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
  2
• 2.1 Vehicle identification number
  2
• 2.2 Type plate
  3
• 2.3 Vehicle data sticker
  4
• 3 Safety information
  5
• 4 Body work for which HV electrical system must be de-energised
  6
• 4.1 The following body work requires the HV electrical system to be de-energised
  6
• 5 Moulded foam inserts
  7
• 6 Galvanized body parts, high- and higher-strength and hot-formed body panels
  9
• 7 Laser welding
  12
• 8 Gaps/shut lines
  13
• 8.1 Body – front
  13
• 8.2 Body, centre
  14
• 8.3 Body, rear
  16
• 9 Body dimensions
  18
• 9.1 Body – front
  18
• 9.2 Body, centre
  19
• 9.3 Body, rear
  24
• 9.4 Floor panel, front
  25
• 9.5 Floor panel, centre
  26
• 9.6 Floor panel, rear
  27
• 10 Straightening bracket set
  29
• 10.1 Overview
  29
• 11 Portal gauge
  31
• 11.1 Setup overview of complete body
  31
• Body - front
  33
• 1 Overview of parts
  33
• 2 Renewing right bracket
  34
• 2.1 Tools
  35
• 2.2 Removing
  35
• 2.3 Installing
  36
• 3 Repairing threads for securing subframe
  40
• 3.1 Contents of thread repair kit
  41
• 3.2 Repairing threads
  42
• 4 Renewing mounting bracket for subframe
  46
• 4.1 Tools
  47
• 4.2 Removing
  47
• 4.3 Installing
  49
• 5 Renewing front longitudinal member end plate
  53
• 5.1 Tools
  54
• 5.2 Removing
  54
• 5.3 Installing
  56
• 6 Renewing upper wheel housing longitudinal member
  59
• 6.1 Tools
  60
• 6.2 Removing
  60
• 6.3 Installing
  62
• 7 Renewing upper wheel housing longitudinal member - part section
  66
• 7.1 Tools
  67
• 7.2 Removing
  67
• 7.3 Installing
  69
• 8 Renewing upper inner wheel housing longitudinal member
  73
• 8.1 Tools
  74
• 8.2 Removing
  74
• 8.3 Installing
  76
• 9 Renewing front wheel housing
  80
• 9.1 Tools
  81
• 9.2 Removing
  81
• 9.3 Installing
  84
• 10 Renewing front left longitudinal member, ROW models (Rest of the World)
  90
• 10.1 Tools
  91
• 10.2 Removing
  91
• 10.3 Installing
  93
• 11 Renewing front left longitudinal member, NAR models (North America Region)
  100
• 11.1 Tools
  101
• 11.2 Removing
  101
• 11.3 Installing
  103
• 12 Renewing front right longitudinal member, ROW models (Rest of the World)
  111
• 12.1 Tools
  112
• 12.2 Removing
  112
• 12.3 Installing
  114
• 13 Renewing front right longitudinal member, NAR models (North America Region)
  122
• 13.1 Tools
  123
• 13.2 Removing
  123
• 13.3 Installing
  125
• 14.1 Tools
  134
• 14.2 Removing
  134
• 14.3 Installing
  137
• 15 Renewing front right longitudinal member (part section), ROW models (Rest of the World)
  143
• 15.1 Tools
  144
• 15.2 Removing
  144
• 15.3 Installing
  147
• 16 Renewing studs
  152
• Body - centre
  153
• 1 Overview of parts
  153
• 2 Renewing roof - vehicles with no panorama tilting sunroof
  154
• 2.1 Tools
  155
• 2.2 Removing
  156
• 2.3 Installing
  159
• 3 Renewing roof - vehicles with panorama tilting sunroof
  170
• 3.1 Tools
  171
• 3.2 Removing
  172
• 3.3 Installing
  175
• 4 Renewing A-pillar
  185
• 4.1 Tools
  187
• 4.2 Removing
  187
• 4.3 Installing
  189
• 5 Renewing upper A-pillar reinforcement (part section)
  194
• 5.1 Tools
  195
• 5.2 Removing
  195
• 5.3 Installing
  198
• 6 Renewing A-pillar reinforcement (part section)
  206
• 6.1 Tools
  207
• 6.2 Removing
  207
• 6.3 Installing
  209
• 7 Renewing B-pillar
  213
• 7.1 Tools
  215
• 7.2 Type plate
  215
• 7.3 Removing
  216
• 7.4 Installing
  218
• 8 Renewing B-pillar reinforcement
  223
• 8.1 Tools
  224
• 8.2 Type plate
  224
• 8.3 Removing
  225
• 8.4 Installing
  227
• 9 Renewing inner B-pillar
  232
• 9.1 Tools
  233
• 9.2 Removing
  233
• 9.3 Installing
  234
• 10 Renewing outer side member
  238
• 10.1 Tools
  239
• 10.2 Type plate
  239
• 10.3 Removing
  240
• 10.4 Installing
  242
• 11 Renewing side member reinforcement, ROW models (Rest of the World)
  247
• 11.1 Tools
  248
• 11.2 Removing
  248
• 11.3 Installing
  250
• 12 Renewing side member reinforcement, NAR models (North America Region)
  254
• 12.1 Tools
  255
• 12.2 Removing
  255
• 12.3 Installing
  257
• 13 Renewing side member cover plate
  261
• 13.1 Tools
  262
• 13.2 Removing
  262
• 13.3 Installing
  263
• Body - rear
  267
• 1 Overview of parts
  267
• 2 Renewing rear cross panel
  268
• 2.1 Tools
  269
• 2.2 Removing
  269
• 2.3 Installing
  272
• 3 Renewing rear cross member
  277
• 3.1 Tools
  278
• 3.2 Removing
  278
• 3.3 Installing
  279
• 4 Renewing corner reinforcing
  283
• 4.1 Tools
  284
• 4.2 Removing
  284
• 4.3 Installing
  286
• 5 Renewing luggage compartment floor (front-wheel drive)
  290
• 5.1 Tools
  291
• 5.2 Removing
  291
• 5.3 Installing
  293
• 6 Renewing luggage compartment floor (all-wheel drive)
  298
• 6.1 Tools
  299
• 6.2 Removing
  299
• 6.3 Installing
  301
• 7 Renewing rear longitudinal member (part section)
  306
• 7.1 Tools
  307
• 7.2 Removing
  307
• 7.3 Installing
  309
• 8.1 Tools
  313
• 8.2 Moulded foam inserts
  313
• 8.3 Removing
  313
• 8.4 Installing
  316
• 9.1 Tools
  326
• 9.2 Moulded foam inserts
  326
• 9.3 Removing
  326
• 9.4 Installing
  330
• 10 Renewing side panel (part section)
  340
• 10.1 Tools
  342
• 10.2 Removing
  342
• 10.3 Installing
  344
• 11 Renewing outer wheel housing liner, ROW models (Rest of the World)
  350
• 11.1 Tools
  351
• 11.2 Removing
  351
• 11.3 Installing
  354
• 12 Renewing outer wheel housing liner, NAR models (North America Region)
  360
• 12.1 Tools
  361
• 12.2 Removing
  361
• 12.3 Installing
  364