Body -> The body for Your Volkswagen Multivan SUV Fifth Generation (2003-2015)

Body  
The body  
To a large extent, the body has been taken from the previous model.  
The front end is new - it has been adapted to the current face of the Volkswagen family and is the same for the  
Multivan and commercial vehicles. The engine cover and the exterior mirrors have been improved in terms of  
their aerodynamics and reduced wind noise.  
Acoustic glazing is also available as an option.  
Innovations on the front end in detail:  
– An engine cover with new lines and more angular  
beading  
– The engine cover extends further upwards and  
covers the wiper arms in the windscreen area.  
– In the lower area, the engine cover extends further  
into the radiator grille area.  
– The front end has a new assembly mount.  
– New exterior mirrors  
– New radiator grille  
– Modified VW emblem design  
– New headlights  
S453_131  
Assembly mount  
Front end  
Cooler for power steering  
The front end is composed of the following main  
Ventilator  
components:  
Radiator  
– Assembly mount  
– Bumper mount  
– Bulkhead  
Ventilator  
– Radiator  
– Condenser  
– Intercooler (in the variants for TDI engine and TDI  
engine with bi-turbocharger unit)  
– Cooler for power steering  
Bulkhead  
Condenser  
S453_124  
Intercooler (for TDI engine)  
Bumper mount  
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Structure of the front end - exploded view  
Assembly mount  
Cooler for power steering  
Ventilator  
Radiator  
Condenser  
Intercooler  
(for TDI engine)  
Bulkhead  
S453_054  
Bumper mount  
The attachments for all components on  
the assembly mount have changed.  
Please always refer to the information  
in the workshop manual.  
The double fan concept in the previous model will  
be discontinued - the T5 2010 now has a single fan  
exclusively. The cooling power is adapted to the  
equipment level by means of three different fan  
powers (450 W, 600 W, 850 W).  
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Body  
Assembly mount  
In contrast to the assembly mount in the previous model, the one in the T5 2010 is no longer made from steel but  
from a composite material comprising plastic with a steel insert.  
The main advantage is the increased weight saving.  
In order to guarantee the necessary stability and crash safety of the assembly mount, the upper cross member of  
the assembly mount has been fitted with a steel insert. The plastic part is connected to the steel insert by hot  
riveting. This involves the steel insert being pushed onto the extruded projections of the plastic part, and then  
riveted by compression under the effect of heat.  
All other parts of the assembly mount are made entirely of plastic.  
Projection of the  
plastic part  
Projection of the plastic  
part compressed by hot  
riveting  
Hot riveting  
Upper crossmember  
of the assembly mount  
Steel insert of the assembly mount -  
hot-riveted with assembly mount  
Plastic part - hot-riveted  
with assembly mount  
Bumper mount  
S453_055  
Chassis rail  
It is essential to comply with the information in the workshop manual with  
regard to repair work on the front end - this applies in particular to the  
service position as well  
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