Body Repairs

Kapitelübersicht

• Technical data
  1
• 1 Vehicle identification data
  1
• 1.1 Vehicle identification number
  1
• 2 Safety information
  3
• 3 Gas vehicles
  4
• 4 Moulded foam inserts
  5
• 5 Galvanized body parts, high/higher-strength and hot-formed body panels
  7
• 5.1 Installing
  7
• 6 Laser welding
  10
• 7 Body panel gaps/shut lines
  11
• 7.1 Body - front
  11
• 7.2 Body - centre
  12
• 7.3 Body - rear
  13
• 7.4 Body - rear (Variant)
  14
• 8 Body dimensions
  15
• 8.1 Body - front
  15
• 8.2 Body - centre
  17
• 8.3 Body - centre (Variant)
  22
• 8.4 Body - rear
  23
• 8.5 Body - rear (Variant)
  24
• 8.6 Floor panel - front
  25
• 8.7 Floor panel - centre
  26
• 8.8 Floor panel - rear
  27
• 9 Tools
  28
• 10 Alignment bracket set
  29
• 10.1 Overview
  29
• 11 Portal gauge
  31
• 11.1 Overview
  31
• Body - front
  33
• 1 Renewing left bracket
  33
• 1.1 Tools
  33
• 1.2 Removing
  33
• 1.3 Installing
  36
• 2 Renewing right bracket
  38
• 2.1 Tools
  38
• 2.2 Removing
  38
• 2.3 Installing
  40
• 3 Renewing retaining bracket for subframe
  42
• 3.1 Tools
  42
• 3.2 Removing
  42
• 3.3 Installing
  44
• 4 Renewing bumper bracket
  46
• 4.1 Tools
  47
• 4.2 Removing
  47
• 4.3 Installing
  48
• 5 Renewing upper wheel housing longitudinal member
  50
• 5.1 Tools
  51
• 5.2 Removing
  52
• 5.3 Installing
  54
• 6 Renewing front wheel housing
  58
• 6.1 Tools
  59
• 6.2 Removing
  59
• 6.3 Installing
  61
• 7 Repairing threads for securing subframe (suspension subframe)
  68
• 7.1 Tools
  69
• 7.2 Contents of thread repair kit
  69
• 7.3 Repairing threads
  69
• 8 Renewing front longitudinal member
  73
• 8.1 Tools
  74
• 8.2 Removing
  74
• 8.3 Installing
  77
• 9 Renewing front longitudinal member - part section
  84
• 9.1 Tools
  85
• 9.2 Removing
  85
• 9.3 Installing
  88
• Body - centre
  93
• 1 Renewing roof
  93
• 1.1 Tools
  94
• 1.2 Removing
  95
• 1.3 Installing
  97
• 2 Renewing roof - vehicles with sliding/tilting sunroof
  108
• 2.1 Tools
  109
• 2.2 Removing
  110
• 2.3 Installing
  113
• 3 Renewing roof (Variant)
  125
• 3.1 Tools
  126
• 3.2 Removing
  127
• 3.3 Installing
  129
• 4 Renewing roof - Variant with panorama sliding sunroof
  140
• 4.1 Tools
  141
• 4.2 Removing
  142
• 4.3 Installing
  145
• 5 Renewing roof side member
  157
• 5.1 Tools
  158
• 5.2 Removing
  158
• 5.3 Installing
  160
• 5.4 Foam treating roof side member
  166
• 6 Renewing front cross member for roof
  169
• 6.1 Tools
  170
• 6.2 Removing
  171
• 6.3 Installing
  172
• 7 Renewing rear roof cross member (saloon)
  174
• 7.1 Tools
  175
• 7.2 Removing
  175
• 7.3 Installing
  176
• 8 Renewing rear roof cross member (Variant)
  178
• 8.1 Tools
  179
• 8.2 Removing
  179
• 8.3 Installing
  180
• 9 Renewing A-pillar
  183
• 9.1 Tools
  184
• 9.2 Removing
  184
• 9.3 Installing
  186
• 10 Renewing A-pillar reinforcement - part section
  193
• 10.1 Tools
  194
• 10.2 Removing
  194
• 10.3 Installing
  196
• 11 Renewing B-pillar
  200
• 11.1 Tools
  201
• 11.2 Removing
  201
• 11.3 Installing
  203
• 12 Renewing B-pillar reinforcement - part section
  211
• 12.1 Tools
  212
• 12.2 Removing
  212
• 12.3 Installing
  214
• 13 Renewing inner B-pillar
  224
• 13.1 Tools
  225
• 13.2 Removing
  225
• 13.3 Installing
  227
• 14 Renewing side member
  230
• 14.1 Tools
  231
• 14.2 Removing
  231
• 14.3 Installing
  233
• 15 Renewing front side member reinforcement
  239
• 15.1 Tools
  240
• 15.2 Removing
  240
• 15.3 Installing
  241
• 16 Renewing rear side member reinforcement
  246
• 16.1 Tools
  247
• 16.2 Removing
  247
• 16.3 Installing
  248
• 17 Renewing seat middle cross member
  251
• 17.1 Tools
  251
• 17.2 Removing
  251
• 17.3 Installing
  253
• 18 Renewing inner mounting for seat cross member
  256
• 18.1 Tools
  256
• 18.2 Removing
  256
• 18.3 Installing
  258
• 19 Renewing outer mounting for seat cross member
  261
• 19.1 Tools
  262
• 19.2 Removing
  263
• 19.3 Installing
  264
• Body - rear
  267
• 1 Renewing cross panel
  267
• 1.1 Tools
  268
• 1.2 Removing
  268
• 1.3 Installing
  270
• 2 Renewing rear cross panel (Variant)
  274
• 2.1 Tools
  275
• 2.2 Removing
  275
• 2.3 Installing
  277
• 3 Renewing lock carrier
  281
• 3.1 Tools
  281
• 3.2 Removing
  281
• 3.3 Installing
  283
• 4 Renewing tail light mounting
  285
• 4.1 Tools
  286
• 4.2 Removing
  286
• 4.3 Installing
  288
• 5 Renewing tail light mounting (Variant)
  292
• 5.1 Tools
  293
• 5.2 Removing
  293
• 5.3 Installing
  294
• 6 Renewing C-pillar reinforcement
  297
• 6.1 Tools
  298
• 6.2 Removing
  298
• 6.3 Installing
  299
• 7 Renewing C-pillar reinforcement (Variant)
  303
• 7.1 Tools
  304
• 7.2 Removing
  304
• 7.3 Installing
  306
• 8 Renewing D-pillar reinforcement - part section
  311
• 8.1 Tools
  312
• 8.2 Removing
  312
• 8.3 Installing
  314
• 9 Renewing inner D-pillar
  318
• 9.1 Tools
  319
• 9.2 Removing
  319
• 9.3 Installing
  320
• 10 Renewing rear longitudinal member - part section
  323
• 10.1 Tools
  324
• 10.2 Removing
  325
• 10.3 Installing
  327
• 11 Renewing side panel - part section
  333
• 11.1 Tools
  334
• 11.2 Removing
  334
• 11.3 Installing
  336
• 12 Renewing side panel (Variant) - part section
  343
• 12.1 Tools
  344
• 12.2 Removing
  344
• 12.3 Installing
  346
• 13 Renewing outer wheel housing liner
  353
• 13.1 Tools
  354
• 13.2 Removing
  354
• 13.3 Installing
  356
• 14 Renewing outer wheel housing liner (Variant)
  361
• 14.1 Tools
  362
• 14.2 Removing
  362
• 14.3 Installing
  365
• 15 Renewing spare wheel well
  371
• 15.1 Tools
  371
• 15.2 Removing
  372
• 15.3 Installing
  374