Body Repairs

Kapitelübersicht

• Technical data
  1
• 1 Key vehicle data
  1
• 1.1 Vehicle identification number
  1
• 1.2 Type plate
  2
• 1.3 Vehicle data sticker
  3
• 2 Safety information
  4
• 2.1 Safety precautions when working with moulded foam inserts
  4
• 3 Moulded foam inserts
  5
• 4 Tools
  7
• 5 Gaps/shut lines
  8
• 5.1 Body - front
  8
• 5.2 Body - centre, vehicles with double cab
  9
• 5.3 Body - centre, vehicles with single cab
  9
• 5.4 Body - rear, vehicles with double cab
  10
• 5.5 Body - rear, vehicles with single cab
  11
• 5.6 Body add-on parts
  12
• 6 Body dimensions
  15
• 6.1 Double cab chassis dimensions
  15
• 6.2 Single cab chassis dimensions
  20
• 6.3 Double cab box dimensions
  26
• 6.4 Single cab box dimensions
  31
• 6.5 Double cab load surface dimensions
  37
• 6.6 Single cab load surface dimensions
  41
• 7 Alignment jig
  46
• 7.1 Tools
  46
• 7.2 Alignment bracket fixture overview of complete vehicle
  46
• 7.3 Alignment bracket fixture overview of vehicle chassis
  47
• 7.4 Alignment bracket fixture overview of vehicle cab
  47
• 7.5 Alignment bracket fixture overview of vehicle cab
  48
• Body - front
  51
• 1 Renewing cross member
  51
• 1.1 Removing
  51
• 1.2 Installing
  53
• 2 Renewing deformation element
  56
• 2.1 Removing
  56
• 2.2 Installing
  57
• 3 Renewing engine mounting cross member
  60
• 3.1 Removing
  60
• 3.2 Installing
  61
• 4 Renewing differential cross member
  65
• 4.1 Removing
  65
• 4.2 Installing
  67
• 5 Renewing propshaft cross member
  70
• 5.1 Removing
  70
• 5.2 Installing
  71
• 6 Renewing cross member for shock absorber mounting
  76
• 6.1 Removing
  76
• 6.2 Installing
  78
• 7 Renewing suspension turret
  84
• 7.1 Removing
  85
• 7.2 Installing
  86
• 8 Renewing anti-roll bar mountings
  89
• 8.1 Removing
  89
• 8.2 Installing
  90
• 9 Renewing wing connecting plate
  93
• 9.1 Removing
  93
• 9.2 Installing
  95
• 10 Renewing connection piece
  98
• 10.1 Removing
  98
• 10.2 Installing
  99
• 11 Renewing headlight mounting
  102
• 11.1 Removing
  102
• 11.2 Installing
  104
• 12 Renewing upper wheel housing longitudinal member
  109
• 12.1 Removing
  109
• 12.2 Installing
  110
• 13 Renewing front wheel housing
  113
• 13.1 Removing
  113
• 13.2 Installing
  114
• 14 Renewing front part of longitudinal member - part section 1-
  116
• 14.1 Removing
  116
• 14.2 Installing
  117
• 15 Renewing longitudinal member - part section 2-
  120
• 15.1 Removing
  120
• 15.2 Installing
  121
• 16 Renewing longitudinal member complete
  127
• 16.1 Removing
  129
• 16.2 Installing
  135
• Body - centre
  149
• 1 Renewing roof (double cab)
  149
• 1.1 Tools
  150
• 1.2 Removing
  150
• 1.3 Installing
  152
• 2 Renewing roof, single cab
  156
• 2.1 Removing
  156
• 2.2 Installing
  158
• 3 Renewing roof side member, double cab
  162
• 3.1 Removing
  163
• 3.2 Installing
  166
• 4 Renewing roof side member, single cab
  172
• 4.1 Removing
  172
• 4.2 Installing
  174
• 5 Renewing front cross member for roof
  178
• 5.1 Removing
  178
• 5.2 Installing
  179
• 6 Renewing roof reinforcement
  182
• 6.1 Removing
  182
• 6.2 Installing
  183
• 7 Renewing rear roof cross member
  186
• 7.1 Removing
  186
• 7.2 Installing
  187
• 8 Renewing rear window frame
  190
• 8.1 Removing
  190
• 8.2 Installing
  192
• 9 Renewing cross member
  196
• 9.1 Removing
  196
• 9.2 Installing
  197
• 10 Renewing outer side panel completely, double cab
  200
• 10.1 Removing
  201
• 10.2 Installing
  204
• 11 Renewing outer side panel completely, single cab
  212
• 11.1 Removing
  213
• 11.2 Installing
  216
• 12 Renewing complete side panel, cargo box
  224
• 12.1 Removing
  224
• 12.2 Installing
  226
• 13 Renewing hinge pillar (A-pillar)
  230
• 13.1 Removing
  232
• 13.2 Installing
  234
• 14 Renewing hinge pillar (A-pillar) reinforcement
  240
• 14.1 Removing
  240
• 14.2 Installing
  242
• 15 Renewing inner A-pillar
  246
• 15.1 Removing
  246
• 15.2 Installing
  248
• 16 Renewing centre pillar (B-pillar)
  251
• 16.1 Removing
  252
• 16.2 Installing
  254
• 17 Renewing centre pillar (B-pillar) reinforcement
  257
• 17.1 Removing
  258
• 17.2 Installing
  259
• 18 Renewing lock column, C-pillar, double cab
  262
• 18.1 Removing
  263
• 18.2 Installing
  266
• 19 Renewing lock column, B-pillar, single cab
  270
• 19.1 Removing
  270
• 19.2 Installing
  272
• 20 Renewing outer side member, double cab
  276
• 20.1 Removing
  276
• 20.2 Installing
  278
• 21 Renewing outer side member, single cab
  282
• 21.1 Removing
  282
• 21.2 Installing
  284
• 22 Renewing rear inner side member
  289
• 22.1 Removing
  290
• 22.2 Installing
  291
• 23 Renewing C-pillar reinforcement, double cab
  295
• 23.1 Removing
  296
• 23.2 Installing
  297
• 24 Renewing inner C-pillar
  300
• 24.1 Removing
  300
• 24.2 Installing
  302
• 25 Renewing mounting bracket for front seat
  306
• 25.1 Removing
  306
• 25.2 Installing
  307
• 26 Renewing mounting bracket for driver cab
  310
• 26.1 Removing
  310
• 26.2 Installing
  311
• 27 Renewing mounting plate
  314
• 27.1 Removing
  314
• 27.2 Installing
  315
• Body - rear
  318
• 1 Renewing rear apron
  318
• 1.1 Removing
  318
• 1.2 Installing
  320
• 2 Renewing rear cross panel carrier
  324
• 2.1 Removing
  324
• 2.2 Installing
  325
• 3 Renewing D-pillar
  328
• 3.1 Removing
  328
• 3.2 Installing
  329
• 4 Renewing front leaf spring mounting bracket
  332
• 4.1 Removing
  332
• 4.2 Installing
  333
• 5 Renewing rear leaf spring mounting bracket
  335
• 5.1 Removing
  335
• 5.2 Installing
  336
• 6 Renewing cargo box shock absorber mounting
  339
• 6.1 Removing
  339
• 6.2 Installing
  340
• 7 Renewing rear longitudinal member - part section 1
  343
• 7.1 Removing
  344
• 7.2 Installing
  346
• 8 Renewing rear longitudinal member - part section 2
  352
• 8.1 Removing
  352
• 8.2 Installing
  353
• 9 Renewing rear side panel
  357
• 9.1 Removing
  357
• 9.2 Installing
  361
• 10 Renewing upper load surface cross member
  366
• 10.1 Removing
  367
• 10.2 Installing
  368
• 11 Renewing lower load surface cross member
  371
• 11.1 Removing
  371
• 11.2 Installing
  372
• 12 Renewing load surface floor panel, part section
  375
• 12.1 Removing
  376
• 12.2 Installing
  377
• 13 Renewing load surface bulkhead
  380
• 13.1 Removing
  380
• 13.2 Installing
  381