D4B804A9DB3 Body Repairs

Service
Body Repairs
Golf 2013 ➤
Edition 02.2015
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00 - General, Technical Data
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50 - Body Front
51 - Body Center, Chassis, Roof
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53 - Body Rear
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2015 Volkswagen AG, Wolfsburg D4B804A9DB3

Golf 2013 ➤
Body Repairs - Edition 02.2015
Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Vehicle Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Vehicle Identification Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Type Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Vehicle Data Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 Molded Foam Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5 Galvanized Body Parts and High-Strength/Highest Strength Hot Formed Body Panels . . 7
5.1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.2 2-Door Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.3 4-Door Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6 Laser Welds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
AG. Volkswagen
7 Gap Dimensions .lk.s.w.ag. e.n. . . . . . . . . . . A. G. d. o.e.s .n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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7.1 Body Front .ed. b.y.V. . . . . . . . . . . . . . . . . . . . . . . . .g.ua.ra. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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7.2 Body, Centertho . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .te.e.o . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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7.3 Body, Rear
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a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ac. . . . . . . . . . . . . . . . . . . . . . . . . . 18
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8 Body Panel Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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8.1 Body Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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8.2 Body, Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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8.3 Body, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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8.4 Front Floor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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8.5 Center Floor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
urposes, in part or in wh
8.6 Rear Floor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

t to the co 30
9 Alignment Bracket Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
9.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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10 Portal Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
s
50 - Body Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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1 Subframe Mounting Bracket, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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1.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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1.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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2 Front Bumper Bracket, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

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2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
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2.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
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2.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
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3 Upper Wheel Housing Longitudinal Member, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . 41
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3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
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3.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4 Front Wheel Housing, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5 Subframe Mount Thread, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.1 Contents of Thread Repair Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.2 Threads, Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6 Front Longitudinal Member, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Contents i
Golf 2013 ➤
6.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7 Front Longitudinal Member, Replacing, Left Partial Section . . . . . . . . . . . . . . . . . . . . . . . . 62
7.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
8 Front Longitudinal Member, Replacing, Rightn Partial . VolksSection
wagen AG . . . . . . . . . . . . . . . . . . . . . . 67
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8.1 Tools . . . . . . . . . . . . . . . . . . . . . . . V.o.lk.sw. a. . . . . . . . . . . . . . . . .oe. s.n.ot. g. . . . . . . . . . . . . . . . . . 68
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8.2 Removing . . . . . . . . . . . . . . . .ise.d. . . . . . . . . . . . . . . . . . . . . . . . . . . . .ar.an.t . . . . . . . . . . . . . .
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8.3 Installing . . . . . . . . . . . . . .au.th. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .e o. r .a . . . . . . . . . . .
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9 Special Tools . . . . . . . . .s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
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51 - Body Center, Chassis, Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

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1 Roof Replacing- Vehicles without a Panorama-Sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . 73
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1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
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1.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
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1.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
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2 Roof, Replacing, Vehicles with Panorama Sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
rrectne
2.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
s
3 A-Pillar, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
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3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
f inform
3.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
mer
3.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
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4 A-Pillar Reinforcement, Replacing Partial Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
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4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

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4.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
pr
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4.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

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5 B-Pillar, 4-Door Vehicle, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
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5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
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copy Vo
lksw
5.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
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5.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
6 B-Pillar Reinforcement, Replacing, 4-Door (Partial Section) . . . . . . . . . . . . . . . . . . . . . . . . 122
6.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
6.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
6.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
7 Outer Sill Panel, Replacing, 4-Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
7.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
7.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
7.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
8 Outer Sill Panel, Replacing, 2-Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
8.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
8.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
8.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
9 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
53 - Body Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

1 Rear Cross Panel, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
1.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
1.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
2 Corner Reinforcement, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
ii Contents
Golf 2013 ➤
2.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

2.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
3 Tail Lamp Mount, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
3.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
3.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
4 End Crossmember, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
4.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
4.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
5 Luggage Compartment Floor, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
5.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
5.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
6 Luggage Compartment Floor, Replacing, with Hybrid Drive . . . . . . . . . . . . . . . . . . . . . . . . 181
6.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
6.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
6.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
7 Luggage Compartment Floor, Replacing, Hybrid Vehicles . . . . . . . . . . . . . . . . . . . . . . . . 188
7.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a.ge. n.A.G.. .V.ol.ks.w.a.g.en. A. G. d. o. . . . . . . . . . . . . . . . . . . . . 189
sw es
7.2 Removing . . . . . . . . . . . . . . . . . . . b. y.V.ol.k . . . . . . . . . . . . . . . . . . . . .no. t .gu. a. . . . . . . . . . . . . . . 190
d r
7.3 Installing . . . . . . . . . . . . . . . . . o.ri.se. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a.nt.ee. . . . . . . . . . . . 191
h
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8 Rear Longitudinal Member, sReplacing, sa Partial Section . . . . . . . . . . . . . . . . . .r a.c . . . . . . . . . 195
8.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
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8.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
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8.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
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9 Side Panel, Replacing, 4-Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
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9.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
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9.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
spec
es, in part or in w
9.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
t to the co
10 Side Panel, Replacing, 2-Door Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
10.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
rrectness of i
10.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
10.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
l purpos
11 Outer Wheel Housing Liner, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

nf
11.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

ercia
or
11.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

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11.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

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12 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

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13 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

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Contents iii
Golf 2013 ➤
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iv Contents
Golf 2013 ➤
00 – General, Technical Data

1 General Information
(Edition 02.2015)
This repair manual only describes selected labor operations. If
labor operations are not described, proceed as follows: separate
the original joint and recreate it with the replacement part. Repairs
using methods that differ from the original manufacturing process
are described.
If sub-parts are delivered, fit them and butt weld them using a gas-
shielded arc continuous weld seam.
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1. General Information 1
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Golf 2013 ➤ auth or
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Body Repairs - Edition 02.2015 ss
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2 Vehicle Data
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⇒ “2.1 Vehicle Identification Number”, page 2
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⇒ “2.2 Type Plate”, page 3
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⇒ “2.3 Vehicle Data Label”, page 3
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2.1 Vehicle Identification Number
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The VIN -1- is in the direction of travel under the windshield on

the left side.
Note
♦ The VIN is stamped on three additional positions on the vehi‐

cle.
♦ If the components must be replaced due to damage, service
should be documented according to market requirements.
2 Rep. Gr.00 - General, Technical Data

Golf 2013 ➤
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2.2 Type Plate

rrectne
The type plate is located on the door post on the driver side B-
pillar. Vehicles for certain export countries do not have a type
s
plate.
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2.3 Vehicle Data Label

form
mer
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The vehicle data label is located in the luggage compartment

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2. Vehicle Data 3
Golf 2013 ➤
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3 Safety Precautions lks es n
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Before starting any separating work, repairs or bulge correc‐
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Notes, Body Collision Repair and Body Repair Manuals. Refer
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to ⇒ General Information; Body Repairs, Body Collision Repair
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Golf 2013 ➤
4 Molded Foam Parts

Various hollow body areas are equipped with molded foam parts
in this vehicle.
The transfer of driving noises into the passenger compartment
are reduced by molded foam parts.
Exact positions of molded foam parts are depicted at the begin‐
ning of the respective repair descriptions.
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Exact positions of molded foam parts are depicted at the begin‐

ning of the respective repair descriptions.
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Note
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Replacement parts made of foam will react and foam only when
at
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the temperature is approximately 180 °C. For this reason, use

p
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Butyl Sealing Cord - AKL 450 005 05- or 2K Filler Foam - D 506
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KD1 A3- for positioning the molded foam parts when performing
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Do the following when performing a repair: cted agen
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4. Molded Foam Parts 5

Golf 2013 ➤
– Remove excess foam from vehicle.

– Apply corrosion protection.
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Before performing these work steps, the sheet metal otoris be re‐
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placed must be prepared for installation, for example,
aut by cutting,
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Replacing Molded Foam Part
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Either reuse the molded foam part or cut it from the universal
erm
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Partition - 000 864 663- .
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Secure the molded foam part to the body using the Butyl Sealing
h re
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Cord - AKL 450 005 05- .
spec
es, in part or in w
Then apply either the Butyl Sealing Cord - AKL 450 005 05- or
t to the co
the 2K Filler Foam - D 506 KD1 A3- to the molded foam part.
Secure new part by gently pressing on it around the molded foam
rrectness of i
part until it makes contact and then weld it.
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The foam hardens within 25 minutes.

Do not perform any gas-shielded welding 15 mm next to the mol‐
nform
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ded foam part.

m
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After painting vehicle, seal cavities in the area of the repair.
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Golf 2013 ➤
5 Galvanized Body Parts and High-

Strength/Highest Strength Hot
Formed Body Panels
⇒ “5.1 Assembly”, page 7 agen
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⇒ “5.2 2-Door Vehicle”, page 9 ed by gu
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⇒ “5.3 4-Door Vehicle”, page 11 aut
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Note
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All repairs must be performed according to the manufacturer
hole
spec
specifications in the Repair Manual. High-strength and hot-
es, in part or in w
formed steel can be only be repaired with inverter technology for
t to the co
optimum passenger safety after the repair is completed. Body
panels, made from hardened steel, are used in areas where there
are extreme loads. These body panels, which are light weight,
rrectness of i
have a much higher strength than conventional high-strength
body panels.
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General information applies to all work on higher-strength body
nform
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panels. Refer to ⇒ General Information; Body Repairs, Body Col‐

lision Repair .
m
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Vehicle construction is predominantly manufactured from galvan‐
c
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The steel panels, which are made of high strength to hot formed
p
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steel, are shown in color in the following illustrations (see Table).

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5. Galvanized Body Parts and High-Strength/Highest Strength Hot Formed Body Panels 7
Golf 2013 ➤
AG. Volkswagen AG d
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Color Type of steel Tensile strength in MPa
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1 Gray Soft < 350
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2 Yellow High-strength 300 - 590
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3 Magenta Modern high-strength 500 - 980
4 Blue Ultra-high strength 980 - 1150
5 Red Ultra high-strength hot- greater than 1400
formed

AG. Volkswagen AG d Golf 2013 ➤
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Volksw
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5.2 2-Door Vehicle
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To illustrate the body more clearly, the outer side panel and the
roof are not shown in the illustration These body parts are made
out of »standard« body steel.
AG. Volkswagen AG d
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Golf 2013 ➤ rise
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Body Repairs - Edition
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Golf 2013 ➤
5.3 4-Door Vehicle
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Golf 2013 ➤
Body Repairs - Edition 02.2015 agen
AG. Volkswagen AG d
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Golf 2013 ➤
Body
n AG. VolkswaRepairs
gen AG - Edition 02.2015
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6 Laser Welds ris nte
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On this vehicle, roof and body are partially welded by laser.
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In laser welding, a high energy light beam is directed onto the
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weld points via optical lenses or fiber optics.
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During the welding process, the upper plate is melted through and
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the lower plate is partially melted, thereby forming a weld without
h re
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using any additional materials.
spec
es, in part or in w
During repairs (except roof repairs), laser weld seams are re‐
t to the co
placed by gas-shielded arc continuous weld seams or straight-
line spot weld seam.
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6. Laser Welds 13
Golf 2013 ➤
7 Gap Dimensions
Note
♦ Use the Gauge - Gap Adjustment - 3371- to adjust or check.

♦ Panel gaps are always indicated in mm.
7.1 Body Front
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Golf 2013 ➤
Dimension -a- = 2.5 mm ± 0.5 mm

Dimension -b- = 2.7 mm ± 0.5 mm
Dimension -c- = 0.6 mm ± 0.5 mm.
Dimension -d- = 3.5 mm ± 0.5 mm
Dimension -e- = 5.0 mm ± 0.5 mm.
Dimension -f- = 4.5 mm ± 0.5 mm
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Prote AG.

Dimension -c- = 5.4 mm ± 0.8 mm.
7. Gap Dimensions 15
Golf 2013 ➤
AG. Volkswagen AG d
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d by ara
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Dimension -a- = 3.5 mm t±ho0.5 mm
r eo
au ra
s c
Dimension -b- = 0.0 mm
s - 1.0 mm
ce
e
nl
pt
du
Dimension -c- = 0.0 mm ± 1.0 mm

an
itte
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ility
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Dimension -e- = 0.0 mm ± 1.0 mm

wit
, is n
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spec
es, in part or in w
Dimension -g- = 5.5 mm ± 0.8 mm

t to the co
Dimension -h- = 5.4 mm ± 0.8 mm

rrectness of i
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nf
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16
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Rep. Gr.00 - General, Technical Data Prote
cted AG.
agen
lkswage es n Golf 2013 ➤
o ot g
byV ua Body Repairs - Edition 02.2015
d ran
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nl
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nf
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Prote AG.
7. Gap Dimensions 17
Golf 2013 ➤
Dimension -a- = 1.8 mm

Dimension -b- = 0.2 mm
Dimension -c- = 4.9 mm
Dimension -d- = 4.6 mm
Dimension -e- = 0.0 mm
Dimension -f- = 0.6 mm
7.3 Body, Rear
lkswage es n
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Cop py
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Dimension -a- = 4.0 mm ±0.5 mm

Dimension -c- = - 1.2 mm ± 0.8 mm
Dimension -e- = 1.4 mm ± 0.8 mm

Golf 2013 ➤
8 Body Panel Dimensions
Note
♦ The body dimensions serve only for inspection. The Alignment

Bracket Set is standard.
♦ Bolts, plugs, trim and attachments must be removed before
the measuring procedure.
♦ Use the Telescoping Gauge - 41.5-92.5cm - VAS 5159- or the
Telescoping Gauge - 92-260cm - VAS 5160- to determine the
body dimensions.
Volkswagen AG
♦ Ensure measuring points are always the same length to avoid
swa
gen AG
.
does
inaccuracy when measuring. by
Vol
k not
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th
8.1 Body Front ss
au ra
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nl
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c
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8. Body Panel Dimensions 19

AG. Volkswagen AG d
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Golf 2013 ➤ aut
h
ra
s c
Body Repairs - Edition 02.2015 s
ce
e
nl
pt
du
an
Dimension -a- = 975 mm ± 2.0 mm
itte
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Dimension -b- = 1125 mm ± 2.0 mm
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Dimension -c- = 1310 mm ± 2.0 mm
h re
hole
spec
Dimension -d- = 1400 mm ± 2.0 mm
es, in part or in w
t to the co
8.2 Body, Center
rrectness of i
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nf
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Prote AG.

Golf 2013 ➤

8.2.1 2-Door Vehicle
AG. Volkswagen AG d
agen oes
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Prote AG.
Note
This dimension is the same in 2- and 4-door vehicles.

Golf 2013 ➤
AG. Volkswagen AG d
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Prote AG.

Golf 2013 ➤
AG. Volkswagen AG d
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Prote AG.

Golf 2013 ➤

8.2.2 4-Door Vehicle lksw

agen
AG. Volkswagen AG d
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not
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Prote AG.


Golf 2013 ➤
lkswage es n
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for
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Cop py
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Vo
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Prote AG.


Golf 2013 ➤
lkswage es n
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d ran
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a ac
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nl
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Vo
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Prote AG.

Golf 2013 ➤

8.3 Body, Rear
AG. Volkswagen AG d
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Prote AG.

Golf 2013 ➤

8.4 Front Floor Assembly
lkswage es n
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Vo
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Prote AG.

Golf 2013 ➤
Dimension -a- = 965 ± 2.0 mm

Dimension -b- = 610 ± 2.0 mm
Dimension -c- = 1030 ± 2.0 mm
Dimension -d- = 875 ± 2.0 mm
Dimension -e- = 680 ± 2.0 mm
Dimension -f- = 400 ± 2.0 mm
8.5 Center Floor Assembly
AG. Volkswagen AG d
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or eo
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Cop py
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Prote AG.

Golf 2013 ➤
Dimension -a- = 1490mm ± 2.0 mm
8.6 Rear Floor Assembly
AG. Volkswagen AG d
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nl
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Dimension -a- = 1325 ± 2.0 mm

wit
, is n
h re
Dimension -b- = 1000 ± 2.0 mm.

hole
spec
Dimension -c- = 1090 ± 2.0 mm

es, in part or in w
t to the co
Dimension -d- = 990 ± 2.0 mm

Dimension -f- = 270 ± 2.0 mm
rrectness of i
l purpos
nform
mercia
at
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ion
c
in t
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do
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for
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t.
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Cop py
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Vo
co lksw
by
30
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Prote AG.
Rep. Gr.00 - General, Technical Data
Golf 2013 ➤
9 Alignment Bracket Set
Note
Use a Alignment Bracket Set or Measuring and Alignment System

approved by Volkswagen AG to perform any aligning work.
9.1 Overview
Special tools and workshop equipment required
♦ Measuring And Alignment System - VAS 6526- or
♦ Measuring And Alignment System - VAS 6527- or
♦ Measuring And Alignment System w/Wall System - VAS 6528-
or
♦ Straightening Bracket Set - Audi A3 - VAS 6789-
Note
Refer to assembly plan supplied with alignment bracket set for

detailed information on the assembly.
AG. Volkswagen AG d
agen oes
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d by ara
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or eo
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aut ra
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tion in
r
te o
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Prote AG.
9. Alignment Bracket Set 31

Golf 2013 ➤
10 Portal Gauge lksw

agen
AG. Volkswagen AG d
oes
not
Vo gu
y
Special tools and workshop equipmentrise required
d b ara
nte
tho eo
♦ Portal Gauge - VAS 5007- s a u ra
c
s
ce
le
un
pt
an
d
itte
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cial p
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mer
atio
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c
i
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t.
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Cop py
t. rig
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Vo
co lksw
by
cted agen
Prote AG.

Golf 2013 ➤
50 – Body Front
RO: 50 43 55 60
1 Subframe Mounting Bracket, Remov‐

ing and Installing
⇒ “1.1 Tools”, page 34
⇒ “1.2 Removing”, page 34
⇒ “1.3 Installing”, page 35
WARNING
Follow all safety precautions. Refer to ⇒ General Information;

Body Repairs, Body Collision Repair
1 - Subframe Retaining Brack‐

et
2 - Upper Corner Reinforce‐
ment
3 - Lower Corner Reinforce‐
ment
4 - Steering End Panel
AG. Volkswagen AG d
agen oes
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d by ara
ise nte
or eo
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d
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es, in part or in w
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l purpos
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mercia
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tion in
r
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s
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t.
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Cop py
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Vo
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Prote AG.
1. Subframe Mounting Bracket, Removing and Installing 33

Golf 2013 ➤ agen
AG. Volkswagen AG d
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by
V 02.2015
ol not
gu
ara
ed nte
oris e
th or
au ac
ss
Note
ce
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nl
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du
an
itte
In the example, replacement of retaining bracket for subframe is
y li
erm
ab
described for left front retaining bracket on this vehicle. Work pro‐
ility
ot p
cedure must be transferred to the other 3 retaining brackets
wit
, is n
accordingly as necessary.
h re
hole
spec
1.1 Tools
es, in part or in w
t to the co
Note
rrectness of i
l purpos
Due to the different types of steel and material strength, use only
welding equipment approved by Volkswagen AG to perform any
service work.
nform
mercia
at
1.2 Removing
om
ion
c
in t
or
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ate
do
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t.
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Vo
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Prote AG.
– Separate the original joint.
34 Rep. Gr.50 - Body Front

Golf 2013 ➤
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
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aut ra
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ce
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nl
pt
du
an
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– Remove residual material.

ility
ot p
wit
1.3 Installing
, is n
h re
hole
spec
⇒ “1.3.1 Preparing New Parts”, page 35

es, in part or in w
t to the co
⇒ “1.3.2 Welding”, page 36

rrectness of i
Note
l purpos
When using different types of steel and materials of different

strengths, one of the inverters listed under Tools are required to
nform
ercia
perform repair work correctly. Refer to ⇒ “1.1 Tools”, page 34 .

m
at
om
ion
c
1.3.1 Preparing New Parts

in t
or
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ate
do
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Replacement Part
p
cum
for
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♦ Front Subframe Retaining Bracket

ng
t.
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♦ Upper corner reinforcement t. C rig
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♦ Lower corner reinforcement
o Vo
by c lksw
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Prote AG.
♦ Steering end panel
1. Subframe Mounting Bracket, Removing and Installing 35

Golf 2013 ➤
Preparing New Parts

– Drill 8 mm holes for a gas shielded arc plug weld seam.
1.3.2 Welding
– Fit new part to vehicle standing on Straightening Bracket Set
and secure.
AG. Volkswagen AG d
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spec
– Weld in the new part, Straight-line spot weld seam and gas-
es, in part or in w
t to the co
shielded arc plug weld seam.

rrectness of i
l purpos
nform
mercia
at
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ion
c
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do
priv
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for
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ng
t.
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Cop py
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36
cop Vo
by lksw
Rep. Gr.50 - Body Front Prote
cted AG.
agen
AG. Volkswagen AG d
agen oes
olksw not
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ara
rised
Golf 2013nte ➤
o eo
aut
h
Body Repairs - Edition 02.2015 ra
ss c
ce
e
nl
pt
du
an
itte
RO: 50 65 55 00
y li
erm
ab
2 Front Bumper Bracket, Replacing
ility
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WARNING
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nf
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m
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or c
1 - Bumper Bracket
thi
te
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t.
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by lksw
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Prote AG.
2. Front Bumper Bracket, Replacing 37

Golf 2013 ➤
2.1 Tools
Note
♦ Due to the different types of steel and material strength, use

only welding equipment approved by Volkswagen AG to per‐
form any service work.
♦ For a list of welding equipment and body tools approved by
Volkswagen AG.
2.2 Removing
AG. Volkswagen AG d
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es, in part or in w
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nf
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Cop py
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rig ht
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Prote AG.

Golf 2013 ➤
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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ce
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nl
pt
du
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erm
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ility
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es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
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ion
c
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do
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for
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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.
2.3 Installing
Note

2.3.1 Welding
Replacement Part
♦ Front bumper bracket
and secure.
2. Front Bumper Bracket, Replacing 39

Golf 2013 ➤
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
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
– Weld the bumper bracket, gas-shielded arc plug weld seam.

in t
or
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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.

Golf 2013 ➤
RO: 50 72 55 50
3 Upper Wheel Housing Longitudinal

Member, Replacing
WARNING

1 - Upper Wheel Housing Lon‐

gitudinal Member
2 - Bonded Area
3 - Laser Seam
4 - Separating Cut
Note
Dimension -a- = 50 mm behind the

laser seam
AG. Volkswagen AG d
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d by ara
ise nte
or eo
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aut ra
ss c
ce
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nl
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du
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ility
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es, in part or in w
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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.
3. Upper Wheel Housing Longitudinal Member, Replacing 41

Golf 2013 ➤
3.1 Tools
Note

Volkswagen AG.
3.2 Removing
AG. Volkswagen AG d
agen oes
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tho eo
au ra
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nl
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du
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itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
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atio
om
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or c
thi
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sd
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Cop py
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– Separate the original joint. gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2013 ➤
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
y li
erm
ab
ility
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wit
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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.
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Cop py
t. rig
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pyri by
Vo
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lksw
cted agen
Prote AG.
– Completely remove any remaining adhesive.
3.3 Installing
Note


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

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
Golf 2013ris ➤
ed
nte
o eo
BodyauRepairs
th - Edition 02.2015 ra
ss c
ce
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un
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an
d
itte
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erm
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ility
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wit
is n
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ole,
spec
t to the co
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.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Preparing New Parts

– Transfer separating cuts onto new part and cut to shape.
– Drill holes for gas-shielded arc plug weld seam.
3.3.2 Welding
and secure.
– Check fit with attachments.

Golf 2013 ➤
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es, in part or in w
– Weld the new part, straight-line spot weld seam, gas-shielded

t to the co
arc plug weld seam.

– Apply the 2K Body Adhesive - D 180 KD3 A2- in the area
rrectness of i
where adhesive was applied during production.

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

Golf 2013 ➤
RO: 50 75 55 50
4 Front Wheel Housing, Replacing

⇒ “4.3 Installing”, page 48 n AG. Volkswagen AG do
lkswage es n
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WARNING tho tee
or
au ac
ss
ce
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un
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an
d
itte
y li
rm
ab
pe
ility
ot
• Longitudinal member for upper wheel housing already re‐
wit
, is n
moved. Refer to
h re
hole
⇒ “3 Upper Wheel Housing Longitudinal Member, Replacing”,
spec
page 41
es, in part or in w
t to the co
1 - Suspension Strut Tower
Mount
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2013 ➤
4.1 Tools
Note
♦ Due to the different types of steel and material strength, usegen AG. Volkswagen AG d
only welding equipment approved by Volkswagen AGVtoolksper‐
wa oes
not
form any service work. ed by gu
ara
is nte
or
♦ For a list of welding equipment and body tools
au approved by
th eo
ra
Volkswagen AG. ss c
ce
le
un
pt
an
d
4.2 Removing
itte
y li
erm
ab
ility
ot p
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is n
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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
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pr
cum
r
fo
en
ng
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.
– Remove the wheel housing original joint leading to the longi‐

tudinal member cover place the to the bulk head.
Partial replacement is possible with the separating cut -1-.
4. Front Wheel Housing, Replacing 47

lkswage es n
o ot g
byV ua
Golf 2013 ➤ ir se
d ran
tee
o
auth or
ac
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un
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an
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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
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
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4.3 Installing
Note

4.3.1 Welding
Replacement Part
♦ Wheel Housing
♦ Brace
– Fit and secure the new part using the Alignment Bracket Set
on the vehicle.

AG. Volkswagen AG d
agen oes
ksw not
by Vol
gu
ara
Golf 2013 ➤
d
rise Body Repairs - Edition
nte 02.2015
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
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Weld in the new part, Straight-line spot weld seam and gas-
4. Front Wheel Housing, Replacing 49

Golf 2013 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
RO: 50 79 41 50 ised
nte
r
5 Subframe Mount Thread, Servicing ho eo
aut ra
ss c
ce
e
⇒ “5.1 Contents of Thread Repair Set”, page 52

nl
pt
du
an
itte
⇒ “5.2 Threads, Repairing”, page 52
y li
erm
ab
ility
ot p
wit
, is n
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WARNING
hole
spec
es, in part or in w
t to the co
rrectness of i
• Subframe was already removed. Refer to ⇒ Suspension,
l purpos
Wheels, Steering; Rep. Gr. 40 ; Subframe .
nf
ercia
o
Note
rm
m
atio
om
n in
In the example, thread repair on this vehicle is described for left
or c
front retaining bracket for subframe and is to be employed at the
thi
te
sd
a
other 3 retaining brackets accordingly as necessary.

iv
o
r
rp
cu
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f
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ng

t.
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Cop py
. rig
♦ Thread Repair Kit M12x1.5 - VAS 6058-
ht ht
rig by
copy Vo
lksw
♦ Drill - VAS 6267-
by
cted agen
Prote AG.

Golf 2013 ➤
1 - Heli-Coil insert
Note
If damaged once again, the retain‐

ing bracket must be replaced. Re‐
place retaining bracket. Refer to
⇒ “1 Subframe Mounting Bracket,
Removing and Installing”, page 33 .
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
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
5. Subframe Mount Thread, Servicing 51

Golf 2013 ➤
5.1 Contents of Thread Repair Set
1 - Spiral Drill Diameter 12.5

mm
2 - Tap M 12 x 1.5
3 - Installing Spindle
4 - M 12 x 1.5 x 24 Threaded
Insert ( HeliCoil Plus - Thread wagen AG. Volkswagen AG doe
Inserts - VAS 6058/1- ) y Volks s no
t gu
b ara
ed
5 - Peg Breaker with rMagnetic
is nte
tho e
Tips sa
u or
ac
s
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.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
5.2 Threads, Repairing

⇒ “5.2.1 Threads, Drilling”, page 52
⇒ “5.2.2 Threads, Cutting”, page 53
⇒ “5.2.3 Thread Inserts, Inserting”, page 54
5.2.1 Threads, Drilling
Caution
Wear protective eyewear when drilling out the threads.

Golf 2013 ➤
– Drill out the threads with the spiral drill.
Note
. Volkswagen AG
gen AG
♦ Use the Drill - VASksw6267- for drilling and grinding.
a oes d
not
Vol y gu
db a
♦ While drilling,
or
ise drill must be held by a second person
ran
teusing an
additional
au
th handle. e or
ac
ss
♦ Do not angle the drill.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
5.2.2 Threads, Cutting

nf
ercia
orm
m
atio
Caution
om
n in
or c
Wear protective eyewear when cutting the thread and when

thi
te
sd
a
cleaning the threaded bushing with compressed air.

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

Golf 2013 ➤
– Cut the threads with the thread tap.

– Clean threaded bushing (blow with pressurized air).
5.2.3 Thread Inserts, Inserting

– Turn the threaded insert -3- onto the spindle until the drive peg
-2- makes contact on drive tab -1- of installing spindle.
Note
kswage es n
Thread insert must be able to be turned easily. byV
ol ot g
ua
d ran
ir se tee
tho
u or
a ac
ss
ce
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un
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an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Screw the threaded insert into the threaded plate until the
threaded insert is seated flush with the outer edge of the threa‐
ss
ded plate (check visually).

o
cial p
f in
– Then tighten the threaded insert an additional 1/4 turn.

form
mer
atio
m
– Remove the spindle.

o
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.

Golf 2013 ➤
– Break off thread insert driver tang using tang breaker.

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

Golf 2013 ➤
RO: 50 79 55 03
6 Front Longitudinal Member, Replac‐

ing
WARNING

1 - 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
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2013 ➤
6.1 Tools
Note

Volkswagen AG.
6.2 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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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en

ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
6. Front Longitudinal Member, Replacing 57

Golf 2013 ➤
AG. Volkswagen AG d
Body Repairs - Edition 02.2015 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.
6.3 Installing
Note


Replacement Part
♦ Longitudinal Member
♦ Ground bolt

Golf 2013 ➤
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
– Drill the 8 and 10 mm holes for the gas-shielded arc plug weld
t to the co
seam.
6.3.2 Welding
rrectne
on the vehicle.
ss o
– Check fit with neighboring components.

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.

Golf 2013 ➤
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.
– Weld in the new part with a straight-line spot weld seam and
gas-shielded arc plug weld seam.

Golf 2013 ➤
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.
– Mark the ground bolt location with the ground cable location.
– At the marked location -1-, weld the ground bolt with two op‐
posing stitch welds = 12 mm.
Note
Rework the contact surface to restore the electric conductivity of

the ground bolt.

Golf 2013 ➤
RO: 50 79 55 06

ing, Left Partial Section
WARNING

1 - Front Longitudinal Member

2 - Separating Cut
Note
Dimension -a- = 110 mm
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2013 ➤
7.1 Tools
Note

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

110 mm
7. Front Longitudinal Member, Replacing, Left Partial Section 63

Golf 2013 ➤
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
7.3 Installing
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
⇒ “7.3.2 Welding”, page 65 cted agen
Prote AG.
Note


Replacement Parts
♦ Longitudinal member cover plate
♦ Front Longitudinal Member

Golf 2013 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
7.3.2 Welding
au ra
ss c
ce
le
un
pt

an
d
itte
and secure.
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
65
cted agen
Prote AG.
7. Front Longitudinal Member, Replacing, Left Partial Section
Golf 2013 ➤
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 the longitudinal member separating cut along the cir‐

cumference using a gas shielded arc continuous seam.

Golf 2013 ➤
RO: 50 79 55 06

ing, Right Partial Section
WARNING

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
1 - Front Longitudinal Member horise nte
eo
ut ra
a
2 - Separating Cut ss c
ce
e
nl
pt
du
Note
an
itte
y li
erm
ab
ility
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.
8. Front Longitudinal Member, Replacing, Right Partial Section 67

Golf 2013 ➤
8.1 Tools
Note

only welding equipment approved waby
genVolkswagen
AG. VolkswagenAG
AG dto
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form any service work. by
Volks s no
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Volkswagen AG. au ac
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8.2 Removing
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c
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ate
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Cop py
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– Label and perform separating cut as shown.

25 mm

Golf 2013 ➤
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8.3 Installing
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Note cop Vo
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Prote AG.
8.3.1 New Part, Preparing

Replacement Parts
♦ Longitudinal Member Cover Plate
♦ Front Longitudinal Member

Golf 2013 ➤
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an
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8.3.2 Welding
pe
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ot
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on the vehicle.
hole
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t to the co
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nform
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a
com
tion in
r
te o
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iva
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en
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t.
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Cop py
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Vo
co lksw
by
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Prote AG.

Golf 2013 ➤
AG. Volkswagen AG d
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– Weld the longitudinal member separating cut along the cir‐

le
un
pt
cumference using a gas shielded arc continuous seam.

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Cop py
t. rig
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Vo
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by
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Prote AG.

Golf 2013 ➤
9 Special Tools
♦ Thread Repair Kit M12x1.5 - VAS 6058-
♦ Drill - VAS 6267-
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Cop py
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Vo
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by
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Prote AG.

Golf 2013 ➤
51 – Body Center, Chassis, Roof

RO: 51 03 55 00
1 Roof Replacing- Vehicles without a

Panorama-Sunroof
DANGER!

1 - Roof
2 - Laser Brazed Seam
3 - Bonded Area
AG. Volkswagen AG d
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73
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1. Roof Replacing- Vehicles without a Panorama-Sunroof
AG.
Golf 2013 ➤
1.1 Tools
Note

Volkswagen AG.
1.2 Removing
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spec
t to the co
rrectness o
cial p
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mer
atio
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n
c
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t.
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Cop py
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Vo
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Prote AG.
Note
♦ Apply cloth reinforced adhesive tape parallel to the laser brazed seams on the left and right side of the roof
pillars. It prevents pillars from getting damaged or dirty while servicing.
♦ Maintain a distance of approximately 15 mm to the roof pillar so that the roof pillar does not get damaged.
♦ The roof reinforcement is not removed.
74 Rep. Gr.51 - Body Center, Chassis, Roof

Golf 2013 ➤
– Cut the original joint at the front of the roof crossmember.

– Cut the original joint inside the rear lid opening.
– Roughly cut out the roof parallel to the laser brazed seams.
AG. Volkswagen AG d
agen oes
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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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nl
pt
du
an
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ility
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es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
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ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
♦ When removing the remaining roof material -1-, do not damage the side panel.
♦ Do not use separating- or roughing blades.

– Remove any adhesive and sealant still remaining on the front
and rear roof crossmembers and on the roof reinforcement.
– Remove any remaining adhesive on the left and right roof pil‐
lars.
– Touch up any paint damage using the paint repair manual.
1. Roof Replacing- Vehicles without a Panorama-Sunroof 75

AG. Volkswagen AG d
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Golf 2013 ➤ ut
ho eo
ra
a
ss 02.2015 c
ce
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un
pt
1.3 Installing
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
⇒ “1.3.2 Roof Depth Dimension, Adjusting”, page 77
h re
ole,
spec
⇒ “1.3.3 Roof, Bonding”, page 78
t to the co
rrectne
Note
ss o
cial p
f
inform
mer
atio
om
n
c
i
or
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Replacement part
um
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♦ Roof
Co
Cop py
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♦ 1K Assembly Adhesive - D 190 MKD A3- , (3 cartridges) rig ht
py by
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♦ 2K Body Adhesive - D 180 003 M2- (2 cartridge sets)
cted agen
Prote AG.
♦ Primer - ALN 002 003 04-

♦ Adhesive - AKD 476 KD5 05-
♦ Felt - 533 867 910 B-
♦ Cavity Sealant - AKR 321 M15 4-
Note
♦ In order to guarantee problem-free and long lasting roof repair,

the following work procedure must always be followed.
♦ Be sure to follow the work procedure exactly to prevent making
any mistakes.

Golf 2013 ➤
lkswage es n
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a ac
ss
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nl
pt
du
an
itte
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ility
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es, in part or in w
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rrectness of i
l purpos
nform
mercia
at
om
– Mount the roof onto the roof frame.

on
c
in t
or
– Make sure the roof fits correctly with the rear lid and the wind‐
his
ate
shield.
do
priv
cum
for
1.3.2 Roof Depth Dimension, Adjusting

en
ng
t.
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Cop py
The tensioning straps -1- prevent roof from lifting off the roof
t. rig
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frame and sliding during the adhesive procedure. cop Vo
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Prote
To prevent damage, do not overtighten the tensioning straps.
AG.
Dimension -a- is determined by tightening or loosening the ten‐

sion straps so that the roof is lower than the side panels.

Golf 2013 ➤
Use the Gauge - Gap Adjustment - 3371- to check the dimension

-a-.
AG. Volkswagen AG d
agen oes
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d by ara
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un
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an
d
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ab
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ot p
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is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
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te
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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.
– Tension the Tensioning Strap - T10038- across the roof in the

areas shown to adjust the roof height.
– Secure the roof on the opening for the window at the front and
rear with locking pliers.
– Check the roof alignment to the roof pillars.
– If necessary, place Felt - 533 867 910 B- on the roof frame to
balance it out.
1.3.3 Roof, Bonding

– Remove the roof.
– Apply corrosion protection.
– Clean the adhesive surface on the roof and the vehicle with
Silicone Remover - LVM 020 000 A5- .

Golf 2013 ➤
Note
♦ The adhesive sealant must be applied very quickly.

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

2 mm from the nozzle
agen -B-.
AG. Volkswagen AG d
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olks ot g
byV ua
ed ran
ris tee
Note
tho or
au ac
ss
♦ To ensure a proper and long-lasting roof repair, always follow
ce
e
nl
pt
du
the procedure exactly.
an
itte
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erm
ab
ility
any mistakes.
ot p
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
m
atio
om
n in
or c
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te
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m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2013 ➤
Body Repairs - Edition 02.2015 agen
AG. Volkswagen AG d
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yV gu
– Apply One-Part Assembly Adhesive rised- D190 MKD A3- using
b ara
nte
the Pneumatic Cartridge Gun -uVAG1761/1-
tho on the front and eo
ra
rear roof crossmember and the
ss a roof reinforcement in the area c
near the adhesive applied at the factory.
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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hole
spec
es, in part or in w
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rrectness of i
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nf
ercia
orm
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atio
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or c
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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.
– Apply One-Part Assembly Adhesive - D190 MKD A3- using

the Pneumatic Cartridge Gun - VAG1761/1- in the area of the
roof pillar.
Dimension -a- = approximately 12 mm
Dimension -b- = approximately 14 mm

Golf 2013 ➤
AG. Volkswagen AG d
agen oes
olksw not
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ara
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aut ra
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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
the Pneumatic Cartridge Gun - VAG1761/1- on the inside of

t to the co
the roof parallel to the left and right roof flange.

rrectness of i

l purpos
Note
nform
mercia
♦ The processing time (time on pot) for Two-Part Body Adhesive

a
com
tio
- D 180 003 M2- is approximately 90 minutes.

n in
r
te o
thi
♦ An assistant is required for the following work steps.

s
iva
do
r
rp
♦ Remove any Two-Part Body Adhesive - D 180 003 M2- that

um
fo
en
g
leaks out immediately. The Two-Part Body Adhesive - D 180

n
t.
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003 M2- can only be removed mechanically once it has hard‐ Cop py
.
ened.
ht rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Golf 2013 ➤
– Cut off the first section of the static mixer -A- to get the correct
bead diameter.
– Operate the Double Cartridge Gun - VAS5237- without mixer,
until adhesive extrudes evenly out of both chambers of car‐
tridge union.
– Attach the mixer to the cartridge union.
– Apply the first 100 mm of adhesive onto a piece of cardboard
and only then begin the application on the vehicle.
AG. Volkswagen AG d
agen oes
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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
– Fill the roof pillar area with Two-Part Body Adhesive - D 180
or
his
e
003 M2- using the Double Cartridge Gun - VAS5237- .

at
do
priv
cum
– Apply Two-Part Body Adhesive - D 180 003 M2- on the rear

for
en
g
roof crossmember near the adhesive applied at the factory.

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

Golf 2013 ➤
Note

any mistakes.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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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.
– Coat the roof flange with Two-Part Body Adhesive - D 180 003
M2- .
– Mount the roof immediately and align it.
– Secure the roof to the openings for the front window and the
rear lid as well as to the center area with the tensioning straps
using locking pliers.
– Check the roof depth dimension -a- and adjust the roof if nec‐
essary.
– Remove any Two-Part Body Adhesive - D 180 003 M2- that
leaks out on the roof edge using a cloth soaked in Silicone
Remover - LVM 020 000 A5- .

Golf 2013 ➤

leaks out of the hinge holes in the rear lid opening.
Note
wage es n
♦ After adhering, vehicle must stand on a level surface yat
Voroom
lks ot g
temperature (at least 15 ℃) for 8 to 10 hours so the ed adhesive
b ua
ran
ris
components can cure. utho tee
or
a ac
♦ Further work can only be performed on the vehicle after the ss
ce
e
“minimum curing time” has passed.
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
using locking pliers. Refer to
spec
es, in part or in w
⇒ “1.3.2 Roof Depth Dimension, Adjusting”, page 77 .
t to the co
– Check the roof depth dimension -a- and adjust if necessary.
Refer to
rrectness of i
l purpos

Remover - LVM 020 000 A5- .
nform
ercia

m
at
leaks out of the hinge holes in the rear lid opening.
om
ion
c
in t
or
his
ate
Note
do
priv
cum
for
en
g
♦ After adhering, vehicle must stand on a level surface at room

n
t.
yi Co
temperature (at least 15 °C (59 °F)) for 8 to 10 hours so the Cop py
t. rig
adhesive components can cure. opyri
gh by
Vo
ht
by c
♦ Further work can only be performed on the vehicle after the
lksw
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Prote
AG.
1.3.4 Welding

Golf 2013 ➤
AG. Volkswagen AG d
agen oes
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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
– Weld the roof to the windshield opening and to the rear lid
wit
, is n
opening using a straight-line spot weld seam.

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.

Golf 2013 ➤
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
– Apply a fine-seal of adhesive seam -1- to the seam between

nf
ercia
the roof and the roof pillar with Adhesive - AKD 476 KD5 05- .
orm
m
atio
– After painting, protect the hollow roof cavities -arrow- with

om
n in
Cavity Sealant - AKR 321 M15 4- .

or c
thi
te

sd
iva
r
rp
cu
o
m
f
en
ng

t.
yi Co
op
Cavity Sealant - AKR 321 M15 4- . C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2013 ➤
RO: 51 03 55 03
2 Roof, Replacing, Vehicles with Pan‐

orama Sunroof
DANGER!

1 - Roof
2 - Laser Brazed Seam
3 - Bonded Area
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
87
co Vo
by lksw
cted
2. Roof, Replacing, Vehicles with Panorama Sunroof
agen
Prote AG.
Golf 2013 ➤
2.1 Tools
Note

Volkswagen AG.
2.2 Removing
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
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
r
Note
p
cum
r
fo
en
ng
t.
yi
♦ Apply cloth reinforced adhesive tape parallel to the laser brazed seams on the left and right side of the roof
Co
Cop py
pillars. It prevents pillars from getting damaged or dirty while servicing.
t. rig
gh ht
pyri by
Vo
o
♦ Maintain a distance of approximately 15 mm to the roof pillar -1- so that the roof pillar does not get damaged.
by c lksw
cted agen
Prote AG.
♦ The roof reinforcement on the sunroof opening is also removed.

Golf 2013 ➤
– Cut the original joint at the front of the roof crossmember.

wage
es ks not
Vol gu
– Roughly cut out the roof parallel to the
ed laser brazed seams
by ara
nte
-2-. thoris 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
co lksw
by
cted agen
Prote AG.
Note
♦ When removing the remaining roof material -1-, do not damage the side panel.
♦ Do not use separating- or roughing blades.

– Remove any excess adhesive and sealant on the center and
rear roof crossmembers.
– Remove any remaining adhesive on the left and right roof pil‐
lars.
– Repair any paint damage.
2. Roof, Replacing, Vehicles with Panorama Sunroof 89

Golf 2013 ➤
2.3 Installing
⇒ “2.3.1 New Part, Preparing”, page 90
⇒ “2.3.2 Roof Depth Dimension, Adjusting”, page 92
⇒ “2.3.3 Roof, Bonding”, page 93
Note
When using different types of steel and materials of

agedifferent
es n
strengths, one of the inverters listed under bTools
o lksware required to ot g
yV ua
perform repair work correctly. Refer to ⇒rise“2.1
d Tools”, page 88 . ran
t ee
tho or
au ac
2.3.1 New Part, Preparing ss
ce
e
nl
pt
du
an
Replacement Part
itte
y li
erm
ab
♦ Roof
ility
ot p
wit
, is n
♦ One-Part Assembly Adhesive - D 190 MKD A3- , (3 cartridges)
h re
hole
♦ Two-Part Body Adhesive - D 180 003 M2- (2 cartridge sets)
spec
es, in part or in w
t to the co
♦ Primer - ALN 002 003 04-
♦ Adhesive - AKD 476 KD5 05-
rrectness of i
♦ Felt - 533 867 910 B-
l purpos
♦ Cavity Sealant - AKR 321 M15 4-
nform
ercia
Note
m
at
om
io
n
c
in t
or

his
ate
do
riv

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

Golf 2013 ➤
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
e
– Sand the left and right adhesive areas on the roof down to the
at
do
riv
bare metal.
p
cum
for
en
g
This ensures that the Two-Part Body Adhesive - D 180 003 M2-
n
t.
yi Co
can achieve a good bond with the adhesive surface. Cop py
t. rig
gh ht
yri
– Mount the roof onto the roof frame. p by
co Vo
by lksw
cted agen
– Make sure the roof fits correctly with the rear lid and the wind‐ Prote AG.
shield.

Golf 2013 ➤
2.3.2 Roof Depth Dimension, Adjusting
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
Note
nf
ercia
orm
m
♦ The Tensioning Strap - T10038- prevents the roof from being lifted or slid off of the roof frame during the
atio
m
adhesive procedure.
o
n in
or c
thi
e
♦ To prevent any damage, do not overtighten the Tensioning Strap - T10038- .

t
sd
iva
o
r
rp
cu
♦ For a 2-door vehicle with the side windows installed, position the Tensioning Strap - T10038- around the
o
m
f
en
ng
entire vehicle.
t.
yi Co
Cop py
t. rig
gh
– Tension the Tensioning Strap - T10038- across the roof in the
ht
pyri by
Vo
o
areas shown -arrows- to modify the roof height. by c lksw
cted agen
Prote AG.
Dimension -a- is determined by tightening or loosening the Ten‐
sioning Strap - T10038- so that the roof is lower than the side
panels.
Use the Gauge - Gap Adjustment - 3371- to check the dimension
-a-.
If the dimension -a- is exceeded, place Felt - 533 867 910 B- on
the roof fame to even it out.

Golf 2013 ➤
If the rear dimension -a- cannot be adjusted, it may be necessary

to remove the rear roof crossmember and to weld it again.
– Check the roof alignment to the side panels.
wage es n
2.3.3 Roof, Bonding olks ot g
byV ua
d ran
ir se tee
– Remove the roof. utho
or
a ac
ss
– Apply corrosion protection. Refer to ⇒ Paint; Rep. Gr. 00 .
ce
le
un
pt
– Clean the adhesive surface on the roof and the vehicle with
an
d
itte
y li
Silicone Remover - LVM 020 000 A5- .
erm
ab
ility
ot p
wit
is n
Note
h re
ole,
spec
♦ The adhesive sealant must be applied very quickly.
t to the co
♦ Pay close attention to the processing time (working life).
♦ To apply the adhesive sealant, use a compressed air gun or
rrectne
electric cartridge pistol.
ss
– For the corresponding bead geometry, cut off approximately
o
cial p
f
2 mm from the nozzle -B-.
inform
mer
atio
om
Note
n
c
i
or
n thi
te
sd
a

iv
o
pr
c
um
r
fo
en
ng
t.
yi Co
op py
any mistakes. t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2013 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

the Pneumatic Cartridge Gun - VAG1761/1- on the front and

AG. Volkswagen AG d
lksw
agen oes
no Golf 2013 ➤
o
d by
V
Body Repairst g-uaEdition
ran 02.2015
e
oris tee
th or
au ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

the Pneumatic Cartridge Gun - VAG1761/1- in the area of the
roof pillar.

Golf 2013 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

the Pneumatic Cartridge Gun - VAG1761/1- on the inside of
the roof parallel to the left and right roof flange.
Note
♦ The processing time (time on pot) for Two-Part Body Adhesive

- D 180 003 M2- is approximately 90 minutes.
♦ An assistant is required for the following work steps.
♦ Remove any Two-Part Body Adhesive - D 180 003 M2- that
leaks out immediately. The Two-Part Body Adhesive - D 180
003 M2- can only be removed mechanically once it has hard‐
ened.

Golf 2013 ➤
– Cut off the first section of the static mixer -A- to get the correct
bead diameter.
– Operate the Double Cartridge Gun - VAS5237- without mixer,
until adhesive extrudes evenly out of both chambers of car‐
tridge union.
– Attach the mixer to the cartridge union.
– Apply the first 100 mm of adhesive onto a piece of cardboard
and only then begin the application on the vehicle.
Note

any mistakes.
AG. Volkswagen AG d
agen oes
olksw not
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.
– Fill the area with Two-Part Body Adhesive - D 180 003 M2-
using the Double Cartridge Gun - VAS5237- .

Golf 2013 ➤
– Apply Two-Part Body Adhesive - D 180 003 M2- on the rear

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
– Coat the roof flange with the Two-Part Body Adhesive - D 180
003 M2- .
rrectness of i

l purpos
nform
ercia
using locking pliers. Refer to

m
at
om
io
– Check the roof depth dimension -a- and adjust if necessary.

n
c
in t
r
Refer to
o
his
te

a
do
priv
cum
or

f
en
g

n
t.
yi Co
op
Remover - LVM 020 000 A5- . C py
t. rig
gh ht
yri by
– Remove any Two-Part Body Adhesive - D 180 003 M2- that cop Vo
by lksw
leaks out of the hinge holes in the rear lid opening. cted agen
Prote AG.

Golf 2013 ➤
AG. Volkswagen AG d
ksw
agen oes
not
Vol
by gu
ara
ed nte
oris eo
th
Note ss
au ra
c
ce
le
un
pt
♦ After adhering, vehicle must stand on a level surface at room
an
d
itte
temperature (at least 15 °C (59 °F)) for 8 to 10 hours so the
y li
rm
ab
adhesive components can cure. pe
ility
ot
wit
♦ Further work can only be performed on the vehicle after the
, is n
h re
hole
spec
es, in part or in w
2.3.4 Welding
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Weld the roof to the windshield opening and to the rear lid
opening using a straight-line spot weld seam.

Golf 2013 ➤
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.

Cavity Sealant - AKR 321 M15 4- .

Golf 2013 ➤
RO: 51 37 55 00
3 A-Pillar, Replacing
⇒ “3.1 Tools”, page 102
WARNING

If welding or cutting with spark-producing devices/tools or
when plating in foamed areas where hazardous gases are pro‐
duced that are harmful to humans and the environment, these
procedures are to be omitted in each case.
wage es n
1 - A-Pillar yV
olks ot g
d b ua
ran
2 - Upper Separation Cut ir se tee
tho
u or
a ac
3 - Molded Foam Part ss
ce
le
un
pt
4 - Lower Separation Cut
an
d
itte
y li
5 - Bonded Area
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.
3. A-Pillar, Replacing 101

Golf 2013 ➤
3.1 Tools
Note

form any service work. G. Volkswagen nA AG do
wage es n
♦ For a list of welding equipment and body toolsy Vapproved
olks by ot g
Volkswagen AG. ed
b ua
ran
oris tee
th or
au ac
3.2 Removing ss
ce
le
un
pt
an
d
itte
y li
rm
ab
Note
pe
ility
ot
wit
, is n
♦ Only use the body Pneumatic Body Saw - VAS6780- to per‐
h re
form separating cuts.
hole
spec
es, in part or in w
♦ Be sure not to damage the metal panels behind it when making
t to the co
the separating cut.
♦ If the A-pillar reinforcement is damaged, then is must always
rrectness of i
be replaced.
l purpos
♦ A-pillar reinforcement must not be re-welding for safety rea‐

sons »crash safety«!
nform
ercia
♦ Foam residue must be removed as much as possible before

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

Golf 2013 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Make a separating cut -1- according to the damage.

s
– Make a separating cut -2- according to the damage.

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

Golf 2013 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Completely remove any remaining adhesive and grind the ad‐
hesive surfaces down to bare metal.
3.3 Installing
Note


Golf 2013 ➤
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.

Golf 2013 ➤
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
Note
MIG soldered seams are permitted on the separating cuts shown in the illustration.
rrectne

ss o
cial p
Replacement Part
inform
mer
♦ Sub-part, front side panel (replacement part name: A-pillar

atio
m
sub-part with sill panel)

o
n
c
i
or
♦ 2K Body Adhesive - D 180 003 M2-

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

Golf 2013 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
– Transfer separating cuts onto new part and cut to shape. 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
107
AG.
3. A-Pillar, Replacing
Golf 2013 ➤
3.3.2 Welding
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
Note
do
r
rp
cum
fo
en
g
♦ New part must be installed within 90 minutes, otherwise bonding properties of adhesive will be impaired.
n
t.
yi Co
Cop py
♦ The holes for the hinge mount must be cleaned after applying the adhesive.
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
– Position two Butyl Sealing Cords - AKD 497 010 04 R10- in Prote AG.
area -1-.
– Apply a 4 mm adhesive bead of 2K Body Adhesive - D 180
003 M2- in the areas of the door opening and the door hinges.

Golf 2013 ➤
Note
Place the straight line weld points as far as possible from the outer
edge of the weld flange to provide strength.
– Fit new part to vehicle standing on its wheels or on alignment

bracket set and secure.
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 A-pillar reinforcement, straight-line spot weld seam

and gas-shielded arc plug weld seam.
– Weld the separation cuts, either MIG-L stitch weld seam or a
gas-shielded arc continuous weld seam

Golf 2013 ➤
RO: 51 38 55 50
4 A-Pillar Reinforcement, Replacing

Partial Section
⇒ “4.1 Tools”, page 111
WARNING

Body Repairs, Body Collision Repair wage
e
olks s no
V t gu
by ara
ed
when plating in foamed areas whereoris hazardous gases are pro‐ nte
eo
th
duced that are harmful to humans
au and the environment, these ra
c
procedures are to be omitted
s in each case.
s
ce
e
nl
pt
du
an
itte
y li
erm
• A-pillar already removed. Refer to
ab
ility
⇒ “3 A-Pillar, Replacing”, page 101
ot p
wit
, is n
h re
hole
1 - A-Pillar Reinforcement
spec
es, in part or in w
t to the co
2 - Molded Foam Parts
Note
rrectness of i
Foam residue must be removed as
l purpos
much as possible before sanding

work.
nform
ercia
3 - Bonded Area
m
at
om
io
4 - Lower Inner A-Pillar Sepa‐

n
c
in t
r
rating Cut
o
his
ate
do
riv
Partial renewal
p
cum
or
A partial replacement is possi‐

f
en
ng
ble with this separating cut.

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

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
e o Golf 2013 ➤
ris nte
ho
aut Body Repairs - Edition ra 02.2015
ss c
ce
e
nl
pt
4.1 Tools
du
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Volkswagen AG.
l purpos
4.2 Removing
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.
– Separate original joint of A-pillar reinforcement.

– Perform a separation cut at the inner lower A-pillar hinge cov‐
er.
4. A-Pillar Reinforcement, Replacing Partial Section 111

Golf 2013 ➤
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.

4.3 Installing
Note


Replacement Part
♦ A-Pillar Reinforcement
♦ Molded Foam Part

Golf 2013 ➤
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.
4.3.2 Welding
Note
Place the straight line weld points as far as possible from the outer
edge of the weld flange to provide strength.

Golf 2013 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
Note
nl
pt
du
an
itte
y li
New part must be installed within 90 minutes, otherwise bonding properties of adhesive will be impaired.
erm
ab
ility
ot p
wit
, is n
– Apply 2K Body Adhesive - D 180 003 M2- near the hinge re‐
h re
inforcement and the door opening.

hole
spec
es, in part or in w
– Install new part with vehicle standing on the alignment bracket

t to the co
set and affix it in place.

– Check fit to A-pillar.
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
114
cted agen
Prote AG.
Rep. Gr.51 - Body Center, Chassis, Roof
Golf 2013 ➤
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
op py
– Weld the A pillar reinforcement, straight-line spot weld seam t. C rig
gh ht
and gas-shielded arc plug weld seam and gas-shielded arc pyri by
Vo
co
continuous weld seam.
by lksw
cted agen
Prote AG.

Golf 2013 ➤
RO: 51 41 55 00
5 B-Pillar, 4-Door Vehicle, Removing

and Installing
⇒ “5.1 Tools”, page 117
DANGER!

1 - B-Pillar
2 - Bonded Area
3 - Molded Foam Part
Note

much as possible before sanding n AG. Volkswagen AG do
work. olks
wage es n
o
yV t gu
db ara
4 - B-Pillar Separation Cut rise nte
tho eo
au ra
c
ss
Note
ce
le
un
pt
an
d
itte
The separation cut can be repaired

y li
rm
ab
depending on the degree of dam‐

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

Golf 2013 ➤
5.1 Tools
Note wage
es n
olks ot g
byV ua
♦ Due to the different types oforissteel
ed and material strength, use ran
tee
only welding equipment aapproved
uth by Volkswagen AG to per‐ or
form any service work.ss
ac
ce
e
nl
pt
du
an
Volkswagen AG.
itte
y li
erm
ab
ility
ot p
5.2 Removing
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.
– Make separating cuts -1 through 3- depending on the damage.

– Separate original joint in door cut-outs.
5. B-Pillar, 4-Door Vehicle, Removing and Installing 117

Golf 2013 ➤
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
– Remove residual material. t to the co

rrectness of i
l purpos
5.3 Installing
nf
ercia

rm
m
atio
m

o
n in
or c
thi
te
sd
iva
o
r
rp
cu
Note
o
m
f
en
ng
t.
yi Co
op
When using different types of steel and materials of different C py
t. rig
gh ht
yri by
cop Vo
by lksw
cted agen
Prote AG.

Replacement Part
♦ B-pillar (replacement part name: A-pillar sub-part with sill pan‐
el)

Golf 2013 ➤
♦ 2K Body Adhesive - D 180 KD3 A2- AG. Volkswagen AG d

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

Golf 2013 ➤
5.3.2 Welding
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.
– Apply 2K Body Adhesive - D 180 003 M2- in the shown areas.

and secure.

Golf 2013 ➤
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
– Weld the B pillar, straight-line spot weld seam, gas-shielded

es, in part or in w
arc plug weld seam.

t to the co
– Remove escaped adhesive.

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.

Golf 2013 ➤
RO: 51 42 55 50
6 B-Pillar Reinforcement, Replacing, 4-

Door (Partial Section)
WARNING
Follow all safety precautions.

Refer to ⇒ General Information; Body Repairs, Body Collision

Repair ; Safety Precautions
• B-pillar already removed. Refer to
⇒ “5 B-Pillar, 4-Door Vehicle, Removing and Installing”,
page 116 .
• Outer side sill is already removed. Refer to
⇒ “7 Outer Sill Panel, Replacing, 4-Door”, page 135 .
1 - B-Pillar Reinforcement
3 - Bonded Area
4 - Front Side Sill Separation
Cut
AG. Volkswagen AG d
agen
Dimension -a- = 400 mm olksw
oes
not
byV gu
ara
ed
5 - Roof Pillar Separation Cut horis nte
eo
aut ra
Dimension -b- = 90 mm. ss c
ce
le
un
pt
6 - Rear Side Sill Separation
an
d
itte
y li
Cut
erm
ab
ility
ot p
Dimension -c- = 250 mm
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Golf 2013 ➤
6.1 Tools
Note
Due to the different types of steel and material strength, use only
service work.
6.2 Removing
Note
Before the following procedures are performed, Mechanical Door

Brace - V.A.G 1438- must be inserted in front and rear door open‐
ings. This prevents the roof from changing in its position.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Transfer dimension -a- = 60 mm on the B-pillar reinforcement

-1-.
– Apply the separation cuts -2- and -3-.
6. B-Pillar Reinforcement, Replacing, 4-Door (Partial Section) 123

Golf 2013 ➤
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.
– Transfer and apply the dimension -a- = 30 mm or separation

cut -3- on the side sill reinforcement -1-.
– Transfer and apply the dimension -b- = 10 mm for the sepa‐
ration cut -4- on the inner B-pillar -2-.
– Transfer and apply the dimension -c- = 90 mm or separation
cut -5- on the side sill reinforcement -1-.

Golf 2013 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
– Loosen the inner B-pillar original joint -1-.

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

Golf 2013 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
e

t
sd
iva
o
r
rp
cu
– Sand the welding surfaces down to bare metal.

o
m
f
en
ng
t.
yi
Co
op py
hesive surfaces down to bare metal. t. C rig
gh ht
pyri by
Vo
6.3 Installing
co lksw
by
cted agen
Prote AG.
Note


Replacement Parts
♦ B-Pillar Reinforcement
♦ Crash reinforcement (replacement part name in the Electronic
Parts Catalog (ETKA) ⇒ B-pillar reinforcement)
♦ Inner B-pillar

Golf 2013 ➤
♦ Inner Side Sill

♦ Molded foam part (replacement part name in the Electronic
Parts Catalog (ETKA) ⇒ butyl sealing cord/partition)
♦ Two-Part Body Adhesive - (for the replacement part number
refer to ⇒Electronic Parts Catalog (ETKA))-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Sand the welded surfaces on the new part -1-, -2-, and -3- to
m
the bare metal.

a
com
tion in
– Perform the separation cut as shown.

r
te o
thi
s
iva
– Lightly sand the adhesive surfaces.

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

Golf 2013 ➤
AG. Volkswagen AG d
Body Repairs - Edition 02.2015 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.
– Transfer dimension -a- = 390 mm on the crash reinforcement.

– Perform the separation cut and the exact fit of the double patch
panel -1- with the B-pillar reinforcement.
– Sand the adhesive surfaces and welded surfaces to bare met‐
al.
6.3.2 Molded Foam Parts

Observe repair notes:
Chapter. Refer to ⇒ “4 Molded Foam Parts”, page 5 .

Golf 2013 ➤
6.3.3 Welding
Note
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
– Apply Two-Part Body Adhesive on the inner B-pillar.

rrectness of i
– Fit the inner B-pillar -1- to vehicle standing on its wheels or on

Alignment Bracket Set and secure.
l purpos

nf
ercia
– Insert the molded foam part -2-.

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

Golf 2013 ➤
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
– Fit and attach the side sill reinforcement -1-.

m
at
om
ion

c
in t
or
his
te
– Fold up and secure the inner B-pillar above.

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

Golf 2013 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2013 ➤
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 in
– Apply Two-Part Body Adhesive to the B-pillar reinforcement

form
mer
-1-.
atio
m
– Fit and attach the B-pillar reinforcement -1-.

o
n
c
i
or
n thi
e

t
sd
iva
o
pr
– Attach the B-pillar reinforcement -1- on the side sill reinforce‐

um
r
fo
en
ment -2- use a gas-shielded arc continuous weld seam.

ng
t.
yi Co
op py
– Remove the B-pillar reinforcement and side sill reinforcement t. C rig
gh ht
and weld is using a straight-line spot weld seam. pyri by
Vo
co lksw
by
cted agen
– Apply the Two-Part Body Adhesive on the side sill reinforce‐ Prote AG.
ment -2-.
– Fit and attach the B-pillar reinforcement with the side sill rein‐
forcement.
– Attach the B-pillar reinforcement and side sill reinforcement on
the separation cut using a gas-shielded arc continuous weld
seam. Check the fit of the double patch panel to the B-pillar
reinforcement.
– Weld the separation cuts using a gas-shielded arc continuous
weld seam.

Golf 2013 ➤
– Sand the weld seam as far as necessary for the for the smooth
fit of the double patch panel from the inside.
– Sand the adhesive surface for the double patch panel in the
B-pillar reinforcement to bare metal.
– Apply Two-Part Body Adhesive of the entire surface for the
double patch panel and B-pillar reinforcement.
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.
– Fit and secure the double patch panel -1-.

– Weld the double patch panel as shown, straight-line spot weld
seam.
– Apply Two-Part Body Adhesive to the B-pillar reinforcement.

Golf 2013 ➤
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 in
– Fold back an secure the inner B-pillar -1-.
form
mer
atio
– Weld the inner B-pillar from below upward, straight-line spot
om
weld seam.
n
c
i
or
n thi
e
– Weld the inner B-pillar separation cut, gas-shielded arc con‐

t
sd
iva
tinuous weld seam/

pr
cum
r
fo
en
ng
t.
yi Co
op py
Note
. C rig
ht ht
rig by
copy Vo
lksw
Weld the separation cut only in the marked area to prevent heat impact on the hot-formed B-pillar.
by
cted agen
Prote AG.
– Insert the molded foam part.

• Install the outer side sill. Refer to
⇒ “7.3 Installing”, page 137 .
• Install the B-pillar. Refer to ⇒ “5.3 Installing”, page 118 .

Golf 2013 ➤
Body Repairs
. Volkswage
- Edition 02.2015
AG n AG d
agen oes
olksw not
yV gu
db ara
RO: 51 45 55 00 rise nte
tho eo
7 Outer Sill Panel, Replacing, 4-Door au ra
ss c
ce
le
un
pt
⇒ “7.1 Tools”, page 136
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
WARNING
t to the co
rrectness of i
l purpos

nform
mercia
a
com
tion in
r
te o
thi
1 - Sill Panel
s
iva
do
r
rp
2 - Separating Cuts
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
Note p by
co Vo
by lksw
cted agen
Prote AG.
much as possible before sanding
work.
4 - Bonded Area
7. Outer Sill Panel, Replacing, 4-Door 135

Golf 2013 ➤
7.1 Tools
Note

Volkswagen AG.
7.2 Removing
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
♦ Only use the body Pneumatic Body Saw - VAS6780- to perform separating cuts.
♦ Be careful not to damage the panel behind it when making the separation cuts.
– Make separating cuts -1, 2 and 3- depending on the damage.


Golf 2013 ➤
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
m

o
n
c
i
or
n thi
te
sd
va
– Clean the flanging area on wheel arch (it must be free of dust
i
o
pr
cum
and grease).
r
fo
en
ng
t.
yi Co
7.3 Installing Cop py
t. rig
gh ht
yri by
⇒ “7.3.1 Additional Separation Cuts on the Outer Sill Panel”, page cop Vo
by lksw
137 cted agen
Prote AG.

Note

RO: 51 45 55 02, 51 45 55 04, 51 45 55 08

Golf 2013 ➤
7.3.1 Additional Separation Cuts on the Outer Sill Panel
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
– Make separation cuts according to the degree of damage, or
AG.
follow the displayed separation cuts.

Replacement Part
♦ Side Panel

Golf 2013 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le

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

Golf 2013 ➤
7.3.3 Welding
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
e
Note
at
do
priv
cum
or
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
and secure.
p by
o Vo
by c lksw
cted agen
Prote AG.

Golf 2013 ➤
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.

– Recreate the original joint using straight-line spot weld seam
– Reform the wheel arch flange.
– Remove any escaping adhesive and seal the wheel arch.

Golf 2013 ➤
RO: 51 45 55 10
8 Outer Sill Panel, Replacing, 2-Door

⇒ “8.1 Tools”, page 143
WARNING

1 - Sill Panel
2 - Separating Cuts
Note
. Volkswagen AG
Foam residue must be removed as lkswagen AG does
much as possible before sanding o not
yV gu
db ara
work. or
ise nte
th eo
au ra
c
4 - Bonded Area 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.

Golf 2013 ➤
8.1 Tools
Note

Volkswagen AG.
8.2 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
y li
erm
ab
ility
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
Note
m
atio
om
n in
or c
♦ Only use the body Pneumatic Body Saw - VAS6780- to perform separating cuts.
thi
te
sd
iva
♦ Be careful not to damage the panel behind it when making the separation cuts.
o
r
rp
cu
o
m
f
en
ng
t.
yi
– Make separating cuts -1 and 2- according to the degree of
Co
op py
damage. t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
143
AG.
8. Outer Sill Panel, Replacing, 2-Door
Golf 2013 ➤
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
te

a
do
riv

p
cum
for
en
g
8.3 Installing
n
t.
yi Co
Cop py
t. rig
gh
⇒ “8.3.1 Additional Separation Cuts on the Outer Sill Panel”, page
ht
pyri by
Vo
o
144
c by lksw
cted agen
Prote AG.
Note

RO: 51 45 55 12

Golf 2013 ➤
8.3.1 Additional Separation Cuts on the Outer Sill Panel
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
– Make separation cuts according to the degree of damage, or

h re
hole
follow the displayed separation cuts.

spec
es, in part or in w

t to the co
Replacement Part
rrectness of i
♦ Side Panel
l purpos

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

Golf 2013 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

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

Golf 2013 ➤
8.3.3 Welding
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
Note
Co
Cop py
t. rig
gh ht
yri by
op Vo
by c lksw
cted agen
Prote AG.
and secure.

Golf 2013 ➤
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
– Recreate the original joint using straight-line spot weld seam

atio
m

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.

Golf 2013 ➤
9 Special Tools
♦ Gauge - Gap Adjustment - 3371-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
♦ Pneumatic Cartridge Gun - VAG1761/1- ss c
ce
e
nl
pt
du
♦ Tensioning Strap - T10038-
an
itte
y li
erm
♦ Pneumatic Body Saw - VAS6780-
ab
ility
ot p
♦ Straightening Bracket Set
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.
9. Special Tools 149

Golf 2013 ➤
AG. Volkswagen AG d
agen oes
53 – Body Rear olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
RO: 53 05 55 50
ce
e
nl
1 Rear Cross Panel, Replacing
pt
du
an
itte
y li
erm
ab
⇒ “1.1 Tools”, page 151
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
WARNING
rrectness of i
l purpos
nform
mercia
at
om
i
Note
on
c
in t
or
his
te
To replace the rear cross panel the tail lamp mount and the corner
a
do
riv
reinforcement must be removed on one side.

p
cum
for
en
ng
t.
yi Co
• End crossmember already removed. Refer to Cop py
t. rig
⇒ “4 End Crossmember, Replacing”, page 168 . opyri
gh by
Vo
ht
by c lksw
• Tail lamp mount already removed. Refer to Prote
cted agen
⇒ “3 Tail Lamp Mount, Removing and Installing”, page 162 .
AG.
• The corner reinforcement is already removed. Refer to

⇒ “2 Corner Reinforcement, Replacing”, page 157 .
150 Rep. Gr.53 - Body Rear

Golf 2013 ➤
1 - Rear Cross Panel

2 - Bonded Area
❑ Bonded longitudinal
member area
3 - Tail Lamp Mount
❑ The marked area must
loosened and slightly
bent for the removal of
the back panel
4 - Bonded Area
❑ Bonded in the luggage
compartment floor area
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
1.1 Tools
h re
ole,
spec
t to the co
Note

rrectne

ss o

cial p
f in
Volkswagen AG.
form
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Rear Cross Panel, Replacing 151

Golf 2013 ➤
1.2 Removing AG. Volkswagen AG d

agen oes
olksw not
V gu
d by ara
e
Note horis nte
eo
aut ra
s c
To remove the rear back panel the marked areas -3- must be loosed and slightly bent. 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.

– Loosen the adhesive surfaces -1- and -2- from the luggage
compartment floor.
– Remove the rear back panel from the body.

Golf 2013 ➤
AG. Volkswagen AG d Body Repairs - Edition 02.2015
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.

– Apply corrosion protection to the adhesive surfaces, which will
not be welded. Refer to ⇒ Paint; Rep. Gr. 00 .
– Lightly sand the adhesive surfaces in the connection.
1.3 Installing
Note
Use only welding equipment approved by Volkswagen AG. Refer

to ⇒ “1.1 Tools”, page 151 .

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
Golf 2013 ➤ oris nte
eo
th
s au ra
c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
Replacement Part
ility
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.
– Sand welding surfaces to bare metal.

– Drill holes for SG plug weld seam, 7 mm diameter.

Golf 2013 ➤
AG. Volkswagen AG d Body Repairs - Edition 02.2015
agen oes
olksw not
y V gu
b ara
1.3.2 Welding
d
rise nte
tho eo
au ra
ss c
ce
le
un
Note
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Apply 2K Body Adhesive - D 180 003 M2- in the areas where

it was bonded during production.
– Fit new part -1- to vehicle standing on its wheels or on Align‐
ment Bracket Set and secure.
– Check rear lid closing function.

Golf 2013 ➤
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
– Weld in rear cross panel, straight-line spot weld seam and gas-
ercia

m
a
com
tion in
r
te o
Note
thi
s
iva
do
r
rp
Bend the bent areas back and weld them to the back panel.
um
fo
en
ng
t.
yi Co
op py
– Install the corner reinforcement. Refer to t. C rig
gh ht
⇒ “2.3 Installing”, page 159 . yri
p by
o Vo
by c lksw
cted
– Install the tail lamp mount. Refer to
agen
Prote AG.
– Install end crossmember. Refer to

Golf 2013 ➤
RO: 53 06 55 50
2 Corner Reinforcement, Replacing

⇒ “2.1 Tools”, page 158
DANGER!

Body Repairs, Body Collision Repair gen AG
. Volkswagen AG
d wa oes
olks not
byV gu
ara
d
ise nte
• End crossmember already removed. Referthotor eo
⇒ “4 End Crossmember, Replacing”, page
ss
au 168 . ra
c
ce
le
• Tail lamp mount already removed. Refer to

un
pt
an
d
⇒ “3 Tail Lamp Mount, Removing and Installing”, page 162 .

itte
y li
erm
ab
ility
ot p
1 - Corner Reinforcement
wit
is n
h re
❑ Inner corner reinforce‐
ole,
spec
ment
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Corner Reinforcement, Replacing 157

Golf 2013 ➤
2.1 Tools
Note

Volkswagen AG.
2.2 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
y li
erm
ab
ility
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
– Remove the corner reinforcement -1- from the body.

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

Golf 2013 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

2.3 Installing
Note

to ⇒ “2.1 Tools”, page 158 .

Replacement Part
♦ Corner reinforcement (replacement part name for ETKA Seal‐
ing channel reinforcement)

Golf 2013 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2.3.2 Welding
– Fit new part to vehicle standing on its wheels or on Alignment
Bracket Set and secure.

Golf 2013 ➤
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
– Weld the corner reinforcement, straight-line spot weld seam, pyri by
Vo
co
by lksw
cted agen
Prote AG.
– Install the tail lamp mount. Refer to

Golf 2013 ➤
AG. Volkswagen AG d
RO: 53 10 55 50 agen oes
olksw not
V
3 Tail Lamp Mount, Removing and In‐ by gu
d ara
ise nte
or
stalling h eo
aut ra
ss c
ce
le
⇒ “3.1 Tools”, page 163
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
DANGER!
t to the co
rrectness of i
l purpos
• End crossmember already removed. Refer to

⇒ “4 End Crossmember, Replacing”, page 168 .
nform
mercia
a
com
ti
1 - Tail Lamp Mount
on in
r
te o
thi
2 - Bonded Area
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Golf 2013 ➤
3.1 Tools
lkswage es n
o ot g
byV ua
d ran
Note o
ir se tee
th or
au ac
s
s
ce
only welding equipment approved by Volkswagen AG to per‐ e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Volkswagen AG.
wit
, is n
h re
hole
spec
3.2 Removing
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Loosen the bonded joints and remove the tail lamp assembly
mount from the body.
3. Tail Lamp Mount, Removing and Installing 163

Golf 2013 ➤
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

not be welded..
rrectne
3.3 Installing
ss o
cial p
f in

form
mer

atio
om
n
c
i
or
n thi
te
sd
va
Note
i
o
pr
cum
r
fo
en
ng
t.
yi Co
op
to ⇒ “3.1 Tools”, page 163 .
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Replacement Part
♦ Tail Lamp Assembly Mount

Golf 2013 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Drill 7 mm holes for the gas-shielded arc plug weld seam.

Golf 2013 ➤
AG. Volkswagen AG d
agen
3.3.2 Welding
by
Vol
ksw
oes
not
gu
ara
ed nte
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th
au ra
Note ss c
ce
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un
pt
an
d
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erm
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ility
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wit
is n
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ole,
spec
t to the co
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
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.


Golf 2013 ➤
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
– Weld the tail lamp assembly mount, straight-line spot weld

an
d
itte
seam, gas-shielded arc plug weld seam.

y li
rm
ab
pe
ility
ot
wit
, is n
Note
h re
hole
spec
Use a »heat shield« to avoid paint damage on side panel when welding it with tail light mount.
es, in part or in w
t to the co

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

Golf 2013 ➤
RO: 53 16 55 00
4 End Crossmember, Replacing lksw

agen
AG. Volkswagen AG d
oes
not
Vo gu
⇒ “4.1 Tools”, page 169 d by ara
ise nte
or eo
h
⇒ “4.2 Removing”, page 169 s aut ra
c
s
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e
nl
pt
du
an
itte
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erm
ab
ility
DANGER!
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
1 - End Crossmember
rrectness of i
2 - Separating Cut
l purpos
Partial renewal
Separation cut is permitted for
nform
ercia
the partial replacement.

m
at
om
io
3 - Bonded Area
n
c
in t
or
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ate
do
priv
cum
for
en
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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.

Golf 2013 ➤
4.1 Tools
Note

Volkswagen AG.
4.2 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
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
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4. End Crossmember, Replacing 169

Golf 2013 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

not be welded.
4.3 Installing
Note

to ⇒ “4.1 Tools”, page 169 .

Golf 2013 ➤

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

– Lightly grind the areas which will not be welded.

Golf 2013 ➤
4.3.2 Welding
Note
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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un
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an
d
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ot p
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is n
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spec
t to the co
rrectnes

s o
cial p

inform
mer

atio

om
n
c
i
or

thi
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– Check rear lid closing function.

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

Golf 2013 ➤
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
– Weld in the end crossmember -1-, straight line spot weld

rrectness of i
seam.
l purpos
Note
nform
mercia
For the partial replacement the illustrated separation cut -2- MIG soldered seams/gas-shielded arc continuous
at
om
io
weld seam are permitted.

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.

Golf 2013 ➤
RO: 53 24 55 50
5 Luggage Compartment Floor, Re‐

placing
⇒ “5.1 Tools”, page 175 agen
AG. Volkswagen AG d
oes
olksw not
V gu
⇒ “5.2 Removing”, page 176 d by ara
rise nte
o eo
⇒ “5.3 Installing”, page 177 auth
ra
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pt
an
d
itte
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Caution
erm
ab
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rrectness o
Note
cial p
f inform
mer
♦ For better illustration in the overview the left and right tail lamp
atio
m
mounts are not shown.

o
n
c
i
or
n
♦ The work procedure applies to vehicles with Front Wheel Drive
thi
te
sd
a
(Front Wheel Drive (FWD)).

iv
o
pr
cum
r
fo
en
ng
• Cross panel already removed. Refer to

t.
yi Co
op
⇒ “1 Rear Cross Panel, Replacing”, page 150 .
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2013 ➤
1 - Rear Luggage Compart‐

ment Floor
2 - Separating Cut
❑ Separating Cut for Par‐
tial Replacement
❑ Refer to
⇒ “4 Molded Foam
Parts”, page 5
4 - Spare Tire Retaining Brack‐
et
❑ In replacement part
area of the luggage
compartment floor not
included
5 - Bonded Area
lkswage es n
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wit
, is n
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hole
spec
es, in part or in w
t to the co
5.1 Tools
rrectness of i
l purpos
Note
nform
ercia

m

a
com
tio

n in
r
te o
thi

s
iva
do
Volkswagen AG.
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. Luggage Compartment Floor, Replacing 175

Golf 2013 ➤
5.2 Removing
Note
When performing the separation cut -1- pay attention that the reinforcement underneath is not damaged.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Perform the separating cut -1- as illustrated.
Note
Position the separation cut -1- in the spare wheel well area on the front edge. In this area fold the rear luggage
compartment floor over when installing and weld with a gas-shielded arc plug weld seam.

– Remove the rear luggage compartment floor -2- from the ve‐
hicle.

Golf 2013 ➤
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
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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
– Completely remove adhesive remains and grind welding sur‐
faces down to bare metal.
rrectness of i
l purpos
Note
nform
ercia
The adhesive applied during production in the rear area will be replaced with gas-shielded arc plug weld seam
welding.
m
a
com
tion in
r
te o
5.3 Installing
thi
s
iva
do
r
rp
⇒ “5.3.1 New Part, Preparing”, page 178

um
fo
en
ng
t.
yi
⇒ “5.3.2 Molded Foam Parts”, page 179
Co
Cop py
t. rig
gh
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note

to ⇒ “5.1 Tools”, page 175 .

Golf 2013 ➤

Replacement Part
♦ Rear luggage compartment floor (replacement part name: rear
floor panel)
♦ Spare Tire Retaining Bracket
♦ Two-Part Body Adhesive - D 180 003 M2-
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
– Transfer the separating cut to the new part, cut and remove
rrectness of i
the shaded area.

l purpos
Note
nform
mercia
Position the separation cut in the spare wheel well area on the rear edge. In this area fold the rear luggage
a
com
ti
compartment floor over when installing and weld with a gas-shielded arc plug weld seam.
on in
r
te o
thi
s
iva
– Drill holes for gas-shielded arc plug weld seam and stamp di‐
do
r
rp
ameter 7 mm.
um
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2013 ➤
– Weld the spare tire retaining bracket -1- to the luggage com‐
partment floor using a straight-line spot weld seam.

Observe repair notes.
Molded foam part. Refer to ⇒ General Information; Body Repairs,
Body Collision Repair
Position of molded foam parts. Refer to
⇒ “4 Molded Foam Parts”, page 5 .
5.3.3 Welding
Note
olkswagen AG
en AG. V
New part must be installed
Vol
within
ksw
ag
90 minutes, otherwise
does
not bonding properties of adhesive will be impaired.
by gu
ara
ed nte
oris eo
th
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
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.
– Apply Two-Part Body Adhesive - D 180 003 M2- in the area of

the rear longitudinal member.

Golf 2013 ➤
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
– Weld the luggage compartment floor with a gas-shielded arc
plug weld seam and a straight-line spot weld seam.
rrectness of i
– Weld the luggage compartment floor at the left and right tran‐
l purpos
sition to the front floor panel using a gas-shielded arc contin‐

uous weld seam.
nf
ercia
– Weld the overlap in the front upper spare wheel well area
or
-1-, gas-shielded arc plug weld seam.

m
m
atio
m
– Install the cross panel. Refer to ⇒ “1.3 Installing”, page 153 .

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

Golf 2013 ➤
RO: 53 24 55 50
6 Luggage Compartment Floor, Re‐

placing, with Hybrid Drive
Caution
Follow all safety precautions.

⇒ General Information; Body Repairs, Body Collision Repair
Note
mounts are not shown.
♦ The work procedure applies to vehicles with Front Wheel Drive
(FWD).
• Cross panel already removed. Refer to wage

es n
⇒ “1 Rear Cross Panel, Replacing”, page 150
yV .
olks ot g
u b ara
ed nte
oris e
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
6. Luggage Compartment Floor, Replacing, with Hybrid Drive 181

Golf 2013 ➤

2 - Bonded Area
ment Floor
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
6.1 Tools
is n
h re
ole,
spec
Note
t to the co
Due to the different types of steel and material strength, use only rrectne
service work.
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.

Golf 2013 ➤
6.2 Removing
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co

rrectness of i
l purpos
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.

Golf 2013 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co

rrectness of i

l purpos
Note
nform
ercia
m
welding.
com
tion in
r
te o
thi
6.3 Installing
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Note Cop py
t. rig
gh ht
pyri by
o Vo
by c lksw
cted
to ⇒ “6.1 Tools”, page 182 .
agen
Prote AG.

Replacement Part
floor panel)

Golf 2013 ➤
♦ Two-Part Body Adhesive - D 180 003 M2-
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.

Observe the repair information:
Body Collision Repair ; General Information, Molded Foam Com‐
ponents

Golf 2013 ➤
6.3.3 Welding
Note
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Apply Two-Part Body Adhesive - D 180 003 M2- in the area of

the rear longitudinal member.

Golf 2013 ➤
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

sition to the front floor panel using a gas-shielded arc contin‐
rrectness of i
uous weld seam.

l purpos

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

Golf 2013 ➤
Body Repairs - Edition 02.2015 AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
RO: 53 24 55 50 ho eo
ut ra
7 Luggage Compartment Floor, Re‐ ss a c
ce
e
placing, Hybrid Vehicles
nl
pt
du
an
itte
y li
erm
⇒ “7.1 Tools”, page 189
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Caution
rrectness of i
l purpos

nf
ercia
o
rm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
Note
o
m
f
en
ng
t.
yi Co
op
C py
ht. rig
mounts are not shown. rig ht
py by
co Vo
by lksw
♦ The work procedure applies to vehicles with Front Wheel Drive cted agen
Prote AG.
(Front Wheel Drive (FWD)).
• Cross panel already removed. Refer to

⇒ “1 Rear Cross Panel, Replacing”, page 150 .

Golf 2013 ➤

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

Volkswagen AG.
7. Luggage Compartment Floor, Replacing, Hybrid Vehicles 189

Golf 2013 ➤
7.2 Removing
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Golf 2013 ➤
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
Note
nform
ercia
m
welding.
a
com
tion in
r
te o
thi
7.3 Installing
s
iva
do
r
rp
cum

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

to ⇒ “6.1 Tools”, page 182 .

Golf 2013 ➤

Replacement Part
floor panel)
♦ 2K Body Adhesive - D 180 003waM2-
gen AG
. Volkswagen AG
does
ks not
Vol gu
d by ara
e nte
ris
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
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


Golf 2013 ➤
7.3.3 Welding
Note
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
– Apply 2K Body Adhesive - D 180 003 M2- in the area of the

atio
rear longitudinal member.

om
n
c

or
n thi
e

t
sd
iva
o
pr
cum

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

Golf 2013 ➤
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
va

i
o
pr
cum

r
fo
en
ng
t.
yi
Co
Cop py
sition to the front floor panel, gas-shielded arc continuous weld
t. rig
gh ht
yri
seam.
p by
co Vo
by lksw
cted agen
Prote AG.

Golf 2013 ➤
RO: 53 48 55 50
8 Rear Longitudinal Member, Replac‐

ing, Partial Section
⇒ “8.1 Tools”, page 196
Caution

• The luggage compartment floor panel is already removed. Re‐

fer to
⇒ “5 Luggage Compartment Floor, Replacing”, page 174 .
AG. Volkswagen AG d
agen oes
lksw not
1 - Rear Longitudinal Member d by Vo gu
ara
rise nte
2 - Separating Cut utho eo
ra
a
❑ Separating Cut for Par‐
ss c
ce
le
tial Replacement
un
pt
an
d
itte
3 - Molded Foam Part y li

erm
ab
❑ ⇒ “4 Molded Foam
ility
ot p
Parts”, page 5
wit
is n
h re
ole,
4 - Bracket
spec
❑ Must be remove to per‐

t to the co
form the separation cut

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.
8. Rear Longitudinal Member, Replacing, Partial Section 195

Golf 2013 ➤
-2-.
8.1 Tools
Note

olkswagen AG
en AG. V
♦ For a list of welding equipment
olks and body tools approved
wag does
noby
Volkswagen AG. db
yV t gu
ara
rise nte
tho eo
au ra
8.2 Removing
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Remove the original joint from the bracket -2-.

– Remove the bracket -2- from the rear longitudinal member
-1-.
– Label the separation cut -3- on the rear longitudinal member
-1- all around to the dimension -a-.

Golf 2013 ➤
– Perform the separation cut -3- on the rear longitudinal member
-1-.
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
– Perform the separation cut -2- to the dimension -a- on the rear co Vo
by lksw
longitudinal member -1-. cted agen
Prote AG.
– Remove the rear longitudinal member -1- from the body.

Golf 2013 ➤
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
8.3 Installing
nf
ercia
orm
m
atio

om
n in
or c

thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
Note
t.
yi Co
Cop py
t. rig
gh ht
Use only welding equipment approved by Volkswagen AG. Refer pyri by
Vo
o
to ⇒ “8.1 Tools”, page 196 .
c by lksw
cted agen
Prote AG.

Replacement Part
♦ Rear Longitudinal Member

Golf 2013 ➤
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.
– Remove the original joint from the bracket -2-.

– Remove the bracket -2- from the new part -1-.
Note
Remove the bracket -2- from the new part -1- so that it can be reused when reinstalling.
– Transfer the separation cut -1- from the assembly, cut the new
part and remove the shaded area.
8.3.2 Welding
– Install new part -1- with vehicle standing on the alignment
bracket set and affix it in place.

Golf 2013 ➤
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Weld the separating cut -3- all around; Gas-shielded arc con‐
tinuous weld seam. rrectness of i
l purpos
Note
nform
ercia
♦ The gas-shielded arc continuous weld seam cannot be reworked (sanded or smoothed).
m
at
♦ If the bracket -2 -on the rear longitudinal -1- member via gas-shielded arc continuous weld seam does not
om
ion
come into contact then »readjust« it.

c
in t
or
his
ate
do
riv
– Fit and secure the bracket -2-.

p
cum
for
en
g
– Weld the bracket -2- on both sides, gas-shielded arc plug weld
n
t.
yi Co
op
seam. C py
t. rig
gh ht
yri
– Install the luggage compartment floor panel. Refer to
p by
co Vo
by lksw
⇒ “5.3.3 Welding”, page 179 . Prote
cted AG.
agen
– Install rear cross panel. Refer to

⇒ “1.3.2 Welding”, page 155 .

Golf 2013 ➤
RO: 53 55 55 00
9 Side Panel, Replacing, 4-Door

⇒ “9.1 Tools”, page 202
WARNING

1 - Side Panel
❑ Sub-part
❑ ⇒ “9.3.1 Permitted Sep‐
arating Cuts on Whole
Side Panel”, page 205
2 - C-Pillar Separation Cut
❑ Refer to n AG. Volkswagen AG do
swage es n
⇒ “4 Molded Foam byV
olk ot g
ua
Parts”, page 5 ir se
d ran
te
ho eo
4 - Bonded Area aut ra
ss c
ce
le
5 - Wheel Arch Separation Cut

un
pt
an
d
itte
y li
Partial renewal
erm
ab

ility
ot p

wit
is n
h re
ole,
The separation cut is can be

spec
combined with other damage

separation cuts.
t to the co
6 - Separation Cut for Sill Pan‐

el
rrectne
❑ Observe replacement
panel separating cut
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. Side Panel, Replacing, 4-Door 201

Golf 2013 ➤
AG. Volkswagen AG d
agen oes
lksw not
9.1 Tools Vo gu
d by ara
ise nte
or eo
h
aut ra
ss c
Note
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
Volkswagen AG.
t to the co
9.2 Removing
rrectne
Note
ss o
cial p
♦ Only use the body Pneumatic Body Saw - VAS6780- to perform separating cuts. Do not damaged the inner
f in
reinforcements.
form
mer
atio
♦ Note the replacement part separating cut when making a separating cut -2-.
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.
– Perform the separation cut -1- to the dimension -a- and -b-.

Golf 2013 ➤

Dimension -b-= 100 mm AG. Volkswagen AG d
agen oes
olksw not
– Perform separating cut -2- as shown. d byV gu
ara
ise nte
r
– Separate the original joint. ut
ho eo
ra
s a c
s
– Sand down the outer edge of the wheel arch.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Dimension -b-= 100 mm
– Remove the side panel from the body.
Note
Foam residue -1- must be removed as much as possible before sanding work.

Golf 2013 ➤
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
– Clean the flanging area on wheel arch (it must be free of dust
and grease).
nform
ercia

m
not be welded.
com
tion in
r

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

Golf 2013 ➤
AG. Volkswagen AG d
agen oes
lksw not
9.3 Installing
o
byV gu
ara
ed
ris nte
o eo
⇒ “9.3.1 Permitted Separating aCuts
ut
h
on Whole Side Panel”, ra
page 205 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
Note
t to the co
rrectness of i
to ⇒ “9.1 Tools”, page 202 .
l purpos
9.3.1 Permitted Separating Cuts on Whole Side Panel
nf
ercia
orm
m
Note
atio
om
n in
or c
♦ Use only welding equipment approved by Volkswagen AG. Refer to ⇒ “9.1 Tools”, page 202 .
thi
te
sd
iva
o
♦ MIG soldered seams/gas-shielded arc continuous weld seam are permitted on the separating cuts shown
r
rp
cu
o
m
in the illustration.
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Golf 2013 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
ss
a ac
ce
le
un
pt
Replacement part
an
d
itte
y li
erm
♦ Side panel sub-part

ab
ility
ot p

wit
is n
h re
ole,
♦ 2K Polyurethane Adhesive - D 180 KD2 A1- (for the right side

spec
panel)
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
206
cted agen
Prote AG.
Rep. Gr.53 - Body Rear
Golf 2013 ➤
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
– Transfer separating cuts to new part and cut off shaded area.
rrectness of i

l purpos
ameter 7 mm.
nform
ercia

m
at
om
io

n
c
in t
or
his
ate

do
priv
cum
or

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

Golf 2013 ➤
9.3.4 Welding
Note
♦ For the lock reinforcement, omit the welding areas for the gas-shielded arc plug weld seam when applying
the 2K Body Adhesive - D 180 003 M2- .
♦ The thread for the striker pin mount must be cleaned after applying the adhesive.
♦ For the right side panel, 2K Polyurethane Adhesive - D 180 KD2 A1- must be applied near the fuel filler tube
before welding.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo

en
ng
t.
yi Co
op
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
– Check fit with attachments. cted agen
Prote AG.

Golf 2013 ➤
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
– Weld in the side panel -1-, Straight-line spot weld seam and
ot
wit
, is n

h re
hole
– Weld the separation cuts, either MIG soldered seam/gas-

spec
es, in part or in w

t to the co
– Reform the wheel arch flange -2- and remove any escaped
adhesive.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2013 ➤
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 the side panel in the area of the sealing channel either
MIG soldered seams/gas-shielded arc continuous weld seam
is permitted.
– Weld the connection tail lamp assembly mount, gas-shielded
arc plug weld seam.

Golf 2013 ➤
RO: 53 55 55 10
10 Side Panel, Replacing, 2-Door Vehi‐

cle
⇒ “10.1 Tools”, page 212
WARNING

1 - B-Pillar Separating Cut

❑ Can be set to any height
2 - Bonded Area
3 - Side Panel
❑ Sub-part
❑ Refer to n AG. Volkswagen AG do
swage es n
⇒ “10.3.1 Permitted byV
olk ot g
ua
Separating Cuts ir seon
d ran
tee
Whole Side uPanel”,
tho
or
page 215 ss a ac
ce
le
4 - C-Pillar Separation Cut

un
pt
an
d
itte
y li

erm
ab
ility
ot p
❑ Refer to
wit
is n
h re
Parts”, page 5
ole,
spec
6 - Wheel Arch Separation Cut

t to the co
Partial renewal
rrectne
The separation cut is can be

s
combined with other damage

s o
cial p
separation cuts.
inform
mer
7 - Separation Cut for Sill Pan‐

atio
m
el
o
n
c
i
or
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.
10. Side Panel, Replacing, 2-Door Vehicle 211

Golf 2013 ➤
10.1 Tools
Note

n AG. Volkswagen A
♦ For a list of welding equipment and
olks
wbody
age tools approved by
G do
es n
o
Volkswagen AG. db
yV t gu
ara
rise nte
tho eo
10.2 Removing au ra
ss c
ce
e
nl
pt
du
an
itte
y li
Note
erm
ab
ility
ot p
♦ Only use the body Pneumatic Body Saw - VAS6780- to perform separating cuts. Do not damaged the inner
wit
, is n
h re
reinforcements.
hole
spec
♦ For the separation cut -1- and -3- pay attention to the replacement part separation cut.
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.
– Perform the separating cut -1- and -3- as illustrated.

Golf 2013 ➤
– Perform the separation cut -2- to the dimension -a- and -b-.
– Sand down the outer edge of the wheel arch.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i

l purpos

nform
ercia
– Remove the side panel from the body.

m
a
com
tion in
Note
r
te o
thi
s
iva
do
Foam residue -1- must be removed as much as possible before sanding work.
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2013 ➤
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
r

o
his
ate
do
riv

p
cum
or

f
en
ng
t.
yi Co
– Clean the flanging area on wheel arch (it must be free of dust Cop py
and grease).
t. rig
gh ht
pyri by
Vo
co
by lksw
cted agen
Prote
not be welded.
AG.

Golf 2013 ➤
10.3 Installing
⇒ “10.3.1 Permitted Separating Cuts on Whole Side Panel”, page
215
⇒ “10.3.4 Welding”, page 218
Note

to ⇒ “10.1 Tools”, page 212 .
AG. Volkswagen AG d
agen oes
olksw not
10.3.1 Permitted Separating Cuts on Whole Side Panel ised byV gu
ara
nte
or eo
h
aut ra
ss c
Note
ce
e
nl
pt
du
an
itte
y li
♦ Use only welding equipment approved by Volkswagen AG. Refer to ⇒ “10.1 Tools”, page 212 .
erm
ab
ility
ot p
♦ MIG soldered seams/gas-shielded arc continuous weld seam are permitted on the separating cuts shown
wit
, is n
in the illustration.
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.

Golf 2013 ➤
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Replacement Part
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♦ Side panel sub-part t. C rig
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♦ 2K Polyurethane Adhesive - D 180 KD2 A1- (for the right side
panel)

Golf 2013 ➤
AG. Volkswagen AG d
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– Transfer separating cuts to new part and cut off shaded area.
nform
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m
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com
tion in
r
te o
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ameter 7 mm.
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Observe repair notes. py by
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AG. Volkswagen AG d
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Golf 2013au➤
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Body Repairs
s - Edition 02.2015
ce
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10.3.4 itte Welding
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Note
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♦ For the right side panel, 2K Polyurethane Adhesive - D 180 KD2 A1- must be applied near the fuel filler tube
before welding.
rrectness of i
l purpos
nform
mercia
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te o
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Cop py
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Golf 2013 ➤
AG. Volkswagen AG d
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aut ra
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nl
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c
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do
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t.
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Cop py
t. rig
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– Weld in the side panel -1-, Straight-line spot weld seam and
– Weld the separation cuts, either MIG soldered seam/gas-
– Reform the wheel arch flange -2- and remove any escaped
adhesive.

Golf 2013 ➤
agen
AG. Volkswagen AG d
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te o
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Cop py
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py by
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Prote AG.
– Weld the side panel in the area of the sealing channel either
MIG soldered seams/gas-shielded arc continuous weld seam
is permitted.
– Weld the connection tail lamp assembly mount, gas-shielded
arc plug weld seam.

Golf 2013 ➤
RO: 53 69 55 50
11 Outer Wheel Housing Liner, Replac‐

ing
⇒ “11.1 Tools”, page 222
Includes: Lock Reinforcement

AG. Volkswagen AG d
agen oes
Caution Volksw not
gu
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Follow all safety precautions. Refer to ⇒ General
ut Information;
ho eo
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Body Repairs, Body Collision Repair ss a c
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nl
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Note
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The removal and installation of the outer wheel housing liner is
hole
spec
describes for a 4-door vehicle. The removal and installation for 2-
es, in part or in w
door vehicles is identical to the following description.
t to the co
• Side panel in 4-door vehicle already removed. Refer to
⇒ “9 Side Panel, Replacing, 4-Door”, page 201 .
rrectness of i
• Side panel in 2-door vehicle already removed. Refer to
l purpos
⇒ “10 Side Panel, Replacing, 2-Door Vehicle”, page 211
nform
mercia
at
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c
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or
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for
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t.
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Prote AG.
11. Outer Wheel Housing Liner, Replacing 221

Golf 2013 ➤
1 - Outer Wheel Housing Liner

2 - Lock Reinforcement
3 - Molded Foam Part
❑ Refer to
Parts”, page 5
4 - Bonded Area
lkswage es n
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nf
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orm
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or c
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11.1 Tools
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Prote AG.
Note

Volkswagen AG.

Golf 2013 ➤
11.2 Removing
AG. Volkswagen AG d
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– Remove the bonded areas -1- on the lock reinforcement.

h re
ole,
spec
– Remove the lock reinforcement from the outer wheel housing

liner.
t to the co
rrectness o
cial p
f inform
mer
atio
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n
c
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Cop py
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Prote AG.

Golf 2013 ➤
AG. Volkswagen AG d
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un
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spec
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mer
atio
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n
c
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or
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sd
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fo
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t.
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Cop py
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Prote AG.

– Carefully remove the molded foam part -2- from the outer
wheel housing liner -1-.
Note
Remove the molded foam part -2- from the outer wheel housing liner -1-, so that is can be installed again.
– Remove the outer wheel housing liner -1- from the body.

lkswage es n Golf 2013 ➤
o ot g
byV Body ua Repairs - Edition 02.2015
d ran
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tho
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a ac
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c
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ate
do
priv
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for
en
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Cop py
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Prote AG.

not be welded.
11.3 Installing
⇒ “11.3.2 Welding”, page 227
Note

to ⇒ “11 Outer Wheel Housing Liner, Replacing”, page 221 .

Golf 2013 ➤

Replacement Part
♦ Outer wheel housing liner
♦ Lock reinforcement
AG. Volkswagen AG d
agen oes
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cial p
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mer
atio
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c
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t.
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Cop py
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rig ht
py by
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Prote AG.
– Drill holes for SG plug weld seam, 7 mm diameter.


Golf 2013 ➤
11.3.2 Welding
Note
AG. Volkswagen AG d
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c

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t.
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– Check fit with side panel. . C rig
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rig by
copy Vo
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Prote AG.

Golf 2013 ➤
AG. Volkswagen AG d
agen oes
olksw not
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ara
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ris nte
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ce
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un
pt
an
d
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ab
pe
ility
ot
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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.
– Weld the outer wheel housing liner -1- straight-line spot weld
seam, gas-shielded arc plug weld seam.
– Reinsert the molded foam part -2-. Refer to

Golf 2013 ➤
AG. Volkswagen AG d
agen oes
olksw not
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au ra
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un
pt
an
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the lock reinforcement was bonded during production.

itte
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ab
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ot
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r
te o
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s
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rp
cum
fo
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t.
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Cop py
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by
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Prote AG.

Golf 2013 ➤
Body Repairs - Edition 02.2015 lkswage es n
o ot g
byV ua
d ran
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u or
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ab
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is n
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spec
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mer
atio
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c
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fo
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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.
– Weld the lock reinforcement with a straight-line spot weld

seam.
– Install the 4-door side panel. Refer to
– Install the 2-door side panel. Refer to

Golf 2013 ➤
12 Special Tools
♦ Alignment Bracket Set
♦ Pneumatic Body Saw - VAS6780-
Edition 03/25/2015 - K0059210121 - FU - JY AG. Volkswagen AG d

agen oes
olksw not
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mer
atio
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c
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t.
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Cop py
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Prote AG.
12. Special Tools 231

Golf 2013 ➤
13 Revision History
Re Dat Job Type Feedback # Notes Editor
vi‐ e
sio
n
2 03/ Factory Up‐ Yam‐

AG. Volkswagen AG d
25/ date brick ksw
agen oes
not
201 by
Vol
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5 rised
nte
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1 11/ Factory Up‐ Yam‐s au ra
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12/ date brick
s
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201
un
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4 itte
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mer
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t.
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Cop py
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Prote AG.

Cautions & Warnings
Please read these WARNINGS and CAUTIONS before proceeding with maintenance
and repair work. You must answer that you have read and you understand these
WARNINGS and CAUTIONS before you will be allowed to view this information.
•= If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this manual, we
suggest you leave such repairs to an authorized Volkswagen retailer or other qualified shop. We especially urge
you to consult an authorized Volkswagen retailer before beginning repairs on any vehicle that may still be covered
wholly or in part by any of the extensive warranties issued by Volkswagen.
•= Disconnect the battery negative terminal (ground strap) whenever you work on the fuel system or the electrical
system. Do not smoke or work wage
olks near heaters or other fire
es n hazards. Keep an approved fire extinguisher handy.
ot
yV gu
db ara
rise nte
•= Volkswagen is constantly
tho improving its vehicles and sometimes ethese
or changes, both in parts and specifications,
u ac in this manual are for reference only. Always
are made applicable
ss a to earlier models. Therefore, part numbers listed
check with your authorized Volkswagen retailer parts department for the latest information.
ce
e
nl
pt
du
an
itte
y li
•= Any time the battery has been disconnected on an automatic transmission vehicle, it will be necessary to
erm
ab
ility
reestablish Transmission Control Module (TCM) basic settings using the VAG 1551 Scan Tool (ST).
ot p
wit
, is n
h re
•= Never work under a lifted vehicle unless it is solidly supported on stands designed for the purpose. Do not support
hole
spec
a vehicle on cinder blocks, hollow tiles or other props that may crumble under continuous load. Never work under a
es, in part or in w
vehicle that is supported solely by a jack. Never work under the vehicle while the engine is running.
t to the co
•= For vehicles equipped with an anti-theft radio, be sure of the correct radio activation code before disconnecting the rrectness of i
battery or removing the radio. If the wrong code is entered when the power is restored, the radio may lock up and
become inoperable, even if the correct code is used in a later attempt.
l purpos
•= If you are going to work under a vehicle on the ground, make sure that the ground is level. Block the wheels to
nform
ercia
keep the vehicle from rolling. Disconnect the battery negative terminal (ground strap) to prevent others from
starting the vehicle while you are under it.
m
at
om
ion
c
in t
r
•= Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to yourself and
o
his
te
others if you are tired, upset or have taken medicine or any other substances that may impair you or keep you from
a
do
riv
being fully alert.

p
cum
for
en
ng
t.
yi Co
•= Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills. . Cop py
rig
ht ht
rig by
py
•=
Vo
Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid. Wear
co lksw
by
cted agen
goggles, gloves and other protective clothing whenever the job requires working with harmful substances.
Prote AG.
•= Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near
machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery, severe
injury could result.
•= Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used
only once and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts,
washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners with
new parts where indicated, and any other time it is deemed necessary by inspection.
Page 1 of 3
© 2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0
Cautions & Warnings
•= Illuminate the work area adequately but safely. Use a portable safety light for working inside or under the vehicle.
olkswagen AG
Make sure the bulb is enclosed by a wire cage. The hot filament of san agen AG. V
accidentally broken dbulb
oes can ignite spilled
lk w not
fuel or oil. by Vo gu
a
ed ran
ris tee
tho
•= Friction materials such as brake pads and clutch discs amay
u contain asbestos fibers. Do not create dust by or
ac
s
grinding, sanding, or by cleaning with compressed air. Avoid breathing asbestos fibers and asbestos dust.
s
ce
le
un
Breathing asbestos can cause serious diseases such as asbestosis or cancer, and may result in death.
pt
an
d
itte
y li
erm
ab
•= Finger rings should be removed so that they cannot cause electrical shorts, get caught in running machinery, or be
ility
ot p
crushed by heavy parts.
wit
is n
h re
ole,
•= Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the
spec
instructions thoroughly; do not attempt shortcuts. Use tools that are appropriate to the work and use only
t to the co
replacement parts meeting Volkswagen specifications. Makeshift tools, parts and procedures will not make good
repairs.
rrectne
•= Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or beverage containers that
might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills at
ss
once, but do not store the oily rags, which can ignite and burn spontaneously.
o
cial p
f inform
•=
mer
Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten
atio
fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque
om
n
listed.
c
i
or
n thi
te
sd
va
•= Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping hydrogen gas is
i
o
pr
cum
r
ignited, it will ignite gas trapped in the cells and cause the battery to explode.
fo
en
ng
i t.
py Co
Co py
•= Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of rig
ht. rig
ht
the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local ordinances that py by
co Vo
by lksw
govern the disposal of wastes. Prote
cted AG.
agen
•= The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C system should be
serviced only by trained automotive service technicians using approved refrigerant recovery/recycling equipment,
trained in related safety precautions, and familiar with regulations governing the discharging and disposal of
automotive chemical refrigerants.
•= Before doing any electrical welding on vehicles equipped with anti-lock brakes (ABS), disconnect the battery
negative terminal (ground strap) and the ABS control module connector.
•= Do not expose any part of the A/C system to high temperatures such as open flame. Excessive heat will increase
system pressure and may cause the system to burst.
•= When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the Transmission
Control Module (TCM), the ABS control module, and the trip computer. In cases where one or more of these
components is not separately fused, disconnect the control module connector(s).
•= Some of the vehicles covered by this manual are equipped with a supplemental restraint system (SRS), that
automatically deploys an airbag in the event of a frontal impact. The airbag is operated by an explosive device.
Handled improperly or without adequate safeguards, it can be accidentally activated and cause serious personal
injury. To guard against personal injury or airbag system failure, only trained Volkswagen Service technicians
should test, disassemble or service the airbag system.
Page 2 of 3
Version 1.0
Cautions & Warnings
•= Do not quick-charge the battery (for boost starting) for longer than one minute, and do not exceed 16.5 volts at the
battery with the boosting cables attached. Wait at least one minute before boosting the battery a second time.
AG. Volkswagen
agen AG do
lksw es n
o ot g
•= Never use a test light to conduct electrical tests of the airbag yV
bsystem. The system must only be tested
ran by trained
d ua
ise
Volkswagen Service technicians using the VAG 1551 Scan or Tool (ST) or an approved equivalent. The teairbag
eo unit
h
ut ra
must never be electrically tested while it is not installed
ss a in the vehicle. c
ce
e
nl
pt
du
•= Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that may have been
an
itte
y li
inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of ignition away from the tire repair
erm
ab
ility
area. Inflate and deflate the tire at least four times before breaking the bead from the rim. Completely remove the
ot p
wit
tire from the rim before attempting any repair.
, is n
h re
hole
spec
•= When driving or riding in an airbag-equipped vehicle, never hold test equipment in your hands or lap while the
es, in part or in w
t to the co
vehicle is in motion. Objects between you and the airbag can increase the risk of injury in an accident.
rrectness of i
I have read and I understand these Cautions and Warnings.
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
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Prote AG.
Page 3 of 3
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00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8 Body Panel Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

8.1 Body Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

8.3 Body, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

8.4 Front Floor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

8.6 Rear Floor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 Subframe Mounting Bracket, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

2 Front Bumper Bracket, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

51 - Body Center, Chassis, Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

3.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

4 A-Pillar Reinforcement, Replacing Partial Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

4.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

53 - Body Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

2.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

8.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

9 Side Panel, Replacing, 4-Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

9.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

9.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

9.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

11 Outer Wheel Housing Liner, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

11.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

11.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

11.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

12 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

13 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

00 – General, Technical Data

The VIN -1- is in the direction of travel under the windshield on

♦ The VIN is stamped on three additional positions on the vehi‐

2 Rep. Gr.00 - General, Technical Data

2.2 Type Plate

2.3 Vehicle Data Label

The vehicle data label is located in the luggage compartment

to ⇒ General Information; Body Repairs, Body Collision Repair

4 Rep. Gr.00 - General, Technical Data

4 Molded Foam Parts

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

the temperature is approximately 180 °C. For this reason, use

4. Molded Foam Parts 5

– Remove excess foam from vehicle.

Cord - AKL 450 005 05- .

The foam hardens within 25 minutes.

ded foam part.

6 Rep. Gr.00 - General, Technical Data

5 Galvanized Body Parts and High-

formed steel can be only be repaired with inverter technology for

General information applies to all work on higher-strength body

panels. Refer to ⇒ General Information; Body Repairs, Body Col‐

ized steel panels.

steel, are shown in color in the following illustrations (see Table).

8 Rep. Gr.00 - General, Technical Data

10 Rep. Gr.00 - General, Technical Data

5.3 4-Door Vehicle

out of »standard« body steel.

12 Rep. Gr.00 - General, Technical Data

♦ Use the Gauge - Gap Adjustment - 3371- to adjust or check.

7.1 Body Front

14 Rep. Gr.00 - General, Technical Data

Dimension -a- = 2.5 mm ± 0.5 mm