Amarok 2

Service
Body Repairs
Amarok 2011
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Edition 10.2010
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Service Department. Technical Information
Service
Repair Group overview for Body Repairs
Repair Group
00 - Technical data
50 - Body - front
51 - Body - centre
53 - Body - rear
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Technical information should always be available to the foremen and mechanics, because their
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.
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All rights reserved.

No reproduction without prior agreement from publisher.
Copyright 2010 Volkswagen AG, Wolfsburg
D3E8027D416
Amarok 2011
Body Repairs - Edition 10.2010
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1.1
1.2
1.3
2
3
4
5
5.1
5.2
5.3
5.4
5.5
5.6
6
6.1
6.2
6.3
6.4
6.5
6.6
7
7.1
7.2
7.3
7.4
7.5
Key vehicle data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Moulded foam elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Galvanized body parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body panel gaps/shut lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body - centre, vehicles with double cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body - centre, vehicles with single cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body - rear, vehicles with double cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body - rear, vehicles with single cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body add-on parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Double cab frame dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Single cab frame dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Double cab box dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Single cab box dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Double cab load surface dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Single cab load surface dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alignment jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alignment bracket fixture overview of complete vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alignment bracket fixture overview of vehicle chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. Volkswagen AG
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Alignment bracket fixture overview of vehiclelkcab
swa . . . . . . . . . . . . . .do. e.s.no. . . . . . . . . . . . . . .
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Alignment bracket fixture overview of vehicle
cab . . . . . . . . . . . . . . . . . . t.gu. a.ra. . . . . . . . . . .
by
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1
1
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3
3
4
5
7
8
8
9
10
11
12
13
15
15
21
23
28
31
34
36
36
36
37
38
39
50 - Body - front . . . . . . . . . . . . . . . .s a.ut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .or .ac . . . . . 41

s
Renewing cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing deformation element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing headlight mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing wing connecting plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing connection piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing upper wheel housing longitudinal member . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41
42
43
46
46
46
47
50
50
50
53
57
57
58
59
62
62
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64
66
66
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1
1.1
1.2
2
2.1
2.2
2.3
3
3.1
3.2
3.3
4
4.1
4.2
4.3
5
5.1
5.2
5.3
6
6.1
Contents
Amarok 2011
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing front wheel housing . . . . . . n. A. G. ..V.ol.ks. w. a.g.en. A. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gd
ge
Removing . . . . . . . . . . . . . . . .V.ol.ks.w.a. . . . . . . . . . . . . . . . o.e.s n. o.t . . . . . . . . . . . . . . . . . . . . . .
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Installing . . . . . . . . . . . . .is.e.d b. . . . . . . . . . . . . . . . . . . . . . . . . . . . .ar.an. . . . . . . . . . . . . . . . . . .
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Renewing front part of alongitudinal
member - part section 1- . . . . . . . .or.a . . . . . . . . . . . . . . .
c
s
Removing . . . . . . . .s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing longitudinal member - part section 2- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing longitudinal member complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
rrectness of i
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6.2
6.3
7
7.1
7.2
8
8.1
8.2
9
9.1
9.2
10
10.1
10.2
66
68
71
71
72
75
75
77
81
81
83
89
90
97
51 - Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
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Contents
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Renewing roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing front cross member for roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing roof reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing rear roof cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing rear window frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing hinge pillar (A-pillar) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing hinge pillar (A-pillar) reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing centre pillar (B-pillar) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing centre pillar (B-pillar) reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing lock pillar (C-pillar) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
do
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1
1.1
1.2
1.3
2
2.1
2.2
3
3.1
3.2
4
4.1
4.2
5
5.1
5.2
6
6.1
6.2
7
7.1
7.2
7.3
8
8.1
8.2
8.3
9
9.1
9.2
9.3
10
10.1
10.2
10.3
11
11.1
110
110
112
113
117
117
118
121
121
122
125
125
126
129
130
131
135
135
136
139
140
141
142
148
149
149
150
154
155
155
157
160
161
161
163
166
167
Amarok 2011
11.2
11.3
12
12.1
12.2
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing mounting bracket for front seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
167
170
174
174
175
53 - Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

1
1.1
1.2
2
2.1
2.2
3
3.1
3.2
Renewing rear cross panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing rear longitudinal member - part section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing rear side panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
178
179
180
184
184
186
190
191
194
rrectness of i
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Contents
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Amarok 2011
Amarok 2011
00
Technical data
Key vehicle data
1.1
Vehicle identification number

Note
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If components into which the vehicle ID number (chassis number) is stamped are renewed in the event of
damage, a surveyor must be involved prior to repair.
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Vehicle identification number (chassis number) on the body:

The vehicle identification number (chassis number) is visibly
stamped into the lower left windscreen flange -arrow A-.
1. Key vehicle data
Amarok 2011
Vehicle identification number (chassis number) on the vehicle
frame:
The vehicle identification number (chassis number) is visibly
stamped into the right vehicle frame
longitudinal member
AG. Volkswagen AG d
-arrow B-.
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According to the legislation in Brazil, Argentina and Mexico, a shortened vehicle ID number (chassis num
ber) is located at 3 further points within the vehicle.
The additional identification consists of an identification plate which cannot be removed without destroying
rrectness of i
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Additional, shortened vehicle identification number (chassis num

ber) for Brazil, Argentina and Mexico:
The vehicle identification number (chassis number) is stuck on
to the right wheel housing in the engine compartment
-arrow A-.
to the right front passenger seat -arrow C-.
Rep. gr.00 - Technical data
1.2
Identification plate
The identification plate -arrow- is stuck on the left B-pillar.
Vehicle data sticker

r
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The vehicle data sticker -arrow- is located in the footwell on

the driver's side.
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to the right B-pillar -arrow B-.
Amarok 2011
- Edition 10.2010
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Body
Repairs
eo
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s
1. Key vehicle data
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Amarok 2011
Safety instructions
WARNING
AG. Volkswagen AG d
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Before beginning any cutting, alignment or dent removal, refer

to safety notes in the binder General information, body repairs
and general body repairs.
Amarok 2011
Moulded foam elements

Note
Various body cavities in the Amarok 2010 have been fitted
with moulded foam elements.
The moulded foam elements reduce the amount of driving
noise that is transmitted into the interior.
The moulded elements are fitted during body shell construc
tion and increase their volume in the paint shop drying oven
at approx.180C, after priming.
The exact locations of these moulded foam elements are ad
ditionally shown at the beginning of the respective repair de

scriptions.
es, in part or in w
l purpos
hole
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4 - Lower A-pillar
Moulded foam element
between A-pillar outer
skin and A-pillar rein
forcement.
between A-pillar rein
forcement and inner
panel.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
3 - Lower B-pillar
between B-pillar outer
skin and B-pillar rein
forcement.
between B-pillar rein
forcement and inner
panel.
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2 - Lower C-pillar
between C-pillar outer
skin and C-pillar rein
forcement.
between C-pillar rein
forcement and inner
panel.
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1 - Upper A-pillar
between A-pillar outer
skin and A-pillar rein
forcement.
between A-pillar rein
forcement and inner
panel.
As these temperatures cannot be achieved under normal work

shop conditions, proceed as follows:
Remove foam material remains on vehicle.
3. Moulded foam elements
Amarok 2011
Restore the paint work structure. If necessary, apply two coats
(wet in wet) of glass/paint primer -D 009 200 02- (apply the
second coat in the opposite direction) - flash-off time of about
10 minutes.
Prerequisites
Before continuing with this procedure, ensure that the part for
replacement is correctly prepared e.g. cut and adapt to fit,
corrosion protection measures.
Renewing moulded foam element
a
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Fix moulded foam element to vehicle.
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rrectness of i
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his
Carry out cavity preservation on repair area after painting ve

hicle.
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es, in part or in w
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hole
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Do not do perform shielded arc welding within 15 mm on either

side of moulded foam element.
ility
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Secure new part (e.g. A-pillar)
ut in position. Apply gentle pres
sure to contact new part in sarea
of moulded foam element and
sa
weld in.
does
not
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Wrap moulded foam element with sealing cord -AKD 497 010
04 R10- all round.
. Volkswagen AG
gen AG
Amarok 2011
Galvanized body parts
The vehicle consists partly of body panels galvanized on one or

both sides!
AG. Volkswagen AG d
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Before carrying out body repairs observe the following information

General Information; Body Repairs, General Body Repairs .
4. Galvanized body parts
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Amarok 2011
Body panel gaps/shut lines

Note
Use setting gauge -3371- to set or check shut lines.
5.1
Body - front
A - 2.5 mm + 1.5 mm
B - 3.0 mm + 0.5 mm
C - 5.0 mm 0.5 mm
D - 2.0 mm 1.0 mm
E - 10.5 mm + 1.0 mm
F - 4.0 mm + 1.0 mm
AG. Volkswagen AG d
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G - 8.7 mm + 2.0 mm
Amarok 2011
5.2
Body - centre, vehicles with double cab
H - 0.5 mm 0.3 mm
I - 4.2 mm 0.5 mm
J - 5.0 mm 0.75 mm
K - 7.0 mm 1.0 mm
es n
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L - 34.5 mm 1.5 mm
5. Body panel gaps/shut lines
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Amarok 2011
5.3
Body - centre, vehicles with single cab
J - 5.0 mm 0.75 mm
K - 7.0 mm 1.0 mm
M - 2.5 mm 0.3 mm
Q - 3.0 mm 0.3 mm
R - 35.0 mm 5.0 mm
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Amarok 2011
5.4
Body - rear, vehicles with double cab
B - 3.0 mm + 0.5 mm
M - 2.5 mm 0.3 mm
N - 20.0 mm 5.0 mm
P - 2.0 mm 0.5 mm
R - 35.0 mm 5.0 mm
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V - 1.0 mm 0.3 mm
AG. Volkswagen AG d
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O - 6.0 mm 1.0 mm
11
Prote
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Amarok 2011
5.5
Body - rear, vehicles with single cab
B - 3.0 mm + 0.5 mm
O - 6.0 mm 1.0 mm
P - 2.0 mm 0.5 mm
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rrectness of i
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nf
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m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
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AG. Volkswagen AG d
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Amarok 2011
5.6
Body add-on parts
S - 1.0 mm + 0.5 mm / - 1.0 mm

Shut line between wheel
cover and body part.
AG. Volkswagen AG d
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s
s
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f
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spec
atio
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n
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T - 3.0 mm 1.0 mm
Height difference be
tween wheel cover and
drop sides.
13
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Amarok 2011
AG. Volkswagen AG d
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14
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
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thi
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is n
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U - 10.5 mm 3.0 mm
Shut line between rear
bumper and drop sides.
Amarok 2011
Body dimensions
Note
Dimensions only given for checking purposes. The alignment
bracket set is definitive. Bolts, screws, plugs, trim and attached

components must be removed before starting the measuring
process.
Use Telescopic gauge -VAS 5159- or Telescopic gauge -VAS
5160- to determine body dimensions.
6.1
Double cab frame dimensions
6.1.1
Front frame dimensions
Frame dimensions between front frame longitudinal members

Ma a - 1,320 mm 4.0 mm
Dimension between cab
mounting 2
Ma b - 1,015 mm 3.0 mm
Dimension between
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Ma c - 660 mm 3.0 mm
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Inner dimension be
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6. Body dimensions
15
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Ma c - 840 mm 2.0 mm
Dimension between
front axle mountings
Amarok 2011
6.1.2
Centre frame dimensions
Lower centre frame dimensions

Ma a - 780 mm 2.0 mm
Dimension between
front axle rear mount
ings
Ma b - 810 mm 3.0 mm
Dimension between
gearbox mountings
Ma c - 490 mm 2.5 mm
Dimension between re
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Upper centre frame dimensions
6. Body dimensions
17
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Amarok 2011
Ma a - 1,340 mm 4.0 mm
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Dimension between
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Dimension between
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Dimension between
point 1
Amarok 2011
6.1.3
Rear frame dimensions
Upper centre frame dimensions

Ma a - 1,340 mm 4.0 mm
mounting 3
Ma b - 1,100 mm 4.0 mm
Dimension between
point 1
Ma c - 1,100 mm 4.0 mm
Dimension between
point 2
Ma d - 1,100 mm 4.0 mm
Dimension between
point 3
Ma e - 910 mm 3.0 mm
Inner dimension be
tween frame rear longi
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6. Body dimensions
19
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Amarok 2011
Ma a - 1,345 mm 4.0 mm
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Ma b - 1,658 mm
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Dimension
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point 3 on left
Ma c - 1,195 mm 4.0 mm
bolting point 2 on left
point 3 on right
Ma d - 1,488 mm 2.5 mm
Dimension between
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Amarok 2011
Single cab frame dimensions
6.2.1
Front frame dimensions

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Frame dimensions between front frame longitudinal members

Ma a - 1,320 mm 4.0 mm
mounting 2
Ma b - 1,015 mm 3.0 mm
Dimension between
suspension strut mount
ings
Ma c - 660 mm 3.0 mm
between assembly
mountings
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Ma f - 800 mm 3.0 mm
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Ma d - 645 mm 3.0 mm
Dimension between as
sembly mountings
Front lower frame dimensions
6. Body dimensions
21
Amarok 2011
Ma a - 800 mm 3.0 mm
Inner dimension be
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Prote
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Centre frame dimensions were not yet available at time of going

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

print!
22
AG.
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Centre frame dimensions
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Ma c - 840 mm 2.0 mm
Dimension between
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Ma b - 815 mm 2.0 mm
Dimension between an
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Amarok 2011
6.3
Double cab box dimensions
6.3.1
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Front box dimensions
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Ma - 956 mm 1.0 mm
Dimension between
lock carrier bolting
points
Ma - 1,412 mm 2.0 mm
Dimension between
lamp carriers
Ma - 982 mm 2.0 mm
Dimension between
wheel housings
Ma - 758 mm 2.0 mm
Dimension wing mount
ing flange
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between left wing
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6. Body dimensions
23
Amarok 2011
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Dimension between
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Ma - 1,500 mm 2.0 mm
Dimension between
lower part of front lamp
carriers
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Ma - 935 mm 1.0 mm
Dimension between up
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Ma - 217 mm 2.0 mm
Dimension cross mem
ber to lamp carrier
Ma - 270 mm 2.0 mm
Dimension cross mem
ber to lamp carrier
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Front end box dimensions
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Ma - 950 mm 3.0 mm
Dimension between Apillar and front end
Amarok 2011
rrectness of i
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Ma - 1,067 mm 2.0 mm
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6. Body dimensions
25
ht
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Amarok 2011
6.3.2
Centre box dimensions

Ma - 1,870 mm 3.0 mm
Dimension between Apillars
Ma - 1,870 mm 3.0 mm
Dimension between Bpillars
Ma - 420 mm 2.0 mm: Di
mension
Upper door hinge to low
er door hinge on A-pillar
Ma - 445 mm 2.0 mm
Upper door hinge to low
er door hinge on B-pillar
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26
rrectness of i
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6.3.3
Rear box dimensions
Rear box dimensions

Ma - 1,195 mm 2.0 mm
Dimension between
roof side members
Ma - 1,465 mm 2.0 mm
Dimension rear panel
aperture
Ma - 340 mm 2.0 mm
Dimension rear window
aperture
Ma - 1,524 mm 3.0 mm
Dimension between
side members
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6. Body dimensions
27
AG.
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Amarok 2011
6.4
Single cab box dimensions
6.4.1
Front engine compartment box dimensions
un
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Ma - 1,742 mm 2.0 mm
between left wing
mounting flange at rear
and right wing mounting
flange at front
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Ma - 758 mm 2.0 mm
Dimension wing mount
ing flange
Prote
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28
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Ma - 982 mm 2.0 mm
Dimension between
wheel housings
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Ma - 1,412 mm 2.0 mm
Dimension between
lamp carriers
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Ma - 956 mm 1.0 mm
Dimension between
lock carrier bolting
points
Amarok 2011
Ma - 1,500 mm 2.0 mm
Dimension between
lower part of front lamp
carriers
Ma - 943 mm 2.0 mm
Dimension between
middle of lamp carriers
Ma - 935 mm 1.0 mm
Dimension between up
per part of lamp carriers
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Ma - 217 mm 2.0 mm
Dimension cross mem
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Front end box dimensions
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Ma - 270 mm 2.0 mm
Dimension cross mem
ber to lamp carrier
6. Body dimensions
29
Amarok 2011
Ma - 950 mm 3.0 mm
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6.4.2
Note
Centre box dimensions were not yet available at time of going to

print!
6.4.3
Rear box dimensions
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Rear box dimensions were not yet available at time of going to

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Ma - 1,067 mm 2.0 mm
Amarok 2011
6.5
Double cab load surface dimensions
6.5.1
Upper load surface dimensions
Outer/inner load surface dimensions
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Ma - 2,122 mm 2.0 mm
Diagonal dimension for
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Ma - 1,810 mm 2.0 mm
Dimension outer side of
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Dimension inner side of
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Lashing eye deviations
6. Body dimensions
31
Amarok 2011
Ma - 1,574 mm 2.0 mm
Dimension between
lashing eyes
Ma - 1,656 mm 2.0 mm
Diagonal dimension be
tween lashing eyes
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rrectness of i
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Amarok 2011
6.5.2
Lower load surface dimensions
Lower load surface deviations
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Ma - 1,653 mm 2.0 mm
Dimension between
rear part of wheel hous
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Ma - 1,420 mm 2.0 mm
Dimension lower part of
tailboard aperture
do
c
um
en
ht
rig
py
Co
t.
Ma - 1,663 mm 2.0 mm
Dimension between
front part of wheel hous
ings
6. Body dimensions
33
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Prote
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by
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rig
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Amarok 2011
6.5.3
Rear load surface dimensions
Rear load surface deviations

Ma - 1,421 mm 2.0 mm
tailboard aperture
Ma - 1,362 mm 2.0 mm
Dimension between Dpillars
Ma - 1,421 mm 2.0 mm
Dimension upper part of
tailboard aperture
Ma - 381mm 1.0 mm
Dimension tail light
aperture
6.6
Single cab load surface dimensions
6.6.1
Upper load surface dimensions
Note
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
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Upper load surface dimensions were not yet available at time of

going to print!
Lower load surface dimensions
Prote
cted
by
AG.
34
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Lower load surface dimensions were not yet available at time of

going to print!
ht
rig
py
Co
t.
Note
do
c
um
en
6.6.2
Amarok 2011
6.6.3
Rear load surface dimensions
Rear load surface deviations

Ma - 1,421 mm 2.0 mm
tailboard aperture
Ma - 1,362 mm 2.0 mm
Dimension between Dpillars
Ma - 1,421 mm 2.0 mm
Dimension upper part of
tailboard aperture
Ma - 381mm 1.0 mm
Dimension tail light
aperture
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
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erm
or
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t
a
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f
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6. Body dimensions
35
ht
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Prote
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by
c
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.
C
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Amarok 2011
Alignment jig
7.1
Tools
Special tools and workshop equipment required

Alignment jig -V.A.G 1920/1 Measurement and alignment system -VAS 6526-Basis Measurement and alignment system -VAS 6527-Profi Measurement and alignment system -VAS 6527-Profi-Plus. Volkswage
n AG
wage
ks 6637 Alignment bracket set Amaroky-VAS

Vol
b
ed
ris
Portal gauge supplement,
ho Amarok -VAS 5007/48es, in part or in w
l purpos
hole
ercia
, is n
m
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erm
o
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f
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n
Alignment bracket fixture overview of complete vehicle
Alignment bracket fixture overview of complete vehicle with align

ment bracket set Amarok -VAS 6637-
rrectness of i
t to the co
nform
spec
at
i
h re
o
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wit
in t
his
ht
rig
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36
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7.2
t
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Amarok 2011
Note
Detailed information on setting up the alignment bracket set can be found in the installation plans enclosed with
the alignment bracket set.
7.3
Alignment bracket fixture overview of vehicle chassis
Alignment bracket fixture overview of vehicle chassis

with align
G. Volkswagen AG d
ment bracket set Amarok -VAS 6637- lkswagen A
oes
n
ot g
ua
ran
tee
or
ac
rrectness of i
t to the co
nf
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m
spec
atio
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n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
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Prote
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Note
7. Alignment jig
37
Amarok 2011
7.4
Alignment bracket fixture overview of vehicle cab
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s
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form
spec
atio
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sd
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un
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Alignment bracket fixture overview of vehicle cab with alignment

bracket set Amarok -VAS 6637-
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Note
38
Amarok 2011
7.5
Alignment bracket fixture overview of vehicle cab
Alignment bracket fixture overview of front of vehicle cab with

alignment bracket set Amarok -VAS 5007/48-
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Alignment bracket fixture overview of rear of vehicle cab with

alignment bracket set Amarok -VAS 5007/48-
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
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erm
o
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t
a
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7. Alignment jig
39
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r
fo
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rrectne
s
s
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f
i
t to the co
n
form
spec
atio
h re
n
wit
i
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thi
sd
o
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um
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is n
mer
m
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t
a
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v
i
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p
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rig
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Co
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Amarok 2011
Body Repairs - Edition
AG. Volkswagen AG d
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10.2010 tho
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Prote
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by c
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Note
Detailed information on setting up the portal gauge supplementary set can be found in the installation plans
enclosed with the portal gauge set.
40
Amarok 2011
50
Body - front
RO: 50 34 55 00
Renewing cross member
WARNING
Observe safety notes!
AG. Volkswagen AG d
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rrectness of i
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nform
spec
a
t
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wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
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com
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le
Safety notes General Information; Body Repairs, General Body

Repairs ; Safety notes
1. Renewing cross member
41
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by
AG.
Prote
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by c
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C
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Amarok 2011
1.1
Removing
Carry out the following work:

Note
The bolt for the cross member support -1- was discontinued in production as of July 2010 . Instead the
front cross member support was welded to the frame longitudinal member -2- in production.
If a cross member with bolted support requires replacement, the support must be welded to the new cross
AG. Volkswagen AG d
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rig
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Models July 2010; undo bolt -1- of cross member support.

Models July 2010 : separate original joint of cross member
support.
Separate original joint of cross member from front.
Remove cross member from frame.
42
Rep. gr.50 - Body - front
do
c
um
en
r
te o
iva
r
rp
fo
g
n
rrectness of i
t to the co
nform
spec
a
t
i
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o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
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com
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rm
itte
d
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member when installing the cross member. The bolting point in the frame longitudinal member must be
closed with weld and the support is then welded in position.
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Co
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fo
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n
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
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com
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d
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Amarok 2011
agen
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Prote
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by
c
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Remove remaining material -1- on frame longitudinal mem

bers.
Grind welding surfaces and welding edges down to bare met
al.
1.2
Installing
1.2.1
Preparing new part
Replacement part
Cross member
43
un
le
Prote
cted
by
44
AG.
Grind support down to bare metal.
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Grind welding edges back to bare metal from inside.
do
c
um
en
r
te o
iva
r
rp
fo
g
n
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
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com
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rm
itte
d
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ab
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Co
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Amarok 2011
Amarok 2011
1.2.2
Welding in

Note
It is no longer permissible to bolt the cross member support to the frame longitudinal member.
If a cross member with bolted support was installed in the vehicle, the threaded connection in the frame
longitudinal member must be closed with weld before installing the new cross member.
Then the support must be welded to the frame longitudinal member, SG continuous weld seam.
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
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c
erm
or
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t
a
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o
nl
f
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AG. Volkswagen AG d
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by
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rig
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.
C
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Adapt new part using alignment bracket set and fix in place.
Weld in cross member, SG continuous weld seam.
Weld in support, SG continuous weld seam.
45
Amarok 2011
RO: 50 34 55 10
Renewing deformation element
WARNING

2.1
Tools

Resistance spot welder -VAS 6239 A Resistance spot welder -VAS 6535 Accessory pack -VAS 6535 /1-
2.2
Removing
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rig
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Co
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46
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
ot p
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c
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t
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v
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p
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un
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Separate original
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joint.
a
c
s
s
Remove remaining material.

Grind welding edges back to bare metal.
2.3
Installing
The use of different types and different thicknesses of steel re

quires that one of the welding units (inverter) listed under Tools
must be used for proper spot welding 2.1 Tools, page 46 .
AG.
Preparing replacement part
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2.3.1
ht
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Co
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Note
rrectne
s
s
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f
i
t to the co
n
form
spec
atio
h re
n
wit
i
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thi
sd
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is n
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m
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t
a
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v
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p
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Remove deformation element from body.
Amarok 2011
- Edition 10.2010
Replacement part
Deformation element
Grind welding surfaces on both sides back to bare metal.
2. Renewing deformation element
47
Amarok 2011
2.3.2
Welding in
rrectness of i
t to the co
nf
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r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
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, is n
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Adapt new part on both sides according to -dimension a- and

fix in place.
Dimension a = 270 mm
ht
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thi
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48
Amarok 2011
rrectness of i
t to the co
nf
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m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
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or
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t
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nl
f
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Weld in deformation element, RP spot weld seam.
AG.
2. Renewing deformation element
49
Prote
cted
by
Amarok 2011
RO: 50 60 55 00
Renewing headlight mounting
WARNING

3.1
Tools

3.2
Removing
Deformation element already removed

2 Renewing deformation element, page 46 .
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rig
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50
do
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spec
a
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wit
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es, in part or in w
l purpos
hole
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, is n
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Co
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a
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wit
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Amarok 2011
agen
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Prote
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by
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rig
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.
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Separate original joint.
3. Renewing headlight mounting
51
Amarok 2011
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
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c
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erm
o
e
t
a
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f
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Prote
cted
by
52
AG.
Remove headlight mounting -2- from body.
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Heat bonding surface -1- with hot air blower -V.A.G 1416- .
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Unscrew bolt -1- for cab mounting.
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.
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do
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fo
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nform
spec
a
t
i
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wit
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s
es, in part or in w
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hole
ercia
, is n
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com
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Amarok 2011
Grind bonding surface and welding surfaces on both sides

back to bare metal.
3.3
Installing
Note

3.3.1
Replacement parts
Headlight mounting
Body adhesive 2K adhesive -D 180 KD3 A2Carry out the following work:
53
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Drill specified holes in new part, 7.0 mm.
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54
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Amarok 2011
Amarok 2011
3.3.2
Welding in

Apply body adhesive 2K adhesive -D 180 KD3 A2- to bonding
surface.
Note
Apply adhesive bead sufficiently thickly so that optimal bond
ing with the body is guaranteed.
New part must be welded in within 90 minutes or adhesion
geof
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adhesive will be impaired.
55
Amarok 2011
Adapt new part with vehicle standing on its wheels or on align
ment bracket set and hold in position.
Check fit with all add-on parts.
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Install bolt -1- for cab mounting.

Weld in headlight mounting, SG plug weld seam.
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56
do
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Install deformation element 2.3 Installing, page 47 .
rrectness of i
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nform
spec
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Weld in headlight mounting, RP spot weld seam and SG plug

weld seam.
Amarok 2011
RO: 50 53 55 00
Renewing wing connecting plate
WARNING

1 - Bonded areas
2 - Cutting point
The parting cut is per
mitted for other forms of
damage.
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Tools
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4. Renewing wing connecting plate
57
Removing
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Remove wing connecting plate from body.
58
Prote
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Heat bonded areas with hot air blower -V.A.G 1416- .
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Bend up metal tab -1-.
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Amarok 2011
Amarok 2011
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Grind bonding surfaces and welding surfaces on both sides
back to bare metal.
4.3
Installing
Note

4.3.1
Replacement parts
Wing connecting plate
Body adhesive 2K adhesive -D 180 KD3 A2-
59
Amarok 2011
4.3.2
Welding in
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surface.
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Amarok 2011
Note
Apply adhesive bead sufficiently thickly so that optimal bonding with the body is guaranteed.
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ment bracket set and fix in position.
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New part must be welded in within 90 minutes or adhesion of adhesive will be impaired.
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Weld in wing connecting plate, RP spot weld seam and SG

plug weld seam.
AG.
Prote
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by
Bend metal tab -1- back.
61
Amarok 2011
RO: 50 53 55 10
Renewing connection piece
WARNING
5.1
Tools

5.2
Removing
Note
rrectne
s
s
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i
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form
spec
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62
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Make parting cuts with pneumatic jig-saw -V.A.G 1523- only. Do not damage inner reinforcements.
do
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Amarok 2011
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Make parting cut.

Heat bonding surface -1- with hot air blower -V.A.G 1416- .
Remove connection piece from body.
Grind bonding surfaces and welding surfaces on both sides
back to bare metal.
5. Renewing connection piece
63
Amarok 2011
5.3
Installing
Note

5.3.1
Replacement parts
A-pillar reinforcement
Body adhesive 2K adhesive -D 180 KD3 A2Carry out the following work:
Transfer dimension for parting cut from body and carry out.
Drill out connection piece from A-pillar reinforcement.
Punch specified holes in new part, 7.0 mm.
Grind bonding surface back to bare metal.
rrectness of i
t to the co
nf
o
r
m
spec
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h re
n in
wit
Welding in
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5.3.2
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Grind welding surfaces on both sides back to bare
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surface.
Apply adhesive bead sufficiently thickly so that optimal bond

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New part must be welded in within 90 minutes or adhesion of
Prote
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64
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Note
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AG.
Check fit with bolt-on parts.
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Amarok 2011
Weld in connection piece, RP spot weld seam, SG plug weld

seam and SG continuous weld seam.
Seal cavity after welding work.
5. Renewing connection piece
65
Amarok 2011
RO: 50 72 55 70

6.1
Tools

Resistance spot welder -VAS 6239 A Accessory pack -VAS 6535 /1-
6.2
Removing

2 Renewing deformation element, page 46
Headlight mounting already removed

3 Renewing headlight mounting, page 50
Wing connecting plate already removed

4 Renewing wing connecting plate, page 57
Connection piece already removed

5 Renewing connection piece, page 62
r
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66
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Resistance spot welder -VAS 6535-
rrectne
s
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form
spec
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WARNING
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Renewing upper wheel housing lon

gitudinal member
un
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Amarok 2011
rrectness of i
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nf
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Remove upper longitudinal member for wheel housing from

body.
6. Renewing upper wheel housing longitudinal member
67
AG.
un
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6.3
Installing
Note

6.3.1
Replacement part
Upper longitudinal member for wheel housing
68
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Amarok 2011
Amarok 2011
es, in part or in w
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6.3.2
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Welding in
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do
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Weld in upper longitudinal member for wheel housing, RP spot
weld seam and SG plug weld seam.
6. Renewing upper wheel housing longitudinal member
69
Amarok 2011
Install wing connecting plate 4.3 Installing, page 59 .
Install connection piece 5.3 Installing, page 64 .
Install headlight mounting 3.3 Installing, page 53 .
es n
wage
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70
rrectne
s
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form
spec
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un
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Renewing front wheel housing
WARNING

7.1
Removing

2 Renewing deformation element, page 46
Headlight mounting already removed

3 Renewing headlight mounting, page 50
Wing connecting plate already removed

4 Renewing wing connecting plate, page 57
Connection piece already removed

5 Renewing connection piece, page 62
Upper longitudinal member for wheel housing already re

moved
6 Renewing upper wheel housing longitudinal member,
page 66 .
do
c
um
en
Amarok 2011
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
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, is n
m
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c
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t
a
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f
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RO: 50 74 55 00
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7. Renewing front wheel housing
71
Amarok 2011
es, in part or in w
l purpos
hole
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rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Remove front wheel housing from body.

Grind welding surface on both sides back to bare metal.
Front wheel housing
72
Prote
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by
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rig
ht
.
C
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Replacement part
AG.
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Installing
do
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7.2
Amarok 2011
Punch holes in new part, 7.0 mm.
7.2.2
Welding in
ht
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Co
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rrectne
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s
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Grind welding surface on both sides back to bare metal.
agen
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Prote
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by c
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p
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C
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Weld in front wheel housing, SG plug weld seam.
7. Renewing front wheel housing
73
Amarok 2011
Install upper longitudinal member for wheel housing

6.3 Installing, page 68 .
Install wing connecting plate 4.3 Installing, page 59 .
Install connection piece 5.3 Installing, page 64 .
Install headlight mounting 3.3 Installing, page 53 .
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rig
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Prote
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74
rrectness of i
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nform
spec
at
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hole
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, is n
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Amarok 2011
RO: 50 80 55 00
Renewing front part of longitudinal

member - part section 1-
WARNING

8.1
Removing
Cross member already removed

1 Renewing cross member, page 41 .
Note
Parting cut must be straight.
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8. Renewing front part of longitudinal member - part section 1-
75
Amarok 2011
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
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Carry out parting cut -1- as per -dimension a-.

Dimension a = 60 mm from mounting bracket
Remove front section of longitudinal member.
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76
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Co
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form
spec
atio
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Amarok 2011
agen
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Grind welding surface back to bare metal.
8.2
Installing
8.2.1
Replacement part
Front longitudinal member complete
77
Amarok 2011
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
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Transfer parting cut -1- from body to new part.

Make parting cut -1-.
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.
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do
c
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78
Amarok 2011
8.2.2
Welding in
rrectness of i
t to the co
nf
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m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
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Adapt new part to vehicle standing on alignment bracket set

and fix in place.
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Dimension a = 3.5 mm + 0.5 mm
ht
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t.
Weld parting cut all round in front section of longitudinal mem

ber -1- adhering to -air gap dimension a-, SG continuous weld
seam.
thi
sd
o
cu
m
en
Check fit with adjacent parts.
Adherence to -air gap dimension a- is vital to guarantee proper through-welding.

Before welding longitudinal member, check welder settings; weld several test seams and check roots of
test weld seams (correct welding parameters if necessary).
SG continuous weld seam must not be reworked (ground or smoothed)!

Carry out cavity preservation on front longitudinal member.
79
Amarok 2011
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Co
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80
rrectne
s
s
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form
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atio
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Install front cross member 1.2 Installing, page 43 .
Amarok 2011
RO: 50 79 55 02
Renewing longitudinal member - part

section 2-
WARNING

9.1
Removing

Note

rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
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9. Renewing longitudinal member - part section 2-
81
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C
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yi
Amarok 2011
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
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AG. Volkswagen AG d
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AG.
Prote
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by
82
agen
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Remove longitudinal member.
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c
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Carry out parting cut -1- as per -dimension a-.
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Amarok 2011
9.2
Installing
9.2.1
Replacement parts
do
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Mounting bracket for front for cab mounting
83
AG. Volkswagen AG d
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AG.
Prote
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Grind welding edges of mounting bracket back to bare metal.
84
ht
rig
py
Co
t.
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s
s
o
f
i
t to the co
n
form
spec
atio
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Amarok 2011
Amarok 2011
9.2.2
Producing longitudinal member reinforcement

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n
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thi
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Using in-house material, produce longitudinal member rein

forcement according to deviations -a-, -b- and -c-.
Dimension a = 90 mm
Dimension b = 40 mm
Dimension c = 60 mm
Grind welding edges of longitudinal member reinforcement
back to bare metal.
85
AG. Volkswagen AG d
Amarok 2011
agen
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l
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atio
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Welding in
ht
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9.2.3
ara
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ed
ris
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and fix in place.
Weld parting cut all round in longitudinal member -1- adhering
to -air gap dimension a-, SG continuous weld seam.
Note
86
AG. Volkswagen AG d
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Adapt longitudinal member reinforcement -1- to longitudinal

member -2- and fix in position.
ht
rig
py
Co
t.
r
fo
ng
Weld in longitudinal member reinforcement -1- all round, SG

continuous weld seam.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
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mer
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Amarok 2011
agen
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87
olkswagen AG
en AG. V
does
not
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com
r
te o
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fo
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n
rrectness of i
t to the co
nform
spec
a
t
i
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wit
thi
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Weld in mounting bracket, SG continuous weld seam.

Carry out cavity preservation on front longitudinal member.
88
do
c
um
en
Adapt mounting bracket -1- to fit and fix in position.
ht
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py
Co
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wag
Amarok 2011
olks
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se
Amarok 2011
RO: 50 79 55 00
10
Renewing longitudinal member com

plete
WARNING

AG. Volkswagen AG d
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1 - Longitudinal member
ara
d
nte
ise
r
plete
o
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t
u
ra
a
c
Slid intossmiddle
part of
pe
rm
itte
d
un
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frame and welded.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
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com
2 - Cab mounting
Welded to longitudinal
member.
Replaced during repairs
as well.
3 - Suspension strut mounting
member.
as well.
agen
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6 - Brake line mounting

member.
as well.
ht
rig
py
Co
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5 - Anti-roll bar mounting

member.
as well.
do
c
um
en
r
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iva
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rp
fo
g
n
4 - Mounting bracket
member.
as well.
7 - Reinforcement
member.
Replaced during repairs as well.
8 - Mounting for engine mounting
Welded to longitudinal member.
9 - Bracket
Welded to suspension strut.
For ABS hydraulic unit -N55- and ABS control unit -J104- .
10. Renewing longitudinal member complete
89
Amarok 2011
10 - Mounting for cross member for gearbox mounting
Welded to longitudinal member.
11 - Reinforcing plate
Welded to longitudinal member and frame.
AG. Volkswagen AG d
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Removing
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Caution
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t
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10.1
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rrectness of i
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nform
spec
at
i
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o
n
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in t
his
The frame of the Amarok and the parts fitted on it are welded
using SG continuous weld seams.
When separating individual welded seams, ensure that the
weld edges of adjacent parts are not damaged.
If the weld edges of separated parts do not lie on the frame
when rewelding, then replace these parts.
The cab must be separated from the frame for this repair. Re
moving cab General body repairs, exterior; Rep. gr. 55 ;
Cab .

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ht
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Co
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90
do
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Amarok 2011
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
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c
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erm
o
e
t
a
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du
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f
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Separate original joint of anti-roll bar mounting -1-.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Remove anti-roll bar mounting -1- from longitudinal member

and cross member.
Remove material remains on cross member.
Grind welding surfaces on cross member down to bare metal.
do
c
um
en
ht
rig
py
Co
t.
agen
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by
91
AG.
Prote
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Amarok 2011
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
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o
nl
f
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ng
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es n
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b
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ir se
tee
o
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t
or
u
ac
a
ss
Separate original joints of cross members -1- and -2-.

Note
Ensure the weld edges of the cross member are not damaged when separating the SG continuous weld
seams.
If the weld edges of the separated cross member do not lie on the longitudinal member when rewelding,
then replace this part.
ht
rig
py
Co
t.
agen
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Prote
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by
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gh
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.
C
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yi
thi
sd
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cu
m
en
92
Amarok 2011
Repairs - Edition 10.2010
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
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es n
wage
s
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b
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ran
ir se
tee
o
h
t
or Body
u
ac
a
ss
thi
sd
o
cu
m
en
ht
rig
py
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Prote
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by
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p
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gh
t
.
C
op
yi
Separate original joints of reinforcement -1- and remove from

frame.
Separate original joints of cross members -2- and -3- from be
low.
Note
Ensure the weld edges of the cross member are not damaged when separating the SG continuous weld
seams.
If the weld edges of the separated cross members do not lie on the longitudinal member when rewelding,
then replace these parts.
93
Amarok 2011
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Separate original joint of reinforcement -1- and remove from

frame.
Undo bolts -3- on both sides and remove middle part -2- of
cross member.
agen
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Prote
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by c
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ht
rig
py
Co
t.
94
thi
sd
o
cu
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es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
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r
du
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o
nl
f
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Separate original joint of longitudinal member to middle part

of frame all round.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
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erm
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t
a
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v
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p
ility
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an
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un
le
Amarok 2011
AG.
95
Prote
cted
by
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Prote
cted
by
c
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ht
rig
py
Co
t.
96
do
c
um
en
r
te o
iva
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rp
fo
g
n
Separate longitudinal member -1- from frame and pull out of

middle part of frame.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ility
ab
y li
an
pt
ce
un
le
Amarok 2011
Amarok 2011
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
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du
p
or
nl
f
e
g
n
ility
ab
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an
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ce
es n
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s
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tee
o
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t
or
u
ac
a
ss
Remove material remains from cross members -1- and -2- and
from middle part of frame -3-.
Grind welding surfaces back to bare metal.
Prote
cted
by
c
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.
C
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Replacement parts
AG.
Preparing new part
agen
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by
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ht
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t.
Installing
do
c
um
en
10.2
Front mounting bracket

Anti-roll bar mounting
Reinforcement
Brake line mounting
Suspension strut mounting
Cab mounting
Mounting for cross member for gearbox mounting
Mounting for engine mounting
97
Amarok 2011
Bracket for hydraulic unit
Reinforcing plate
Grind weld surfaces on front longitudinal member -1- down to
bare metal.
ility
ab
y li
an
pt
ce
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
ht
rig
py
Co
t.
98
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Grind welding edges of anti-roll bar mounting -1- down to bare

metal.
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
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n
Grind welding
metal.
AG. Volkswagen AG d
agen
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not
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edges of
mounting
bracket
-1down
to bare
b
ara
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e
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is
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h
ut
ra
a
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s
Amarok 2011
Grind welding edges of reinforcing -1- down to bare metal.
es n
wage
s
k
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ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ility
ab
y li
an
pt
ce
un
le
Grind welding edges of brake line mounting -1- down to bare

metal.
Grind welding edges of cab mounting -1- down to bare metal.
do
c
um
en
r
te o
iva
r
rp
fo
g
n
Grind welding edges of suspension strut mounting -1- down to

bare metal.
ht
rig
py
Co
t.
agen
lksw
Vo
by
99
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Amarok 2011
Grind welding edges of mounting for cross member for gear
box mounting -1- down to bare metal.
Grind welding edges of mounting for engine mounting -1down to bare metal.
Grind welding edges of hydraulic unit bracket -1- down to bare

metal.
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
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l
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ara
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is
r
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h
ut
ra
a
c
s
s
Grind welding edges of reinforcing panel -1- down to bare

metal.
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by c
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C
op
yi
thi
sd
o
cu
m
en
100
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
do
c
um
en
ht
rig
py
Co
t.
Welding in
ility
ab
y li
an
pt
ce
10.2.2
es n
wage
s
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ua Amarok 2011
b
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ran
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tee
o
10.2010
h
t
or
u
ac
a
ss
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Grind welding surfaces -2- on new part down to bare metal.

Adapt longitudinal member -1- to frame positioned on align
ment bracket set -3- and fix in place.
Note
Before welding longitudinal member, check welder settings;
weld several test seams and check roots of test weld

seams (correct welding parameters if necessary).
SG continuous weld seam must not be reworked (ground or
smoothed)!
101
es n
wage
s
k
l
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ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
r
fo
ng
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Weld cross member -3- to front longitudinal member -1-, SG

Weld cross member -2- to front longitudinal member -1-, SG
Note
For clarity, the alignment jig with alignment bracket set is not shown in the following figures.
102
ht
rig
py
Co
t.
Weld longitudinal member -1- to middle part of frame -4- all

round, SG continuous weld seam.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ility
ab
y li
an
pt
ce
un
le
Amarok 2011
AG. Volkswagen AG d
agen
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not
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s
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ility
ab
y li
an
pt
ce
un
le
Amarok 2011
Weld cross member -3- to front longitudinal member -1- from

below, SG continuous weld seam.
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
do
c
um
en
r
te o
iva
r
rp
fo
g
n
Weld cross member -2- to front longitudinal member -1- from

below, SG continuous weld seam.
103
c
o
p
yri
gh
t.
C
op
yi
Amarok 2011
AG.
104
agen
lksw
Vo
by
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Weld in mounting for cross member for gearbox mounting

-3- all round, SG continuous weld seam.
ht
rig
py
Co
t.
Adapt mounting for cross member for gearbox mounting -3using alignment bracket set and fix in place.
do
c
um
en
Position reinforcing panel -1- on longitudinal member -2- and

weld in all round, SG continuous weld seam.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
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not
l
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is
r
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h
ut
ra
a
c
s
s
Amarok 2011
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
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not
l
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b
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is
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h
ut
ra
a
c
s
s
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Weld in mounting for engine mounting -2- all round, SG con

tinuous weld seam.
do
c
um
en
Adapt mounting for engine mounting -2- using alignment

bracket set and fix new part -1- in place.
105
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
Adapt mounting bracket -1- and anti-roll bar mounting -3- us

ing alignment bracket set and fix in place.
Adapt reinforcing -2- to fit and fix in position.
AG.
agen
lksw
Vo
by
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
106
ht
rig
py
Co
t.
r
fo
ng
Weld in new parts -1-, -2- and -3-, SG continuous weld seam.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ility
ab
y li
an
pt
ce
un
le
Amarok 2011
Amarok 2011
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Adapt cab mounting -2- using alignment bracket set on front

longitudinal member -1- and fix in place.
Weld in cab mounting -2-, SG continuous weld seam.
thi
sd
o
cu
m
en
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
107
c
o
p
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gh
t
.
C
op
yi
Amarok 2011
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
es n
wage
s
k
l
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o
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ua
b
d
ran
ir se
tee
o
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t
or
u
ac
a
ss
agen
lksw
Vo
by
c
o
p
yri
gh
t
.
C
op
yi
AG.
Prote
cted
by
Weld in suspension strut mounting -1- and brake line mounting

-3-, SG continuous weld seam.
108
ht
rig
py
Co
t.
Adapt brake line mounting -3- and fix in place, using dimen
sions of old part as an aid.
do
c
um
en
Adapt suspension strut mounting -1- using alignment bracket

set on front longitudinal member -2- and fix in place.
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
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nte
is
r
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h
ut
ra
a
c
s
s
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ility
ab
y li
an
pt
ce
un
le
Amarok 2011
Adapt hydraulic unit bracket -1- to suspension strut mounting

-2- and fix in place, using dimensions of old part as an aid.
Weld in hydraulic unit bracket -1-, SG continuous weld seam.
Carry out cavity preservation on front longitudinal member
-3-.
do
c
um
en
ht
rig
py
Co
t.
r
te o
iva
r
rp
fo
g
n
109
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Amarok 2011
Body - centre
ility
ab
y li
an
pt
ce
RO: 51 03 55 00, 51 03 55 20
Renewing roof
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
WARNING

1 - Roof
2 - Bonded areas of C-pillar

3 - Bonded areas of roof cross
members
110
Rep. gr.51 - Body - centre
AG.
agen
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by
Prote
cted
by
c
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rig
ht
.
C
op
yi
Tools
ht
rig
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Co
t.
1.1
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
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riv
du
p
or
nl
f
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n
51
AG. Volkswagen AG d
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Amarok 2011
Pneumatic cartridge gun -V.A.G 1761/1-
AG. Volkswagen AG d
agen
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is
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h
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ra
a
c
s
s
ht
rig
py
Co
t.
r
fo
ng
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ility
ab
y li
an
pt
ce
un
le
Setting gauge -3371-
1. Renewing roof
111
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Amarok 2011
1.2
Removing
es n
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s
k
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b
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tee
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t
or
u
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a
ss
Prote
cted
by
112
AG.
Remove roof -1- from body.
agen
lksw
Vo
by
c
o
p
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gh
t
.
C
op
yi
Release bonded joints of C-pillars Item 2 (page 110) and to

front and rear roof cross members Item 3 (page 110) . To
release, heat bonded surfaces with hot air blower -V.A.G
1416- .
ht
rig
py
Co
t.
do
c
um
en
r
te o
iva
r
rp
fo
g
n
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ility
ab
y li
an
pt
ce
un
le
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
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b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s
Remove adhesive residues and grind bonding surfaces back

to bare metal.
1.3
Installing
Note

1.3.1
1K assembly adhesive -D 190 MKD A3-
AG.
Prote
cted
by
agen
lksw
Vo
by
c
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p
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gh
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C
op
yi
2K body adhesive -D 180 KD3 A2-
ht
rig
py
Co
t.
Roof
r
fo
ng
Replacement parts
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ility
ab
y li
an
pt
ce
un
le
Amarok 2011
1. Renewing roof
113
Amarok 2011
un
le
ility
ab
y li
an
pt
ce
Grind bonding surfaces down to bare

inside).
AG. Volkswagen AG d
agen
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b
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is
r
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h
metal
ut on one side (from
ra
a
c
s
s
Welding in
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Note
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
1.3.2
pe
rm
itte
d
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lksw
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by
AG.
Prote
cted
by
c
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py
rig
ht
.
C
op
yi
do
c
um
en
114
ht
rig
py
Co
t.
r
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iva
r
rp
fo
g
n
To ensure sufficient sturdiness, the RP weld points must be set

as far as possible from the outer edge of the welding flange.
Amarok 2011
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
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not
l
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is
r
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h
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c
s
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rig
py
Co
t.
agen
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Vo
by
Prote
cted
by c
o
p
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gh
t.
C
op
yi
AG.
Apply 2K body adhesive -D 180 KD3 A2- to bonding surfaces

-4-.
thi
sd
o
cu
m
en
Apply 1K assembly adhesive -D 190 MKD A3- to bonding sur

faces -1-, -2- and -3-.
Note
Apply adhesive beads sufficiently thickly so that optimal bonding with the body is guaranteed.
1. Renewing roof
115
Amarok 2011
Set roof joint gap Item L (page 9) on both sides with setting
gauge -3371- .
AG.
agen
lksw
Vo
by
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
116
ht
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RO: 51 07 55 70
Renewing front cross member for

roof
WARNING

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Roof already removed 1
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117
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Preparing new part
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118
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Install roof 1.3 Installing, page 113 .
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120
Amarok 2011
RO: 51 08 55 70
Renewing roof reinforcement
WARNING

3.1
Removing
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3. Renewing roof reinforcement
121
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Roof reinforcement
122
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Amarok 2011
3.2.2
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3. Renewing roof reinforcement
123
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Adapt roof reinforcing -1- with vehicle standing on its wheels

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Amarok 2011
RO: 51 09 55 70
Renewing rear roof cross member
WARNING

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Roof already removed 1
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125
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Installing
4.2.1
Preparing new part
Replacement parts
Rear roof cross member
126
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4.2.2
Welding in
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Weld in rear cross member for roof, RP spot weld seam.
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Amarok 2011
RO: 51 13 55 00, 51 13 55 20
Renewing rear window frame
WARNING

1 - Rear window frame
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130
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Release bonded joints -1-. To release, heat bonded surfaces

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2K body adhesive -D 180 KD3 A2Carry out the following work:
131
Amarok 2011
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5.2.2
Welding in
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134
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Amarok 2011
RO: 51 14 55 70
Renewing cross
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135
Amarok 2011
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Preparing new part
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Amarok 2011
Welding in
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138
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Install rear window frame 5.2 Installing, page 131 .
ht
rig
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Co
t.
Weld in cross member, RP spot weld seam.
thi
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Adapt cross member -1- with vehicle standing on its wheels or

on alignment bracket set and fix in position.
Amarok 2011
RO: 51 37 55 00, 51 37 55 02
Renewing hinge pillar (A-pillar)
WARNING

Welding, parting using spark generating machines/tools or tin
ning in foam treated areas creates gases which are particularly
hazardous to health and environment. Therefore, refrain from
using these processes under all circumstances.
Note
wagother
en AG forms of damage.
Specified parting cuts -1- to -5- can be
combined
n AG. Volksfor
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Description for other forms ofeddamage
must be derived from this gaccordingly.
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Assembly overview for
ris
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vehicles
with
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spec
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1 - Upper parting cut

Carry out as per dimen
sion -a-.
2 - Parting cut for partial re

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newal
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5 - Parting cut for side member

sion -c-.
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Dimension b = 250 mm
thi
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sion -b-.
Dimension c = 750 mm
6 - Moulded foam element
Reduces the amount of
driving noise transmit
ted into the interior.
must be inserted again
and must not be left out
page 5 .
7. Renewing hinge pillar (A-pillar)
139
Amarok 2011
7 - Bonded area
Cannot be restored in event of repair.
8 - Wing retainer
Renewing wing retainer page 146 .
Assembly overview for vehicles with single cab
sion -a-.
newal
damage
newal
damage
sion -b-.
sion -c-.
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Dimension c = 750 mm sed
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page 5 .
7 - Bonded area
Cannot be restored in event of repair.
8 - Wing retainer
Renewing wing retainer page 146 .
7.1
Tools

Resistance spot welder -VAS 6239 Ac
o
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Prote
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AG.
140
agen
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Accessory pack -VAS 6535 /1-
ht
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Resistance spot welder -VAS 6535-
thi
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Pneumatic sabre saw -V.A.G 1523B-
Amarok 2011
MIG brazing and welding system -VAS 6382-
7.2
Removing
For vehicles with single and double cab

Note
Make parting cuts with pneumatic jig-saw -V.A.G 1523B- only.
Parting cuts must be straight.
Do not damage inner reinforcements when carrying out part
ing cuts.
AG. Volkswagen AG d
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Mark parting cut -1- as per Item 1 (page 139) (400 mm from
top edge of windscreen aperture) and cut.
centre of hole) and cut.
141
Amarok 2011
Release bonded joint Item 7 (page 139) . To release, heat
bonded surface with hot air blower -V.A.G 1416- .
Remove hinge pillar (A-pillar) from body.

to bare metal.
Prepare moulded foam elements -1- for installation
page 5 .
7.3
Installing
Note

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Prote
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142
rrectness of i
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Amarok 2011
7.3.1
Preparing new part, vehicles with dou

ble cab
Replacement parts
Side panel
Wing retainer
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Transfer parting cuts -1- and -2- from body to new part.
Make parting cuts and remove shaded area.
Prepare wing retainer, drill holes, 7.0 mm.
7.3.2
Preparing new part, vehicles with single

cab
Replacement parts
Side panel
143
Amarok 2011
Wing retainer
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Prepare wing retainer, drill holes, 7.0 mm.
AG.
Prote
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144
ht
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spec
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Amarok 2011
7.3.3
Welding in
For vehicles with single and double cab

Note
To ensure sufficient sturdiness, the RP weld points must be
set as far as possible from the outer edge of the welding flange.
MIG brazed seams are permitted at the parting cuts shown in
the illustration.
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Weld in hinge pillar (A-pillar), RP spot weld seam, SG plug
weld seam and SG stitch weld seam.
145
Amarok 2011
Optically process visible weld joints.
Use 2K filler to smooth out rough spots.
7.3.4
Renewing wing retainer
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Position wing with wing retainer on body -1-.

Adapt wing to vehicle (door in position on vehicle).
Remove door.
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146
do
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Tack weld wing retainer from wheel housing -2-.
Amarok 2011
Remove wing.
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Weld in wing retainer, SG plug weld seam.
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147
AG.
Prote
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Amarok 2011
RO: 51 38 55 70
Renewing hinge pillar (A-pillar) rein

forcement
WARNING

Hinge pillar (A-pillar) already removed

7 Renewing hinge pillar (A-pillar), page 139
es, in part or in w
l purpos
hole
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1 - Upper moulded foam ele

ment
AG. Volkswagen AG d
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Reduces the amount of Volksw
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Moulded foam
s elements
page 5 .
rrectness of i
t to the co
nform
spec
at
i
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2 - Lower moulded foam ele

ment
page 5 .
3 - Bonded area
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148
Amarok 2011
8.1
Tools
es, in part or in w
l purpos
hole
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Special tools and workshop equipment
required
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Resistance spot welder -VAS
6239
Ah
t
u
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a
c
s
s
Resistance spot welder -VAS
6535-
Accessory pack -VAS 6535 /1-
Removing
rrectness of i
t to the co
nf
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m
spec
atio
h re
n in
wit
8.2
thi
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Release bonded joint -1-. To release, heat bonded surface
Remove hinge pillar (A-pillar) reinforcement from body.
8. Renewing hinge pillar (A-pillar) reinforcement
149
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Remove adhesive residues and grind bonding surface back to

bare metal.
Prepare moulded foam elements -1- and -2- for installation
page 5 .
8.3
Installing
Note

8.3.1
Replacement parts
Hinge pillar (A-pillar) reinforcement
2K body adhesive -D 180 KD3 A2-
150
ht
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Amarok 2011 rise
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Body Repairs - aEdition
10.2010
ut
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Amarok 2011
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Drill out hinge pillar (A-pillar) reinforcement upper part and re

move shaded area.
Punch and drill specified holes in new part, 7.0 mm.
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Note
Welding in
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8.3.2
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AG.
151
Amarok 2011
Note
Apply adhesive beads sufficiently thickly so that optimal bond
New part must be welded in within 90 minutes or adhesion of
rrectness of i
t to the co
nform
spec
at
i
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in t
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es, in part or in w
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152
do
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Amarok 2011
es, in part or in w
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Hinge pillar (A-pillar) 7.3 Installing, page 142
rrectness of i
t to the co
nform
spec
at
i
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wit
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Weld in hinge pillar (A-pillar) reinforcement,
RP spot weld
t
u
ra
a
c
s
seam, SG plug weld seam and SG
continuous
weld
seam.
s
153
Amarok 2011
RO: 51 41 55 00
Renewing centre pillar (B-pillar)
WARNING

G. Volkswagen AG d
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Specified parting cuts -1- to -5- and -7- can be combined for other forms of damage.

sion -e-.
Dimension e = 520 mm
sion -c-.
Dimension c = 680 mm
damage
sion -b-.
154
Prote
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by

damage
AG.
Dimension d = 250 mm
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sion -d-.
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sion -a-.
r
fo
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Description for other forms of damage must be derived from this accordingly.
rrectne
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f
i
t to the co
n
form
spec
atio
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n
wit
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Note
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p

Amarok 2011
Moulded foam elements must be inserted again and must not be left out page 5 .
7 - Centre parting cut
The parting cut is permitted for other forms of damage
9.1
Tools

Pneumatic sabre saw -V.A.G 1523B Resistance spot welder -VAS 6239 A-
9.2
Removing

ing cuts.
ht
rig
py
Co
t.
r
fo
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rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
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Note
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Accessory pack -VAS 6535 /1- hor
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ss -VAS 6382-
agen
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9. Renewing centre pillar (B-pillar)
155
AG.
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top edge of roof side member) and cut.
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Amarok 2011
reference edge) and cut.
centre of hole) and cut.
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rig
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Co
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156
do
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Remove centre pillar (B-pillar) from body.
Amarok 2011
rrectness of i
t to the co
nf
o
r
m
spec
atio
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n in
wit
es, in part or in w
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hole
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Prepare moulded foam element -1- for installation page 5 .
9.3
Installing
Note

9.3.1
Replacement parts
Side panel
157
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Transfer parting cuts -1-, -2- and -3- from body to new part.
Welding in
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Prote
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Note
c
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9.3.2
the illustration.
158
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Amarok 2011
Weld in centre pillar (B-pillar), RP spot weld seam, SG plug

weld seam and SG stitch weld seam.
159
Amarok 2011
RO: 51 42 55 70
10
Renewing centre pillar (B-pillar) rein

forcement
WARNING

Centre pillar (B-pillar) already removed

9 Renewing centre pillar (B-pillar), page 154
Note
es, in part or in w
l purpos
hole
ercia
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thi
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160
of damage.
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Specified parting cut -1-
AG. Volkswagen AG d
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and scutting points -3- and -4- can be combined for otherc forms
Amarok 2011
AG. Volkswagen AG d
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sion -a-.
rrectness of i
t to the co
nform
spec
a
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i
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wit
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hole
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com
2 - Middle pillar (B-pillar) rein

forcement
Parting at this point is
permitted for other
forms of damage.
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10.1
do
c
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page 5 .
Tools

Pneumatic sabre saw -V.A.G 1523B Resistance spot welder -VAS 6239 A Resistance spot welder -VAS 6535 Accessory pack -VAS 6535 /1-
10.2
Removing
Note
Make parting cut using body saw -V.A.G 1523B- only!

10. Renewing centre pillar (B-pillar) reinforcement
161
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top edge of roof side member) and cut.
Remove centre pillar (B-pillar) reinforcement from body.
162
do
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rrectness of i
t to the co
nform
spec
a
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i
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wit
thi
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es, in part or in w
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hole
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Amarok 2011
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com
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Amarok 2011
Prote
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by
10.3.1
AG.

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Note
c
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Installing
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10.3
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Replacement parts
Middle pillar (B-pillar) reinforcement
163
AG. Volkswagen AG d
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Make parting cut and remove shaded area.
10.3.2
Welding in
Note
AG.
Prote
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164
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rrectness of i
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nform
spec
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wit
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es, in part or in w
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hole
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Amarok 2011
AG. Volkswagen AG d
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Weld in centre pillar (B-pillar) reinforcement, RP spot weld

seam, SG plug weld seam and SG continuous weld seam.
r
fo
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Centre pillar (B-pillar) 9.3 Installing, page 157
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rrectne
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Amarok 2011
165
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an
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RO: 51 39 55 20
Renewing lock pillar (C-pillar)
WARNING

Note
r
fo
ng

Specified parting cuts -1- and -4- to -6- can be combined for other forms of damage.
Prote
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by c
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page 5 .
4 - Lower parting cut
Parting cut is permitted
for other forms of dam
age.
sion -a-.
age.
sion -b-.
166
AG.
2 - Bonded area
Cannot be restored in
event of repair.
agen
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Can be positioned in this
area depending on
damage.
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Amarok 2011
AG. Volkswagen AG d
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10.2010
c
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Amarok 2011
11.1
Tools
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Special tools and workshop equipment
- Edition 10.2010
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AG. VolkswBody
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Pneumatic sabre saw -V.A.G 1523B-
Resistance spot welder -VAS 6239 A-
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Resistance spot welder -VAS 6535 Accessory pack -VAS 6535 /1-
MIG brazing and welding system -VAS 6382-
11.2
Removing
Note


thi
sd
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cu
m
en
ing cuts.
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Co
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11. Renewing lock pillar (C-pillar)
167
AG.
Prote
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by
c
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rig
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Amarok 2011
AG. Volkswagen AG d
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Parting cut -2- as per Item 5 (page
166)
.
Mark
(250
mm
from
o
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h
ut
ra
reference edge) and cut.
a
c
s
s
Mark parting cut -1- and carry out.
rrectness of i
t to the co
nform
spec
at
i
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wit
in t
his
es, in part or in w
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hole
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a
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AG.
Bend metal edge of rear window frame -3- upwards in

-direction of arrow-.
Release underlying, original joint of lock pillar (C-pillar).
Release remaining original joint.
Remove lock pillar (C-pillar) from body.
168
agen
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by
Prote
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by
c
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rig
ht
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C
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Separate original joint along metal edge of rear window frame

-3-.
do
c
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Mark parting cut -1- and carry out.
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Remove remaining section of lock pillar (C-pillar) -1-.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
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wit
i
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p
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Amarok 2011
169
agen
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AG.
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es n
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AG.
Prote
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by
c
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.
C
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Drill holes for installation in rear window frame, 5.0 mm.
11.3
Installing
Note

11.3.1
Replacement parts
Side panel
170
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
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thi
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Amarok 2011
Amarok 2011
rrectness of i
t to the co
nform
spec
at
i
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n
wit
in t
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es, in part or in w
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hole
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, is n
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11.3.2
Welding in
Note
the illustration.
171
AG. Volkswagen AG d
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rig
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C
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Weld in lock pillar (C-pillar), RP spot weld seam, SG plug weld
seam and SG stitch weld seam.
172
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
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thi
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Amarok 2011
Amarok 2011
thi
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Prote
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by c
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p
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gh
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C
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yi
Weld in lock pillar (C-pillar), RP spot weld seam, SG plug weld

seam and SG stitch weld seam.
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
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AG. Volkswagen AG d
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After welding in lock pillar (C-pillar), smooth SG plug weld

seams in area -1-.
Bend metal edge of rear window frame -2- back in
-direction of arrow-.
Weld metal edge of rear window frame -2-, SG plug weld
seam.
173
Amarok 2011
RO: 51 70 55 20
12
Renewing mounting bracket for front

seat
WARNING

12.1
Removing
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
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t
a
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f
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n
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at
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Co
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174
do
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Remove mounting bracket for front seat -1- from body.
Amarok 2011
es, in part or in w
l purpos
hole
ercia
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m
m
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or
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t
a
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AG. Volkswagen AG d
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12.2
Installing
12.2.1
Preparing new part
Replacement parts
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Grind welding surfaces down to bare metal.
Mounting bracket for front seat
thi
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12. Renewing mounting bracket for front seat
175
Amarok 2011
rrectness of i
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nf
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spec
atio
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wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
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or
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f
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176
thi
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Amarok 2011
12.2.2
Welding in
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fo
ng
Adapt mounting bracket for front seat -1- to fit and fix in posi
tion.
Weld in mounting bracket for front seat, SG plug weld seam.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
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ht
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Co
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12. Renewing mounting bracket for front seat
177
agen
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AG.
Prote
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by
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Amarok 2011
53
Body - rear
RO: 53 05 55 00
Renewing rear cross panel

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gen AG
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WARNING
a
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a
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wit
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s
1 - Bonded areas
es, in part or in w
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hole
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m
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com

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AG.
Prote
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by c
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Rep. gr.53 - Body - rear
ht
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178
do
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n
2 - Rear cross panel
Amarok 2011
1.1
Removing
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
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b
ara
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e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
Release bonded joints -1-. To release, heat bonded surfaces

Remove rear cross panel from load surface.
thi
sd
o
cu
m
en
ht
rig
py
Co
t.
1. Renewing rear cross panel
179
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
un
le
r
fo
ng
1.2
Installing
1.2.1
Replacement parts
Rear cross panel
180
AG.

to bare metal.
agen
lksw
Vo
by
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
ot p
o
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erm
or
e
t
a
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p
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Co
t.
Amarok 2011
AG. Volkswagen AG d
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Co
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te o
iva
r
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rrectness of i
t to the co
nform
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a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
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com
pe
rm
itte
d
ility
ab
y li
an
pt
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un
le
Amarok 2011
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Grind bonding surfaces down to bare metal on one side (from

inside).
181
Amarok 2011
1.2.2
Welding in
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

Note
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
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gh
t.
C
op
yi
ht
rig
py
Co
t.
182
thi
sd
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
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f
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pt
ce
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h
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ra
a
c
s
s
Adapt new part to fit and fix in position.
ht
rig
py
Co
t.
r
fo
ng
Weld in rear cross panel, RP spot weld seam.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ility
ab
y li
an
pt
ce
un
le
Amarok 2011
183
agen
lksw
Vo
by
AG.
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
Amarok 2011
RO: 53 48 55 70
Renewing rear longitudinal member part section
WARNING
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
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ra
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c
s
s
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng

Load surface already removed General body repairs, ex

terior; Rep. gr. 55 ; Load surface .
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
thi
sd
o
cu
m
en
184
AG.
agen
lksw
Vo
by
Note
ht
rig
py
Co
t.
Removing
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
2.1
ht
rig
py
Co
t.
un
le
r
fo
ng
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
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t
a
itte
v
i
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p
ility
ab
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pt
ce
AG. Volkswagen AG d
agen
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V
gu2011
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b
Amarok
ara
d
nte
ise
r
o
Body
Repairs
Edition
10.2010
eo
h
t
u
ra
a
c
s
s
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
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t.
C
op
yi
Mark parting cut as per -dimension a- and cut.

Remove longitudinal member.
2. Renewing rear longitudinal member - part section
185
AG. Volkswagen AG d
agen
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is
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h
ut
ra
a
c
s
s
Installing
2.2.1
Replacement part
Rear longitudinal member complete
Mounting bracket
186
AG.
2.2
agen
lksw
Vo
by
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
ht
rig
py
Co
t.
do
c
um
en
r
te o
iva
r
rp
fo
g
n
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ility
ab
y li
an
pt
ce
un
le
Amarok 2011
Amarok 2011
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his

Remove shaded area.
Grind welding surfaces down to bare metal.
Grind welding surfaces of mounting bracket back to bare met
al.
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
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n
ility
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ce
AG. Volkswagen AG d
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h
ut
ra
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c
s
s
ht
rig
py
Co
t.
187
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Amarok 2011
2.2.2
Welding in
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
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ility
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AG. Volkswagen AG d
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do
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en
ht
rig
py
Co
t.
agen
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Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi

and fix in place.
Weld parting cut all round in rear longitudinal member -1- ad
hering to -air gap dimension a-, SG continuous weld seam.
Note
188
Amarok 2011
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
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ng
ility
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c
s
s
thi
sd
o
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en
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Adapt rear mounting bracket for load surface -1- to fit and fix
in position page 19 .
Weld in rear mounting bracket with longitudinal member -2-,
SG continuous weld seam.
Carry out cavity preservation on rear longitudinal member.
189
Amarok 2011
RO: 53 55 55 20
Renewing rear side panel
WARNING

Load surface already removed General body repairs, ex

terior; Rep. gr. 55 ; Load surface .
1 - Bonded areas
newal
age.
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
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gh
t
.
C
op
yi
do
c
um
en
190
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
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es n
wage
s
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ua
b
d
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ir se
tee
o
h
t
or
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ac
a
ss
Amarok 2011
3.1
Removing
AG. Volkswagen AG d
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s
r
fo
ng
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Release bonded joints -1-, -2- and -3-. To release, heat bon
ded surfaces with hot air blower -V.A.G 1416- .
ht
rig
py
Co
t.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ility
ab
y li
an
pt
ce
un
le
3. Renewing rear side panel
191
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
Drill open original joint -2- through 2 material thicknesses.

Remove rear side panel from load surface.
Release original joint from bracket -2-.
AG.
agen
lksw
Vo
by
Prote
cted
by c
o
p
yri
gh
t.
C
op
yi
192
ht
rig
py
Co
t.
r
fo
ng

rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
AG. Volkswagen AG d
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c
s
s
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y li
an
pt
ce
un
le
Amarok 2011
Amarok 2011
Remove bracket -2- from load surface.

to bare metal.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
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l
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b
ara
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ise
r
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eo
h
t
u
ra
a
c
s
s
do
c
um
en
193
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
Replacement parts
Rear side panel
194
Prote
cted
by
AG.
3.2.1
agen
lksw
Vo
by
c
o
p
yri
gh
t
.
C
op
yi
Installing
ht
rig
py
Co
t.
3.2
do
c
um
en
r
te o
iva
r
rp
fo
g
n
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ility
ab
y li
an
pt
ce
un
le
Amarok 2011
Amarok 2011
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Grind bonding surfaces -1- to -6- down to bare metal on one

side (from inside).
thi
sd
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
es n
wage
s
k
l
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ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
195
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
Amarok 2011
3.2.2
Welding in
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
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not
l
o
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nte
is
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h
ut
ra
a
c
s
s
agen
lksw
Vo
by
Prote
cted
by c
o
p
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gh
t.
C
op
yi
AG.
196
ht
rig
py
Co
t.
Note
thi
sd
o
cu
m
en
Amarok 2011
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
Weld in rear of side panel, RP spot weld seam.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
do
c
um
en
ht
rig
py
Co
t.
Adapt rear side
AG. Volkswagen AG d
agen
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nte
is
r
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h
ut -1- to fit and fix in position.
ra
panel
a
c
s
s
197
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Amarok 2011
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
es n
wage
s
k
l
ot g
o
yV
ua
b
d
ran
ir se
tee
o
h
t
or
u
ac
a
ss
Prote
cted
by
AG.
198
agen
lksw
Vo
by
c
o
p
yri
gh
t
.
C
op
yi
ht
rig
py
Co
t.
thi
sd
o
cu
m
en
Weld in rear side panel, RP spot weld seam, SG plug weld

seam and SG continuous weld seam.

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Service

Service Department. Technical Information

All rights reserved.

Key vehicle data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 - Body - front . . . . . . . . . . . . . . . .s a.ut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .or .ac . . . . . 41

Renewing cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Renewing rear cross panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Key vehicle data

Vehicle identification number

Vehicle identification number (chassis number) on the body:

1. Key vehicle data

ber) is located at 3 further points within the vehicle.

Additional, shortened vehicle identification number (chassis num

Rep. gr.00 - Technical data

The identification plate -arrow- is stuck on the left B-pillar.

Vehicle data sticker

The vehicle data sticker -arrow- is located in the footwell on

The vehicle identification number (chassis number) is stuck on

1. Key vehicle data

Rep. gr.00 - Technical data

Before beginning any cutting, alignment or dent removal, refer

Moulded foam elements

Various body cavities in the Amarok 2010 have been fitted

with moulded foam elements.

The moulded foam elements reduce the amount of driving

noise that is transmitted into the interior.

The moulded elements are fitted during body shell construc

The exact locations of these moulded foam elements are ad

ditionally shown at the beginning of the respective repair de

As these temperatures cannot be achieved under normal work

3. Moulded foam elements

Rep. gr.00 - Technical data

Carry out cavity preservation on repair area after painting ve

Do not do perform shielded arc welding within 15 mm on either

Galvanized body parts

The vehicle consists partly of body panels galvanized on one or

Before carrying out body repairs observe the following information

4. Galvanized body parts

Body panel gaps/shut lines

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

Rep. gr.00 - Technical data

Body - centre, vehicles with double cab

5. Body panel gaps/shut lines

Body - centre, vehicles with single cab

Rep. gr.00 - Technical data

Body - rear, vehicles with double cab

5. Body panel gaps/shut lines

Body - rear, vehicles with single cab

Rep. gr.00 - Technical data

Body add-on parts

S - 1.0 mm + 0.5 mm / - 1.0 mm

5. Body panel gaps/shut lines

Rep. gr.00 - Technical data

Dimensions only given for checking purposes. The alignment

bracket set is definitive. Bolts, screws, plugs, trim and attached