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
♦ Roof with roof cross member
l purpos
1.1.3 Welding in
– Centralize roof with assembly holes for roof railing.
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 roof, RP spot weld seam.
– Weld in roof, RP spot weld seam.
52 Rep. Gr.51 - Body - centre

Sharan 1996 ➤
RO: 51 07 55 50
2 Renewing front roof cross member
WARNING

AG. Volkswagen AG d
agen
2.1 Removing
oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
2.1.1 Cutting locations 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.
2. Renewing front roof cross member 53

Sharan 1996 ➤
– Cut out roof cross member.


AG. Volkswagen AG d
♦ Roof cross member lksw
agen oes
not
Vo gu
by
2.1.3 Welding in d ara
ise nte
or eo
h
aut ra
– Adapt new part to fit and fix in position.
ss c
ce
e
nl
pt
du
an
itte
y li
– Weld in roof ⇒ page 52 .
erm
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.

Sharan 1996 ➤
RO: 51 08 55 00
3 Renewing roof reinforcement
WARNING

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
Safety notes ⇒ General Information;
oris Body Repairs, General Body
e nte
eo
Repairs ; Safety notes . aut
h
ra
ss c
3.1 Removing
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
The roof reinforcement can be renewed without removing the roof.
3. Renewing roof reinforcement 55

Sharan 1996 ➤
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
– Separate original joint. t. Cop py
rig
gh ht
– Remove remaining material. pyri by
Vo
co lksw
by
cted agen
Prote AG.
3.2 Installing
3.2.1 Preparing new part

Replacement part
♦ Roof reinforcement
♦ 1K assembly adhesive -D 190 MKD A3-

Sharan 1996 ➤
Note
If roof is renewed, drill 8 mm Ø holes in replacement part for SG

plug weld seam.
– Apply 1K assembly adhesive -D 190 MKD A3- to the required

areas of roof reinforcement (bead diameter approx. 8 mm)
AG. Volkswagen AG d
agen oes
olksw not
3.2.2 Welding in y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Renewing roof reinforcement 57

Sharan 1996 ➤
– Weld original joint, SG plug weld seam.
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.

Sharan 1996 ➤
RO: 51 09 55 50
4 Renewing rear roof cross member
WARNING
⇒ General Information; Body Repairs, GeneralAG.Body

VolkswRepairs
agen AG ;
agen does
Chapter 1 - Safety notes Volksw not
y gu
db ara
4.1 Removing tho
rise nte
eo
s au ra
c
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4. Renewing rear roof cross member 59

Sharan 1996 ➤
– Cut out roof cross member.

Note
The replacement part has no holes for securing the rear lid. The
holes must be produced in the roof cross member using workshop
equipment.
AG. Volkswagen AG d
agen oes
lksw not
♦ Roof cross member d by V o gu
ara
rise nte
4.1.3 Welding in
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte

y li
rm
ab
pe
ility
– Weld in roof ⇒ page 52 .

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.

Sharan 1996 ➤
RO: 51 27 55 12
5 Renewing outer side panel - partial

renewal
WARNING

5.1 Removing
Note
Keep the cutting of the replacement part in mind!
5.1.1 Cutting locations swage

es n
olk 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.
5. Renewing outer side panel - partial renewal 61

Sharan 1996 ➤ AG. Volkswagen AG d
Body Repairs - Edition 11.2004agen oes
olksw not
V gu
by ara
ed nte
– ris
Make parting cut belowthoC-pillar reinforcement according to eo
degree of damage. ss au ra
c
ce
le
– Position side member parting cuts according to degree of
un
pt
an
damage. d
itte
y li
erm
ab
– Cut out side panel.
ility
ot p
wit
is n
h re
ole,
5.1.2 Replacement part ▸ 05.00
spec
t to the co
♦ Side panel subpart
Preparing new part
rrectne
s
– Adapt side member to fit with vehicle stress free.
s o
cial p
f
– Check gaps and shut lines to door.
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
5.1.3 Replacement part 06.00 ▸
rig ht
py by
co Vo
by lksw
cted agen
♦ Side panel subpart Prote AG.
Preparing new part

– Check gaps and shut lines to door.
5.1.4 Welding in
– Place backing plate behind parting cuts.
– Weld parting cuts, SG stepped weld seam.
– Weld in side panel, RP spot weld seam.

Sharan 1996 ➤
RO: 51 27 55 24
6 Renewing outer side panel - partial

renewal
WARNING

6.1 Removing
Note
♦ Keep the cutting of the replacement part winagmind!

en AG. V
olkswagen AG
doe
ks s no
Vol t gu
♦ Make parting cut above wheel housing
ed
by with pneumatic jig-saw ara
-V.A.G 1523- . tho
ris nte
eo
au ra
♦ Renew C-pillar reinforcement
ss as well. c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
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
– Make parting cut on C-pillar according to degree of damage.

r
fo
en
ng
t.
yi Co
– Position side member parting cuts according to degree of Cop py
damage. ht. rig
rig ht
py by
o Vo
– Cut out side panel.
by c lksw
cted agen
Prote AG.


Sharan 1996 ➤
♦ C-pillar reinforcement
Preparing new part
– Spot weld rear cross panel reinforcement, RP spot weld seam.
6.1.3 Welding in
– Before welding in, check gaps to adjacent parts.
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
rrectnes

s o
cial p
f in
– Spot weld rear cross panel reinforcement from interior, RP

form
mer
spot weld seam.

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

Sharan 1996 ➤
RO: 51 29 55 50
7 Renewing inner side panel
WARNING

Chapter 1 - Safety notes G. Volkswagen nA AG do
wage es n
olks
7.1 Removing by
V ot g
ua
ed ran
oris tee
th or
au ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Locate parting cut on D-pillars according to extent of damage.

– Drill out original joint of C-pillar.

Sharan 1996 ➤
– Cut out inner side panel.


♦ Inner side panel
♦ Lower D-pillar connecting plate
♦ Rear connecting plate
Preparing new part
– Drill out C-pillar reinforcement.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
7.1.3 Welding in ed
ris nte
ho eo
aut ra
– Weld in inner side panel, RP spot weld seam. 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.
7. Renewing inner side panel 67

olkswagen AG
Sharan 1996 ➤ wage
n AG. V does
olks not
db
y V gu
ara
e nte
ris
ho eo
– Weld in inner side panel, SG
au continuous weld
t seam. ra
c
ss
– Check correctness of fit with attached parts.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Weld in D-pillar lower connecting plate, RP spot weld.

nform
ercia

m
at
om
– Weld in side panel ⇒ page 107 .
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.

Sharan 1996 ➤
RO: 51 37 55 12
8 Renewing A-pillar- partial renewal
WARNING
Welding, parting using spark generating machines/tools or tin‐

ning in foam treated areas creates gases which are hazardous
to health and environment. Therefore, refrain from using these
processes.
Use 2K - component filler material to smooth out irregularities.
Observe safetyolnotes!
ksw
age es n
ot g
V
d by ua
ran
is e
or tee
h
⇒ aut
General Information; Body Repairs, General Body
or
Repairs
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.
8. Renewing A-pillar- partial renewal 69

Sharan 1996 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
by
Note ised ara
nte
or eo
h
ut ra
The Sharan is foam treated below the front triangular window be‐
s a c
s
hind the A-pillar
ce
le
un
pt
an
d
itte
y li
8.1 Removing
erm
ab
ility
ot p
wit
is n
h re
ole,
Note
spec
t to the co
♦ Only use body saw -V.A.G 1523- or compressed air driven
hammer -V.A.G 1577- for parting cut in area of foam treatment!
♦ The upper parting cuts for the A-pillar subpart and inner A-
rrectne
pillar must be offset by 5 cm.
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
o
by c lksw
cted agen
Prote AG.
– Scrape out as much foam remains as possible before starting

grinding work.
– Drill out cover plate for triangular window and A-pillar.

Sharan 1996 ➤
– Cut out lower A-pillar.

– Cut out cover plate for triangular window.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
– Drill out A-pillar ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
♦ A and B-pillar subpart with side member.

m
at
om
♦ Inner A-pillar
ion
c
in t
or
♦ Door hinge his

ate
do
riv
♦ Outer panel (triangular window)

p
cum
for
en
g
♦ 2 packs of 2K foam, Part No. D 000 111 A2

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

Sharan 1996 ➤ agen
AG. Volkswagen AG d
oes
ksw
Body Repairs - Edition 11.2004 by
Vol not
gu
d ara
ise nte
or
Preparing new parts aut
h eo
ra
ss c
– Make holes in outer joint surface of A-pillar.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
a
– Transfer parting cut to new part and remove shaded area. Ob‐
iv
o
r
serve offset for upper parting cut to A-pillar subpart.

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.
– ▸ 05.00, transfer parting cut to new part and remove shaded

area.

Sharan 1996 ➤
– 06.00 ▸, transfer parting cut to new part and remove shaded

area.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Make holes in outer joint surface of new part.

– Spot weld A-pillar subpart to inner A-pillar.
nf
ercia
orm
m
atio
Note
om
n in
or c
thi
e
Lower A-pillar subpart will be welded in later.

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

Sharan 1996 ➤

– Weld in triangular window cover plate, SG plug weld seam.
AG. Volkswagen n AG do
wage es n
Volks ot g
by ua
ed ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Weld in lower A-pillar, RP spot 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
– Butt weld parting cuts, SG stepped weld seam.

o
m
f
en
ng
t.
yi
– Weld in inner A-pillar parting cuts, SG stepped weld seam.
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Weld remaining joint in, SG continuous seam.

– Adapt new door hinge to fit and fix in position.
– Check gaps and shut lines to other attached parts.
– Gaps/shut lines ⇒ page 15 .
– Remove wing.
– Tack weld door hinge, SG spot welds
– Check gaps/shut lines to bolt-on parts again.
– Remove wing.
– Weld in door hinge, SG continuous seam.

Sharan 1996 ➤
8.1.4 Foam insulation
WARNING
Before using foam read instructions for use.
– After painting, carry out cavity protection and allow approx. 10

minutes airing time.
– Mask off other openings in lower area.
– Pour contents of two bottles of component A into a third bottle.
– Pour contents of two bottles of component B into a third bottle.
– Pour contents of bottle with component A into bottle with com‐
ponent B.
– Inject foam into cavity through hole -A- in plenum chamber.
– Remove foam remains immediately with adhesive remover
D 002 000 10.
– After skin has formed (wait approx. 10 minutes) preserve cav‐
ity to close pores.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
75
Prote AG.
8. Renewing A-pillar- partial renewal
Sharan 1996 ➤
RO: 51 41 55 12
9 Renewing B-pillar- partial renewal
WARNING

lkswage es n
o ot g
⇒ General Information; Body Repairs, General Body Repairs d byV ; ua
ran
Chapter 1 - Safety notes o
ir se tee
th or
u
9.1 Removing
a ac
ss
ce
le
un
pt
an
d
itte
y li
Note
erm
ab
ility
ot p
wit
Remember replacement part when making rear side member
is n
h re
separating cut.
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.

Sharan 1996 ➤
– Position parting cut for B-pillar above inner reinforcement

plate.
– Locate side member parting cuts according to degree of dam‐
age.
– Cut out internal reinforcement as well. lkswage es n
o ot g
byV ua
– Remove remaining material. ir se
d ran
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
♦ A and B-pillar subpart with side member.
l purpos
♦ B-pillar reinforcement
nform
♦ Door hinge
mercia
Preparing new parts
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.

9. Renewing B-pillar- partial renewal 77

AG. Volkswagen AG d
agen oes
ksw not
Sharan 1996 ➤ by Vol
gu
ara
d
Body Repairsorise - Edition 11.2004 nte
eo
th
au ra
s c
9.1.3 Welding in
s
ce
e
nl
pt
du
an
– Adapt reinforcing to fit and weld in, RP spot weld seam.
itte
y li
erm
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
– Adapt B-pillar to fit with vehicle stress free.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Spot weld B-pillar, RP spot weld seam.

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

Sharan 1996 ➤

– Adapt new door hinge to fit and fix in position.
– Check gaps and shut lines to other attached parts.
– Gaps/shut lines ⇒ page 15 .
– Open front door.
– Tack weld door hinge, SG spot welds
– Check gaps/shut lines to bolt-on parts again.
– Open front door. agen
AG. Volkswagen AG d
oes
olksw not
V gu
– Weld in door hinge, SG continuous
ed by seam. ara
nte
ris
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
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
9. Renewing B-pillar- partial renewal 79

Sharan 1996 ➤
RO: 51 45 55 00
10 Renewing outer side member
WARNING

10.1 Removing
Note agen
AG. Volkswagen AG d
oes
olksw not
V gu
by ara
If the extent of damage permits, vertical parting cuts can be orismade.
ed
nte
h eo
aut ra
s c
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Locate parting cut according to degree of damage.

Sharan 1996 ➤
– Cut out side member. AG. Volkswagen AG d

agen oes
– Remove remaining material. 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
♦ Side member (subpart)
rrectne
Preparing new part
ss
o
cial p
f inform
10.1.3 Welding in
mer
atio
m

o
n
c
i
or
n thi
– Butt weld parting cuts, SG stepped weld seam.
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.
10. Renewing outer side member 81

Sharan 1996 ➤
RO: 51 47 55 62
11 Renewing inner side member - partial

renewal
WARNING

wage
11.1 Removing yV
olks es n
ot g
ua
d b ran
ir se tee
tho
u or
Note ss
a ac
ce
e
nl
pt
du
Associated procedures: inner side member can only be renewed
an
itte
y li
in conjunction with outer side member ⇒ page 80 .
erm
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.

Sharan 1996 ➤

– Cut out inner side member.

♦ Inner side member - parts designation: web plate for side
member
Preparing new part
– Transfer parting cut to new part and cut out.
11.1.3 Welding in wage

es n
olks ot g
– Weld in new part, RP spot weld seam. byV ua
d ran
ir se tee
o
– Butt weld parting cuts, SG stepped weld seam. auth or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
11. Renewing inner side member - partial renewal 83

Sharan 1996 ➤
RO: 51 73 55 62
12 Renewing floor panel - partial renew‐

al
WARNING

12.1 Removing
Note
The seat cross member may only be renewed complete.

G. Volkswagen AG d
gen Aplate
• Associated procedures: outer side member,
olks web
wa and in‐ oes
not
ner side member removed d byV gu
ar
e an
ris tee
utho 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
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
by
V gu Sharan 1996 ➤
d ara
e nte
horis Body Repairs - Edition
e o 11.2004
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.

– Cut out floor panel.

♦ Floor panel
Preparing new part
– Transfer separating cut to new part plus 10 mm for overlap.
Cut off shaded area.
12. Renewing floor panel - partial renewal 85

Sharan 1996 ➤
12.1.3 Welding in
– At parting cut, carry out offset overlap weld to both sides, stag‐
gered SG continuous seam.
– At side member, RP spot weld seam.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Sharan 1996 ➤
53 – Body - rear
RO: 53 09 55 00
1 Renewing rear lock carrier olksw

agen
AG. Volkswagen AG d
oes
not
V gu
d by ara
ise nte
r
WARNING ut
ho eo
ra
s a c
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
1.1 Removing
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.
1. Renewing rear lock carrier 87

Sharan 1996 ➤

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
♦ Lock carrier
h re
hole
spec
1.1.3 Welding in
es, in part or in w
t to the co
Preparing new part
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.
88 Rep. Gr.53 - Body - rear

Sharan 1996 ➤
RO: 53 10 55 62
2 Renewing tail light mounting - partial

renewal ▸ 05.00
WARNING
AG. Volkswagen AG d
agen oes
olksw not
Observe safety notes! ed by
V gu
ara
ris nte
ho eo
aut ra
s c
⇒ General Information; Body Repairs, General Body Repairs ; s
ce
le
un
pt
an
d
itte
y li
2.1 Removing
rm
ab
pe
ility
ot
wit
, is n
h re
Note
hole
spec
es, in part or in w
Offset parting cut of side panel and mounting plate by 5 cm.
t to the co
• Side panel already cut out.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Renewing tail light mounting - partial renewal ▸ 05.00 89

Sharan 1996 ➤


♦ Tail light mounting parts designation: Water drain plate.
Preparing new part
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
2.1.3 Welding in
t to the co
– Check installation position with fitted side panel and secure

new part.
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.

Sharan 1996 ➤
– Weld in tail light mounting, RP spot weld.

– Butt weld parting cut, SG continuous weld seam.
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.
2. Renewing tail light mounting - partial renewal ▸ 05.00 91

Sharan 1996 ➤
RO: 53 10 55 62
3 Renewing tail light mounting - partial

renewal 06.00 ▸
WARNING

Chapter 1 - Safety notes olkswage es n
o
yV t gu
db ara
3.1 Removing tho
rise nte
eo
au ra
c
ss
ce
e
nl
Note
pt
du
an
itte
y li
erm
ab
Offset parting cut of side panel and mounting plate by 5 cm.
ility
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.

Sharan 1996 ➤

AG. Volkswagen AG d
– Separate original joint. agen oes
olksw not
byV gu
ara
– Remove remaining material. rised
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
rrectne
♦ Tail light mounting parts designation: Water drain plate.
ss
Preparing new part
o
cial p
f in
form
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Butt weld parting cut, SG continuous weld seam.
Note
♦ The replacement part has no holes for securing the tail light
cluster. The holes must be produced on the mounting plate
using workshop equipment.
♦ The respective gap from tail light cluster to side panel can be
set by fitting washers to the threaded studs of the tail light
cluster.
– Gap 1 mm.
♦ Also note the correct fitting of the seal.
3. Renewing tail light mounting - partial renewal 06.00 ▸ 93

Sharan 1996 ➤
RO: 53 16 55 12
4 Renewing rear cross member - parti‐

al renewal
WARNING
G. Volkswagen
⇒ General Information; Body Repairs, General
wage Body Repairs ; does n
nA AG
olks
Chapter 1 - Safety notes db
y V ot g
ua
e ran
ris tee
4.1 Removing au
tho or
ac
ss
ce
le
un
pt
an
d

itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Place parting cut before both bumper brackets.

Sharan 1996 ➤
– Otherwise separate original joints.

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
♦ Cross panel
h re
hole
spec
Preparing new part
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
4.1.3 Welding in
um
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
4. Renewing rear cross member - partial renewal 95

Sharan 1996 ➤
– Butt weld parting cuts, SG continuous weld seam.

– Weld in lock carrier ⇒ page 88 .
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.

Sharan 1996 ➤
RO: 53 24 55 62
5 Renewing luggage compartment

floor, partial renewal
swage es n
WARNING byV
olk ot g
ua
d ran
ir se tee
o
Observe safety notes! auth or
ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
5.1 Removing
ot
wit
, is n
h re
hole
spec
es, in part or in w
Note
t to the co
Pay attention to concealed reinforcement -1-.
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.
5. Renewing luggage compartment floor, partial renewal 97

Sharan 1996 ➤
– Locate parting cut before one of the cross members according

to degree of damage.

♦ Floor panel
Preparing new part
– Transfer separating cut to new part plus 15 mm for overlap.
Cut off shaded area.
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
5.1.3 Welding in
y li
erm
ab
ility
ot p
– Adapt luggage compartment floor, with vehicle stress free, and

wit
, is n
check gaps/shut lines to attached parts. h re

hole
spec
– Weld in luggage compartment floor, RP spot weld seam.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Weld in luggage compartment floor, SG plug weld seam.

m
at
om
– Weld new part inside and outside SG continuous seam (stag‐

ion
c
gered and offset).

in t
or
his
ate
– Weld in rear cross member ⇒ page 95 .

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.

Sharan 1996 ➤
RO: 53 32 55 00
6 Renewing bumper bracket

n AG. Volkswagen AG age does
ksw not
y Vol gu
b
WARNING ris
ed
ara
nte
tho eo
au ra
Observe safety notes! ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
6.1 Removing
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.

6. Renewing bumper bracket 99

Sharan 1996 ➤

♦ Bracket for bumper lkswage es n
o ot g
byV ua
♦ Bumper mounting plate ir se
d ran
tee
tho
u or
Preparing new part ss a ac
ce
le

un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
6.1.3 Welding in
ss o
cial p
f in
– Fix new part using alignment bracket.
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.
– Weld in bracket, SG plug weld seam.
– Weld in mounting plate, RP plug weld seam.

Sharan 1996 ➤
RO: 53 36 55 50
7 Renewing rear cross panel
WARNING

AG. Volkswagen AG d
agen oes
olksw not
⇒ General Information; Body Repairs, General Body Repairs d by; V gu
ara
Chapter 1 - Safety notes horise nte
eo
aut ra
7.1 Removing ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
7.1.1 Cutting locations 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.
7. Renewing rear cross panel 101

Sharan 1996 ➤


♦ End plate for longitudinal member
♦ Longitudinal member sealing plate
7.1.3 Welding in
– Adapt new part and fix in position.
– Weld remaining joint, SG plug weld
agen
seam.
AG. Volkswagen AG d
o w es n
olks ot g
– Weld in lock carrier ⇒ page
d b 88 .
yV ua
ran
e
ris tee
tho or
au ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
RO: 53 48 55 62
8 Renewing rear longitudinal member -

partial renewal
WARNING

8.1 Includes: rear shock absorber mounting

and extension arm
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 parting cut before shock absorber mounting.

– Dimension A = 50 mm.
8. Renewing rear longitudinal member - partial renewal 103

Sharan 1996 ➤
– Remove remaining material of shock absorber mounting.
Note
If the extent of damage permits, the parting cut can also be moved
towards the rear, behind the extension arm.

♦ Rear longitudinal member with reinforcing and captive nuts
♦ D-pillar extension arm
♦ Cross panel
Preparing new part
– Drill out original joint of shock absorber to longitudinal member
part which is not being used.
8.1.3 Welding in
– Secure section of longitudinal member on alignment bracket.
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
– Butt weld longitudinal member, SG continuous seam.

erm
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.

AG. Volkswagen AG d
agen oes
olksw not
V
d by gu
ara Sharan 1996 ➤
ise nte
thor eo Body Repairs - Edition 11.2004
au ra
ss c
– Weld in new part, SG plug weld seam.
ce
e
nl
pt
du
an
– Secure extension arm and rear cross panel.
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Cool electrode often due to the thicker material.
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.
8. Renewing rear longitudinal member - partial renewal 105

Sharan 1996 ➤
RO: 53 55 55 00
9 Renewing side panel - partial renewal

▸ 05.00
WARNING

9.1 Removing lksw

agen
AG. Volkswagen AG d
oes
not
o
byV gu
ara
ed
ris nte
o eo
Note aut
h
ra
ss c
ce
e
Renew C-pillar reinforcement as well.

nl
pt
du
an
itte
y li
erm
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.

Sharan 1996 ➤
– Separate original joint to insert -1-.

– Make parting cut on C and D-pillar according to degree of
damage.
– Make lower parting cut above side member, remember re‐
placement part offset.
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
♦ Insert
wit
, is n
h re
hole
spec
Preparing new parts
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
9.1.3 Welding in
o
m
f
en
ng
t.
yi Co
op
C py
t. rig
gh ht
yri by
– Adapt new part to fit and fix in position. cop Vo
by lksw
cted agen
Prote AG.
– Check gaps and shut lines to door, rear lid and tail lights.
9. Renewing side panel - partial renewal ▸ 05.00 107

Sharan 1996 ➤

– Weld in side panel, 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
e
nl
pt
du
an
itte
y li
erm
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
– Spot weld rear cross panel reinforcement from interior, RP Cop py
spot weld seam. ht. rig
rig ht
py by
o Vo
– Weld in insert, SG plug weld seam.
by c lksw
cted agen
Prote AG.

Sharan 1996 ➤
AG. Volkswagen AG d
lksw
agen oes
not Body Repairs - Edition 11.2004
Vo gu
d by ara
ise nte
or eo
th
RO: 53 55 55 00 s au ra
c
s
10 Renewing side panel - partial renewal
ce
e
nl
pt
du
06.00 ▸
an
itte
y li
erm
ab
ility
ot p
WARNING
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
10.1 Removing
l purpos
nform
ercia
Note
m
at
om
io
Renew C-pillar reinforcement as well.
n
c
in t
or
his
ate
do
riv

p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
10. Renewing side panel - partial renewal 06.00 ▸ 109

Sharan 1996 ➤
– Make parting cut on C and D-pillar according to degree of

damage.
– Make lower parting cut above side member, remember re‐
placement part offset.

♦ Insert
Preparing new parts
10.1.3 Welding in
– Place backing plate behind
olks
wparting
age cuts. es n
ot g
V
by ua
– Adapt new part to rfit
isedand fix in position. ran
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– Check gaps and
ss
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t to the co
– Weld in side panel, SG plug weld seam.

rrectness of i
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Sharan 1996 ➤

– Spot weld rear cross panel reinforcement from interior, RP
spot weld seam.
AG. Volkswagen AG d
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10. Renewing side panel - partial renewal 06.00 ▸ 111

Sharan 1996 ➤
RO: 53 68 55 50
11 Renewing rear wheel housing
WARNING

11.1 Removing
11.1.1 Cutting locations AG. Volkswagen AG d

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– Cut out wheel housing above the web plate

– Separate along with seat belt mounting.

Sharan 1996 ➤

♦ Wheel housing
♦ Seat belt mounting bracket
Preparing new part
11.1.3 Welding in
– Adapt new part to fit and fix innposition.
wage
AG. Volkswagen AG d
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– Check correctnessedof
by fit with attached parts. ara
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– Weld in wheel
au housing, RP spot weld seam.
th ra
ss c
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nl
pt
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ility
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– Weld parting cut, SG continuous weld seam.

es, in part or in w
t to the co
– Spot weld seat belt mounting bracket, RP spot weld seam.

rrectness of i
l purpos
nf
ercia
orm
m
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om
n in
or c
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11. Renewing rear wheel housing 113

Sharan 1996 ➤

– Additionally weld, SG continuous seam.
– Weld in inner side panel ⇒ page 67 .
AG. Volkswagen AG d
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for
en
ng
t.
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Cop py
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Sharan 1996 ➤
RO: 53 82 55 50
12 Renewing cross member
WARNING n AG. Volkswagen AG do

lkswage es n
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Observe safety notes! ir se tee
tho
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12.1 Removing
ility
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– Cut through lower link plates.

– Lower section of link plate remains on vehicle.
12. Renewing cross member 115

lkswage es n
o ot g
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d ran
ir se
Sharan 1996 ➤ tho tee
or
u
Body Repairs - Editionss11.2004
a ac
ce
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nl
pt
du
an
itte
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erm
ab
♦ Cross member for spare wheel.
ility
ot p
wit
, is n
Preparing new part
h re
hole
spec
– Transfer parting cut to new part and cut out.
es, in part or in w
t to the co
– Make holes in outer joint surface of new part.
rrectness of i
l purpos
nf
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orm
m
atio
om
n in
or c
12.1.3 Welding in
thi
te
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m
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en
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Dimension a = 225 mm
– Weld in cross member, RP spot weld seam.
– Butt weld parting cuts, SG continuous weld seam.

– Weld in cross member, SG plug weld seam.

SM 54

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SM 54

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Service

Service Department. Technical Information

All rights reserved.

Copyright © 2010 Volkswagen AG, Wolfsburg SHA53201020

3.2 Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1 Renewing engine bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

11 Renewing inner side member - partial renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

1.2 Identification plate

1.3 Vehicle data sticker

1. Vehicle identification data 1

2.1 Body - front

Distance between front longitudinal members

2 Rep. Gr.00 - Technical data

Diagonal distance between bonnet hinge mounting and wheel

4 Rep. Gr.00 - Technical data

Front door aperture

6 Rep. Gr.00 - Technical data

Rear door aperture

8 Rep. Gr.00 - Technical data

Distance between C-pillars

2.3 Body - rear

Distance flange of cross panel - roof flange, centre of vehicle

Distance between inserts

10 Rep. Gr.00 - Technical data

Distance between rear longitudinal members

12 Rep. Gr.00 - Technical data

3 Body panel gaps/shut lines

3.1 Body - front

14 Rep. Gr.00 - Technical data

3.2 Body - centre

3. Body panel gaps/shut lines 15

3.3 Body - rear

16 Rep. Gr.00 - Technical data

28 - MZ 200 and TV 400

straightening bracket mount‐

Overview - front alignment bracket positions

18 Rep. Gr.00 - Technical data

2 - Longitudinal member end

Overview - middle alignment bracket positions

20 Rep. Gr.00 - Technical data

Overview - rear alignment bracket positions

22 Rep. Gr.00 - Technical data

24 - Rear axle mounting

25 - Distance piece, left and

26 - Rear axle mounting

5 Galvanized body parts

1 - One side galvanized

24 Rep. Gr.00 - Technical data

– Separate engine bracket from wheel housing with a grinder.

1. Renewing engine bracket 25

Preparing new part

– Drill 7 mm ∅ holes for SG plug weld seam.

– Secure vehicle and new part to alignment bracket.

– SG plug weld remainder of joint.

26 Rep. Gr.50 - Body - front

2 Renewing gearbox bracket ▸ 05.00

Observe safety notes!

⇒ General Information; Body Repairs, General Body Repairs ;

2.1.1 Cutting locations

2. Renewing gearbox bracket ▸ 05.00 27

– Drill out SG plug weld seams on longitudinal member.

2.1.2 Replacement part

– SG plug weld remainder of joint.