Body Repairs

Kapitelübersicht

• Technical data
  1
• 1 Safety instructions
  1
• 2 Moulded foam elements
  2
• 3 Galvanized body parts
  3
• 4 Laser welding
  4
• 5 Strengthened steel body panels
  5
• 6 Key vehicle data
  8
• 6.1 Vehicle identification number
  8
• 6.2 Identification plate
  11
• 6.3 Vehicle data sticker
  11
• 7 Gaps/shut lines
  13
• 7.1 Body - front
  13
• 7.2 Body - rear
  15
• 8 Gap dimensions, model year 2011 ▶
  20
• 8.1 Body - front
  20
• 8.2 Body - rear
  22
• 9 Body dimensions
  27
• 9.1 Body - front
  27
• 9.2 Body - centre
  33
• 9.3 Body - rear
  38
• 9.4 Floor group - front
  41
• 9.5 Floor group - centre
  45
• 9.6 Floor group - rear
  46
• 10 Alignment jig
  48
• 10.1 Alignment jig Caddy
  48
• 10.2 Alignment jig Caddy »Maxi«
  49
• 10.3 Portal gauges overview, 2-door vehicles
  50
• 10.4 Portal gauges overview, 4-door vehicles
  51
• Body - front
  53
• 1 Renewing suspension strut turret
  53
• 1.1 Tools
  53
• 1.2 Removing
  54
• 1.3 Installing
  54
• 2 Renewing right bracket
  57
• 2.1 Tools
  57
• 2.2 Removing
  58
• 2.3 Installing
  59
• 3 Renewing left console
  61
• 3.1 Tools
  62
• 3.2 Removing
  62
• 3.3 Installing
  64
• 4 Renewing retaining bracket for subframe
  67
• 4.1 Tools
  67
• 4.2 Removing
  68
• 4.3 Installing
  69
• 5 Renewing lateral cover plate for upper longitudinal member
  71
• 5.1 Tools
  71
• 5.2 Removing
  71
• 5.3 Installing
  72
• 6 Renewing lateral cover plate for upper longitudinal member, model year 2011 ▶
  73
• 6.1 Tools
  73
• 6.2 Removing
  74
• 6.3 Installing
  75
• 7 Renewing upper wheel housing longitudinal member
  79
• 7.1 Tools
  79
• 7.2 Removing
  79
• 7.3 Installing
  80
• 8 Renewing upper longitudinal member for wheel housing - part section
  81
• 8.1 Tools
  81
• 8.2 Removing
  82
• 8.3 Installing
  83
• 9 Renewing upper longitudinal member for wheel housing - part section - model year 2011 ▶
  84
• 9.1 Tools
  85
• 9.2 Removing
  86
• 9.3 Installing
  87
• 10 Renewing front wheel housing - part section
  89
• 10.1 Tools
  90
• 10.2 Removing
  90
• 10.3 Installing
  90
• 11 Repairing threads for securing subframe
  92
• 11.1 Contents of thread repair kit
  94
• 11.2 Repairing threads
  94
• 12 Renewing front longitudinal member
  98
• 12.1 Tools
  99
• 12.2 Removing
  99
• 12.3 Installing
  101
• 13 Renewing front longitudinal member - part section
  107
• 13.1 Tools
  107
• 13.2 Removing
  108
• 13.3 Installing
  110
• 14 Renewing end plate for front longitudinal member
  112
• 14.1 Tools
  112
• 14.2 Removing
  113
• 14.3 Installing
  113
• Body - centre
  115
• 1 Renewing roof
  115
• 1.1 Tools
  115
• 1.2 Removing
  117
• 1.3 Installing
  119
• 2 Renewing roof »vehicles with ladder flap«
  127
• 2.1 Tools
  127
• 2.2 Removing
  129
• 2.3 Installing
  131
• 3 Renewing roof »Caddy Maxi«
  139
• 3.1 Tools
  139
• 3.2 Removing
  141
• 3.3 Installing
  143
• 4 Renewing front roof cross member
  149
• 4.1 Tools
  149
• 4.2 Removing
  149
• 4.3 Installing
  150
• 5 Renewing roof reinforcement
  152
• 5.1 Tools
  152
• 5.2 Removing
  152
• 5.3 Installing
  153
• 6 Renewing rear roof cross member
  155
• 6.1 Tools
  155
• 6.2 Removing
  155
• 6.3 Installing
  157
• 7 Renewing rear roof cross member (vehicles with ladder flap)
  160
• 7.1 Tools
  160
• 7.2 Removing
  161
• 7.3 Installing
  161
• 8 Renewing side panel
  163
• 8.1 Tools
  164
• 8.2 Removing
  164
• 8.3 Installing
  167
• 9 Renewing side panel - part section
  171
• 9.1 Tools
  172
• 9.2 Removing
  172
• 9.3 Installing
  173
• 10 Renewing side panel beneath guide rail
  176
• 10.1 Tools
  177
• 10.2 Removing
  177
• 10.3 Installing
  178
• 11 Renewing side panel - part section »Caddy Maxi«
  183
• 11.1 Tools
  184
• 11.2 Removing
  184
• 11.3 Installing
  186
• 12 Renewing side panel beneath guide rail »Caddy Maxi«
  191
• 12.1 Tools
  192
• 12.2 Removing
  192
• 12.3 Installing
  194
• 13 Renewing hinge pillar (A-pillar) - part section
  199
• 13.1 Tools
  199
• 13.2 Removing
  199
• 13.3 Installing
  203
• 14 Renewing inner hinge pillar (A-pillar)
  207
• 14.1 Tools
  208
• 14.2 Removing
  208
• 14.3 Installing
  208
• 15 Renewing upper hinge pillar reinforcement
  210
• 15.1 Tools
  211
• 15.2 Removing
  211
• 15.3 Installing
  212
• 16 Renewing lower hinge pillar reinforcement - part section
  214
• 16.1 Tools
  214
• 16.2 Removing
  214
• 16.3 Installing
  216
• 17 Renewing middle pillar
  220
• 17.1 Tools
  221
• 17.2 Removing
  221
• 17.3 Installing
  222
• 18 Renewing reinforcing for middle pillar
  226
• 18.1 Tools
  226
• 18.2 Removing
  226
• 18.3 Installing
  229
• 19 Renewing side member (sliding door side)
  231
• 19.1 Overview of parting cuts »Caddy«
  232
• 19.2 Overview of parting cuts »Caddy Maxi«
  233
• 19.3 Tools
  234
• 19.4 Removing
  234
• 19.5 Installing
  235
• 20 Renewing side member reinforcement
  238
• 20.1 Tools
  239
• 20.2 Removing
  239
• 20.3 Installing
  240
• 21 Renewing inner side member reinforcement - part section
  244
• 21.1 Tools
  244
• 21.2 Removing
  244
• 21.3 Installing
  245
• 22 Renewing connecting piece for floor panel - part section
  247
• 22.1 Tools
  247
• 22.2 Removing
  247
• 22.3 Installing
  248
• Body - rear
  251
• 1 Renewing rear cross panel
  251
• 1.1 Tools
  251
• 1.2 Removing
  251
• 1.3 Installing
  253
• 2 Renewing lock carrier
  255
• 2.1 Tools
  256
• 2.2 Removing
  256
• 2.3 Installing
  257
• 3 Renewing tail light mounting
  259
• 3.1 Tools
  259
• 3.2 Removing
  259
• 3.3 Installing
  261
• 4 Renewing cross panel member
  263
• 4.1 Tools
  263
• 4.2 Removing
  264
• 4.3 Installing
  265
• 5 Renewing wheel housing liner
  266
• 5.1 Tools
  267
• 5.2 Removing
  267
• 5.3 Installing
  268
• 6 Renewing rear longitudinal member
  271
• 6.1 Tools
  272
• 6.2 Removing
  272
• 6.3 Installing
  274
• 7 Renewing cross member
  277
• 7.1 Tools
  278
• 7.2 Removing
  278
• 7.3 Installing
  278
• 8 Renewing luggage compartment floor - part section
  280
• 8.1 Tools
  281
• 8.2 Removing
  281
• 8.3 Installing
  282