Body Repairs

Kapitelübersicht

• Technical data
  1
• 1 Key vehicle data
  1
• 1.1 Vehicle identification number
  1
• 1.2 Vehicle identification number
  2
• 1.3 Type plate
  3
• 1.4 Vehicle data sticker
  4
• 2 Safety information
  5
• 3 Moulded foam inserts
  6
• 4 Galvanised body parts
  8
• 5 Strengthened steel body panels
  9
• 5.1 Floor group
  9
• 5.2 Installing
  10
• 6 Laser welding
  11
• 7 Gaps/shut lines
  12
• 7.1 Body - front
  12
• 7.2 Body - centre and rear
  13
• 7.3 Rear body with rear wing doors
  14
• 8 Body dimensions
  15
• 8.1 Body dimensions, front
  15
• 8.2 Body dimensions - centre
  23
• 8.3 Body - rear
  24
• 8.4 Body dimensions of the floor group
  26
• 9 Alignment jig
  30
• 9.1 Overview
  30
• 9.2 Portal gauge
  42
• Body - front
  46
• 1 Renewing suspension turret
  46
• 1.1 Tools
  47
• 1.2 Removing
  47
• 1.3 Installing
  50
• 2 Renewing battery carrier
  55
• 2.1 Tools
  55
• 2.2 Removing
  55
• 2.3 Installing
  57
• 3 Renewing towing eye mounting
  60
• 3.1 Tools
  60
• 3.2 Removing
  60
• 3.3 Installing
  63
• 4 Replacing intermediate piece/end plate for front wheel housing
  69
• 4.1 Tools
  69
• 4.2 Removing
  69
• 4.3 Installing
  70
• 5 Renewing bumper bracket
  72
• 5.1 Tools
  72
• 5.2 Removing
  72
• 5.3 Installing
  73
• 6 Renewing reinforcement for front wheel housing - partial renewal
  75
• 6.1 Tools
  75
• 6.2 Removing
  75
• 6.3 Installing
  77
• 7 Renewing front wheel housing
  78
• 7.1 Tools
  78
• 7.2 Removing
  78
• 7.3 Installing
  81
• 8 Repairing threads for securing subframe
  84
• 8.1 Contents of thread repair kit
  85
• 8.2 Repairing threads
  86
• 9 Renewing front part of longitudinal member (part section)
  89
• 9.1 Tools
  89
• 9.2 Removing
  89
• 9.3 Installing
  91
• 10 Renewing bracket at front
  94
• 10.1 Tools
  94
• 10.2 Removing
  94
• 10.3 Installing
  95
• Body - centre
  98
• 1 Renewing high roof
  98
• 1.1 Removing
  98
• 1.2 Installing
  107
• 2 Renewing roof
  112
• 2.1 Tools
  112
• 2.2 Removing
  112
• 2.3 Installing
  116
• 3 Renewing roof (double cab)
  121
• 3.1 Tools
  121
• 3.2 Removing
  121
• 3.3 Installing
  124
• 4 Renewing front cross member for roof
  128
• 4.1 Tools
  128
• 4.2 Removing
  128
• 4.3 Installing
  129
• 5 Renewing roof reinforcement
  131
• 5.1 Tools
  131
• 5.2 Removing
  131
• 5.3 Installing
  132
• 6 Renewing rear roof cross member (double cab, dropside)
  134
• 6.1 Tools
  134
• 6.2 Removing
  134
• 6.3 Installing
  136
• 7 Renewing rear roof cross member
  137
• 7.1 Tools
  138
• 7.2 Removing
  138
• 7.3 Installing
  140
• 8 Renewing rear window frame (single and double cab)
  142
• 8.1 Tools
  143
• 8.2 Removing
  143
• 8.3 Installing
  145
• 9 Renewal of cross member (single and double cab)
  149
• 9.1 Tools
  149
• 9.2 Removing
  149
• 9.3 Installing
  151
• 10 Renewing front outer side panel
  153
• 10.1 Tools
  154
• 10.2 Removing
  154
• 10.3 Installing
  157
• 11 Renewing rear outer side panel (double cab)
  162
• 11.1 Tools
  163
• 11.2 Removing
  163
• 11.3 Installing
  166
• 12 Renewing outer side panel completely (panel van)
  171
• 12.1 Tools
  172
• 12.2 Removing
  172
• 12.3 Installing
  176
• 13 Renewing outer side panel (window aperture of Kombi)
  181
• 13.1 Tools
  182
• 13.2 Removing
  182
• 13.3 Installing
  186
• 14 Renewing outer side panel (vertical window section of Kombi)
  191
• 14.1 Tools
  192
• 14.2 Removing
  192
• 14.3 Installing
  195
• 15 Renewing outer side panel (part section, panel van and Kombi)
  200
• 15.1 Tools
  200
• 15.2 Removing
  200
• 15.3 Installing
  202
• 16 Renewing outer side panel on sliding door side (window section of Kombi)
  204
• 16.1 Tools
  205
• 16.2 Removing
  205
• 16.3 Installing
  207
• 17 Renewing outer side panel on sliding door side (part section, panel van)
  211
• 17.1 Tools
  212
• 17.2 Removing
  212
• 17.3 Installing
  215
• 18.1 Tools
  224
• 18.2 Removing
  224
• 18.3 Installing
  228
• 19 Renewing hinge pillar (part section)
  232
• 19.1 Tools
  233
• 19.2 Removing
  233
• 19.3 Installing
  234
• 20 Renewing reinforcing for hinge pillar
  237
• 20.1 Tools
  238
• 20.2 Removing
  238
• 20.3 Installing
  240
• 21 Renewing lock column, single cab
  243
• 21.1 Tools
  244
• 21.2 Removing
  244
• 21.3 Installing
  247
• 22 Renewing C-pillar (double cab)
  252
• 22.1 Tools
  253
• 22.2 Removing
  253
• 22.3 Installing
  254
• 23 Renewing front step
  257
• 23.1 Tools
  258
• 23.2 Removing
  258
• 23.3 Installing
  260
• 24 Renewing rear step
  264
• 24.1 Tools
  265
• 24.2 Removing
  265
• 24.3 Installing
  268
• 25 Renewing rear step (double cab)
  273
• 25.1 Tools
  273
• 25.2 Removing
  273
• 25.3 Installing
  276
• 26 Renewing middle pillar (part section)
  279
• 26.1 Tools
  280
• 26.2 Removing
  280
• 26.3 Installing
  283
• 27 Renewing reinforcing for middle pillar
  285
• 27.1 Tools
  286
• 27.2 Removing
  286
• 27.3 Installing
  287
• 28 Renewing lower guide rail for sliding door
  290
• 28.1 Tools
  290
• 28.2 Removing
  290
• 28.3 Installing
  291
• 29 Renewing outer side member
  294
• 29.1 Tools
  295
• 29.2 Removing
  295
• 29.3 Installing
  296
• 30 Renewing centre section of side member (part section, double cab)
  298
• 30.1 Tools
  298
• 30.2 Removing
  298
• 30.3 Installing
  299
• 31 Renewing front inner side member
  302
• 31.1 Tools
  303
• 31.2 Removing
  303
• 31.3 Installing
  304
• 32 Renewing gusset plate for roof side member
  307
• 32.1 Tools
  307
• 32.2 Removing
  307
• 32.3 Installing
  309
• 33 Renewing C-pillar reinforcement (double cab, part section)
  312
• 33.1 Tools
  313
• 33.2 Removing
  313
• 33.3 Installing
  314
• 34 Renewing C-pillar reinforcement (part section)
  317
• 34.1 Tools
  318
• 34.2 Removing
  318
• 34.3 Installing
  320
• 35 Renewing floor panel (double cab)
  323
• 35.1 Tools
  324
• 35.2 Removing
  324
• 35.3 Installing
  325
• 36 Renewing threaded nut for fastening ring
  328
• 36.1 Tools
  329
• 36.2 Removing
  329
• 36.3 Installing
  330
• 37 Renewing centre floor panel
  333
• 37.1 Tools
  334
• 37.2 Removing
  334
• 37.3 Installing
  335
• 38 Renewing fastening ring for loadbed
  338
• 38.1 Tools
  339
• 38.2 Removing
  339
• 38.3 Installing
  340
• Body - rear
  343
• 1 Renewing lower corner reinforcement
  343
• 1.1 Tools
  343
• 1.2 Removing
  343
• 1.3 Installing
  344
• 2 Renewing inner lock carrier
  347
• 2.1 Tools
  347
• 2.2 Removing
  347
• 2.3 Installing
  349
• 3 Renewing tail light mounting
  351
• 3.1 Tools
  351
• 3.2 Removing
  351
• 3.3 Installing
  353
• 4 Renewing cross panel member
  354
• 4.1 Tools
  354
• 4.2 Removing
  354
• 4.3 Installing
  355
• 5 Renewing rear part of luggage compartment floor
  358
• 5.1 Tools
  359
• 5.2 Removing
  359
• 5.3 Installing
  361
• 6 Renewing D-pillar reinforcement (part section)
  364
• 6.1 Tools
  365
• 6.2 Removing
  365
• 6.3 Installing
  366
• 7 Renewing D-pillar reinforcement
  369
• 7.1 Tools
  370
• 7.2 Removing
  370
• 7.3 Installing
  372
• 8 Renewal of rear cross panel member (single and double cab)
  377
• 8.1 Tools
  377
• 8.2 Removing
  377
• 8.3 Installing
  379
• 9 Renewing rear longitudinal member (part section, panel van and Kombi)
  381
• 9.1 Tools
  381
• 9.2 Removing
  381
• 9.3 Installing
  385
• 10 Renewal of rear longitudinal member (single and double cab)
  393
• 10.1 Tools
  393
• 10.2 Removing
  393
• 10.3 Installing
  396
• 11 Renewing outer wheel housing liner
  401
• 11.1 Tools
  402
• 11.2 Removing
  402
• 11.3 Installing
  403
• 12 Renewing cross member
  406
• 12.1 Tools
  407
• 12.2 Removing
  407
• 12.3 Installing
  408