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2 General notes on body repairs
The aim of the repair is always to restore the original joint.
The Workshop Manuals describe the standard repairs. They do
not include any descriptions of more complex repair work, as such
work involves detaching the damaged parts at the original joint.
Where possible, the joining techniques described can be used
provided that their suitability has been ensured beforehand.
All repair work involving special separating cuts and joining tech‐
niques which do not restore the original joint (as manufactured)
is checked and approved by Technical Development using cal‐
culations, strength tests and crash tests.
2.1 Original joint
The term “original joint” refers to joints which were made during
manufacture of the vehicle.
These joints must be restored when carrying out body repairs.
When doing this, ensure that no fewer than the standard number
of spot welds are made when carrying out repairs.
Repair methods and procedures which do not restore the original
joint are described in the relevant Body Repairs workshop man‐
ual.
2.2 Galvanised body parts
The use of fully galvanised panels ensures a high level of corro‐
sion protection for the body shell. In order to maintain the warranty
cover against rust perforation when performing repairs, it is es‐
sential to comply with the procedures described; refer to
⇒ page 56 .
WARNING
As the welding of galvanised sheet steel gives off toxic zinc
oxide in the welding fumes, the workshop must have efficient
ventilation and fume extraction, e.g. in the form of a welding
fume extractor - V.A.G 1586 A- .
2.3 Removing remaining material
If the damaged body part has been roughly cut out by making the
separating cuts shown in the relevant workshop manual (e.g. us‐
ing body saw), most spot welds can be drilled out using the spot
weld breaker.
We also recommend using a parallel grinder and an angle grinder
to remove the weld joints which cannot be removed with the spot
weld breaker.
2.4 New parts
New parts which are no longer accessible from inside once the
repair has been completed (e.g. side members) should be provi‐
ded with suitable corrosion protection before being welded in. It
is advisable to mask off the welding flanges when doing so.
Please refer to the Paintwork manual for further information.
Check new replacement parts e.g. doors, bonnet and boot lid/
tailgate or wing panel for transportation damage before passing
them on to the paintshop. This avoids a second painting operation
which would become necessary if transportation or other damage
was not noticed until a later stage.
General InformationBody Repairs, General Body Repairs - Edition 04.2018
2. General notes on body repairs 3
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