Body Repairs

Kapitelübersicht

• Technical data
  1
• 1 Basic instructions
  1
• 1.1 Original joint
  1
• 1.2 Used joining techniques
  1
• 2 Vehicle identification data
  3
• 2.1 Vehicle identification number
  3
• 2.2 Identification plate
  4
• 2.3 Vehicle data sticker
  5
• 3 Safety information
  7
• 4 Moulded foam inserts
  8
• 5 Galvanized body parts, high- and higher-strength and hot-formed body panels
  10
• 6 Laser welding
  13
• 7 Gaps/shut lines
  14
• 7.1 Body - front
  14
• 7.2 Body, centre
  16
• 7.3 Body, rear
  19
• 8 Body dimensions
  22
• 8.1 Body - front
  22
• 8.2 Body, centre
  23
• 8.3 Body, rear
  28
• 8.4 Floor panel, front
  29
• 8.5 Floor panel, centre
  30
• 8.6 Floor panel, rear
  31
• 9 Straightening bracket set
  33
• 9.1 Setup overview of complete body
  33
• 10 Portal gauge
  35
• 10.1 Setup overview of complete body
  35
• Body - front
  37
• 1 Overview of parts - LWB, MEX
  37
• 2 Overview of parts - LWB, EU
  38
• 3 Renewing bracket (right) - LWB, MEX
  39
• 3.1 Tools
  40
• 3.2 Removing
  40
• 3.3 Installing
  42
• 4 Renewing bracket (right) - LWB, EU
  45
• 4.1 Tools
  46
• 4.2 Removing
  46
• 4.3 Installing
  47
• 5 Repairing threads for securing subframe
  50
• 5.1 Contents of thread repair kit
  51
• 5.2 Repairing threads
  52
• 6 Renewing mounting bracket for subframe
  56
• 6.1 Tools
  57
• 6.2 Removing
  57
• 6.3 Installing
  59
• 7 Renewing front longitudinal member end plate
  62
• 7.1 Tools
  63
• 7.2 Removing
  63
• 7.3 Installing
  64
• 8 Renewing upper wheel housing longitudinal member
  67
• 8.1 Tools
  68
• 8.2 Removing
  68
• 8.3 Installing
  69
• 9 Renewing upper inner wheel housing longitudinal member
  73
• 9.1 Tools
  74
• 9.2 Removing
  74
• 9.3 Installing
  75
• 10 Renewing front wheel housing - LWB, MEX
  79
• 10.1 Tools
  80
• 10.2 Removing
  80
• 10.3 Installing
  82
• 11 Renewing front wheel housing - LWB, EU
  87
• 11.1 Tools
  88
• 11.2 Removing
  88
• 11.3 Installing
  90
• 12 Renewing front wheel housing (part section) - LWB, MEX
  95
• 12.1 Tools
  96
• 12.2 Removing
  96
• 12.3 Installing
  98
• 13 Renewing front wheel housing (part section) - LWB, EU
  103
• 13.1 Tools
  104
• 13.2 Removing
  104
• 13.3 Installing
  106
• 14 Renewing front longitudinal member - LWB, MEX
  111
• 14.1 Tools
  112
• 14.2 Removing
  112
• 14.3 Installing
  113
• 15 Renewing front longitudinal member - LWB, EU
  117
• 15.1 Tools
  118
• 15.2 Removing
  118
• 15.3 Installing
  119
• 16 Renewing front left longitudinal member (part section)
  123
• 16.1 Tools
  124
• 16.2 Removing
  124
• 16.3 Installing when using complete longitudinal member assembly
  126
• 16.4 Installing when using individual components of longitudinal member
  130
• 17 Renewing front right longitudinal member (part section)
  137
• 17.1 Tools
  138
• 17.2 Removing
  138
• 17.3 Installing when using complete longitudinal member assembly
  140
• 17.4 Installing when using individual components of longitudinal member
  144
• 18 Renewing studs
  151
• Body - centre
  153
• 1 Overview of parts - LWB, MEX
  153
• 2 Overview of parts - LWB, EU
  154
• 3 Renewing roof - vehicles with no panorama tilting sunroof
  155
• 3.1 Tools
  156
• 3.2 Removing
  156
• 3.3 Installing
  160
• 4 Renewing roof - vehicles with panorama tilting sunroof
  171
• 4.1 Tools
  172
• 4.2 Removing
  172
• 4.3 Installing
  176
• 5 Renewing A-pillar
  186
• 5.1 Tools
  187
• 5.2 Moulded foam inserts
  188
• 5.3 Removing
  188
• 5.4 Installing
  189
• 6 Renewing A-pillar reinforcement - LWB, EU, part section
  195
• 6.1 Tools
  196
• 6.2 Removing
  196
• 6.3 Installing
  197
• 7 Renewing upper A-pillar reinforcement - LWB, EU, part section
  202
• 7.1 Tools
  203
• 7.2 Moulded foam inserts
  203
• 7.3 Removing
  203
• 7.4 Installing
  206
• 8 Renewing B-pillar
  215
• 8.1 Tools
  217
• 8.2 Identification plate
  217
• 8.3 Moulded foam inserts
  219
• 8.4 Removing
  219
• 8.5 Installing
  220
• 9 Renewing B-pillar reinforcement
  225
• 9.1 Tools
  226
• 9.2 Identification plate
  226
• 9.3 Removing
  227
• 9.4 Installing
  229
• 10 Renewing B-pillar reinforcement - LWB, EU, part section
  234
• 10.1 Tools
  235
• 10.2 Identification plate
  235
• 10.3 Removing
  236
• 10.4 Installing
  240
• 11 Renewing outer side member
  249
• 11.1 Tools
  250
• 11.2 Identification plate
  251
• 11.3 Moulded foam inserts
  252
• 11.4 Removing
  252
• 11.5 Installing
  254
• 12 Renewing side member reinforcement - LWB MEX
  259
• 12.1 Tools
  260
• 12.2 Identification plate
  261
• 12.3 Removing
  261
• 12.4 Installing
  263
• Body - rear
  268
• 1 Overview of parts - LWB, MEX
  268
• 2 Overview of parts - LWB, EU
  269
• 3 Renewing rear cross panel
  270
• 3.1 Tools
  271
• 3.2 Removing
  271
• 3.3 Installing
  273
• 4 Renewing rear cross member
  278
• 4.1 Tools
  279
• 4.2 Removing
  279
• 4.3 Installing
  280
• 5 Renewing lower corner part
  285
• 5.1 Tools
  286
• 5.2 Removing
  286
• 5.3 Installing
  287
• 6 Renewing luggage compartment floor
  291
• 6.1 Tools
  292
• 6.2 Moulded foam inserts
  292
• 6.3 Removing
  292
• 6.4 Installing
  294
• 7 Renewing rear longitudinal member - LWB, MEX, part section
  300
• 7.1 Tools
  301
• 7.2 Moulded foam inserts
  301
• 7.3 Removing
  301
• 7.4 Installing
  304
• 8 Renewing rear longitudinal member - LWB, EU, part section
  308
• 8.1 Tools
  309
• 8.2 Moulded foam inserts
  309
• 8.3 Removing
  309
• 8.4 Installing
  312
• 9 Renewing rear longitudinal member - LWB (part section – second parting cut)
  316
• 9.1 Tools
  317
• 9.2 Moulded foam inserts
  318
• 9.3 Removing
  318
• 9.4 Installing
  321
• 10 Permitted parting cuts on side panel
  334
• 11 Renewing side panel (part section)
  335
• 11.1 Tools
  337
• 11.2 Moulded foam inserts
  337
• 11.3 Removing
  337
• 11.4 Installing
  340
• 12 Renewing outer wheel housing liner
  346
• 12.1 Tools
  347
• 12.2 Moulded foam inserts
  347
• 12.3 Removing
  347
• 12.4 Installing
  350
• 13 Renewing rear wheel housing
  355
• 13.1 Tools
  356
• 13.2 Removing
  356
• 13.3 Installing
  358