Body Repairs

Kapitelübersicht

• Technical data
  1
• 1 Basic instructions
  1
• 2 Vehicle identification data
  2
• 2.1 Vehicle identification number
  2
• 2.2 Type plate
  3
• 2.3 Vehicle data sticker
  4
• 3 Safety information
  5
• 4 Moulded foam inserts
  6
• 5.1 Installing
  8
• 5.2 2-door models
  10
• 5.3 4-door models
  13
• 6 Laser welding
  16
• 7 Body panel gaps/shut lines
  17
• 7.1 Body - front
  17
• 7.2 Body - centre
  18
• 7.3 Body - rear
  20
• 8 Body dimensions
  21
• 8.1 Body - front
  21
• 8.2 Body - centre
  24
• 8.3 Body - rear
  34
• 8.4 Floor panel - front
  37
• 8.5 Floor panel - centre
  39
• 8.6 Floor panel - rear
  40
• 9 Tools
  41
• 10 Alignment jig
  42
• 10.1 Overview
  42
• 11 Portal gauge
  43
• 11.1 2-door models
  43
• 11.2 4-door models
  44
• Body - front
  46
• 1 Renewing right engine mounting bracket
  46
• 1.1 Tools
  46
• 1.2 Removing
  46
• 1.3 Installing
  48
• 2 Renewing mounting bracket for subframe
  50
• 2.1 Tools
  50
• 2.2 Removing
  50
• 2.3 Installing
  51
• 3 Renewing front bumper bracket
  54
• 3.1 Tools
  55
• 3.2 Removing
  55
• 3.3 Installing
  56
• 4 Renewing upper wheel housing longitudinal member
  58
• 4.1 Tools
  59
• 4.2 Removing
  59
• 4.3 Installing
  61
• 5 Renewing front wheel housing
  66
• 5.1 Tools
  67
• 5.2 Removing
  67
• 5.3 Installing
  68
• 6 Repairing threads for securing subframe
  70
• 6.1 Contents of thread repair kit
  72
• 6.2 Repairing threads
  72
• 7 Renewing front left longitudinal member
  76
• 7.1 Tools
  77
• 7.2 Removing
  77
• 7.3 Installing
  79
• 8 Renewing front left longitudinal member - part section
  83
• 8.1 Tools
  84
• 8.2 Removing
  84
• 8.3 Installing
  85
• 9 Renewing front right longitudinal member
  88
• 9.1 Tools
  89
• 9.2 Removing
  89
• 9.3 Installing
  91
• 10 Renewing front right longitudinal member - part section
  96
• 10.1 Tools
  97
• 10.2 Removing
  97
• 10.3 Installing
  98
• Body - centre
  101
• 1 Renewing roof
  101
• 1.1 Tools
  102
• 1.2 Removing
  103
• 1.3 Installing
  106
• 2 Renewing front cross member for roof
  117
• 2.1 Tools
  117
• 2.2 Removing
  117
• 2.3 Installing
  119
• 3 Renewing roof reinforcement
  121
• 3.1 Tools
  121
• 3.2 Removing
  121
• 3.3 Installing
  123
• 4 Renewing rear roof cross member
  126
• 4.1 Tools
  126
• 4.2 Removing
  126
• 4.3 Installing
  128
• 5 Renewing A-pillar
  131
• 5.1 Tools
  132
• 5.2 Removing
  132
• 5.3 Installing
  134
• 6 Renewing A-pillar reinforcement
  142
• 6.1 Tools
  143
• 6.2 Removing
  143
• 6.3 Installing
  146
• 7 Renewing B-pillar - 4-door
  152
• 7.1 Tools
  153
• 7.2 Removing
  154
• 7.3 Installing
  155
• 8 Renewing B-pillar reinforcement - 4-door
  160
• 8.1 Tools
  161
• 8.2 Removing
  161
• 8.3 Installing
  163
• 9 Renewing B-pillar reinforcement, 4-door model, part section
  169
• 9.1 Tools
  170
• 9.2 Removing
  170
• 9.3 Installing
  174
• 10 Renewing B-pillar reinforcement - 2-door
  182
• 10.1 Tools
  183
• 10.2 Removing
  183
• 10.3 Installing
  185
• 11 Renewing outer side member - 4-door
  197
• 11.1 Tools
  198
• 11.2 Removing
  198
• 11.3 Installing
  200
• 12 Renewing outer side member - 2-door
  209
• 12.1 Tools
  210
• 12.2 Removing
  211
• 12.3 Installing
  212
• 13 Renewing gusset plate
  218
• 13.1 Tools
  218
• 13.2 Removing
  218
• 13.3 Installing
  219
• 14 Renewing seat cross member
  222
• 14.1 Tools
  222
• 14.2 Removing
  222
• 14.3 Installing
  224
• Body - rear
  227
• 1 Renewing rear cross panel
  227
• 1.1 Tools
  228
• 1.2 Removing
  228
• 1.3 Installing
  229
• 2 Renewing tail light mounting
  232
• 2.1 Tools
  233
• 2.2 Removing
  233
• 2.3 Installing
  234
• 3 Renewing cross panel member
  237
• 3.1 Tools
  238
• 3.2 Removing
  238
• 3.3 Installing
  239
• 4 Renewing luggage compartment floor
  242
• 4.1 Tools
  243
• 4.2 Removing
  243
• 4.3 Installing
  244
• 5 Renewing rear longitudinal member - part section
  247
• 5.1 Tools
  248
• 5.2 Removing
  248
• 5.3 Installing
  250
• 6 Renewing side panel, part section – 4-door
  253
• 6.1 Tools
  254
• 6.2 Removing
  254
• 6.3 Installing
  256
• 7 Renewing side panel - 2-door
  264
• 7.1 Tools
  265
• 7.2 Removing
  265
• 7.3 Installing
  267
• 8 Renewing outer wheel housing liner - part section
  276
• 8.1 Tools
  277
• 8.2 Removing
  278
• 8.3 Installing
  279