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 Type plate
  4
• 2.3 Safety certificate
  5
• 3 Safety information
  7
• 4 Body work for which HV electrical system must be de-energised
  8
• 4.1 The following body work requires the HV electrical system to be de-energised
  8
• 5 If the high-voltage battery is removed, note the following:
  9
• 6 Moulded foam inserts
  10
• 7 Galvanized body parts, high- and higher-strength and hot-formed body panels
  12
• 8 Laser welding
  15
• 9 Straightening bracket set
  16
• 9.1 Overview of setup, entire body
  16
• 10 Portal gauge
  18
• 10.1 Overview of setup, entire body
  18
• Body - front
  20
• 1 Renewing front longitudinal member end plate
  20
• 1.1 Tools
  21
• 1.2 Removing
  21
• 1.3 Installing
  23
• 2 Renewing battery carrier
  26
• 2.1 Tools
  27
• 2.2 Removing
  27
• 2.3 Installing
  28
• 3 Renewing upper wheel housing longitudinal member - part section
  31
• 3.1 Tools
  32
• 3.2 Removing
  32
• 3.3 Installing
  34
• 4 Renewing upper inner wheel housing longitudinal member - part section
  38
• 4.1 Tools
  39
• 4.2 Removing
  39
• 4.3 Installing
  41
• 5 Renewing front wheel housing
  45
• 5.1 Tools
  46
• 5.2 Removing
  46
• 5.3 Installing
  49
• 6 Renewing front wheel housing (part section)
  55
• 6.1 Tools
  56
• 6.2 Removing
  56
• 6.3 Installing
  59
• 7 Renewing front left longitudinal member (part section)
  65
• 7.1 Tools
  66
• 7.2 Removing
  66
• 7.3 Installing
  69
• 8 Renewing front right longitudinal member (part section)
  76
• 8.1 Tools
  77
• 8.2 Removing
  77
• 8.3 Installing
  80
• 9 Renewing front left longitudinal member (part section – second parting cut)
  87
• 9.1 Tools
  88
• 9.2 Removing
  88
• 9.3 Installing
  91
• 10 Renewing front right longitudinal member (part section – second parting cut)
  102
• 10.1 Tools
  103
• 10.2 Removing
  103
• 10.3 Installing
  106
• 11 Renewing studs
  117
• Body - centre
  119
• 1 Renewing roof – vehicles with no panoramic sliding sunroof
  119
• 1.1 Tools
  120
• 1.2 Removing
  120
• 1.3 Installing
  124
• 2 Renewing roof – vehicles with panoramic sliding sunroof
  134
• 2.1 Tools
  135
• 2.2 Removing
  135
• 2.3 Installing
  139
• 3 Renewing roof side member
  149
• 3.1 Tools
  150
• 3.2 Removing
  151
• 3.3 Installing
  153
• 4 Renewing A-pillar
  159
• 4.1 Tools
  161
• 4.2 Removing
  161
• 4.3 Installing
  163
• 5 Renewing A-pillar reinforcement (part section)
  168
• 5.1 Tools
  169
• 5.2 Removing
  169
• 5.3 Installing
  172
• 6 Renewing B-pillar
  177
• 6.1 Tools
  179
• 6.2 Type plate
  179
• 6.3 Removing
  180
• 6.4 Installing
  182
• 7 Renewing B-pillar reinforcement
  187
• 7.1 Tools
  188
• 7.2 Type plate
  188
• 7.3 Removing
  189
• 7.4 Installing
  191
• 8 Renewing inner B-pillar
  195
• 8.1 Tools
  196
• 8.2 Removing
  196
• 8.3 Installing
  198
• 9 Renewing outer side member
  202
• 9.1 Tools
  203
• 9.2 Type plate
  203
• 9.3 Removing
  204
• 9.4 Installing
  206
• 10 Renewing side member reinforcement
  211
• 10.1 Tools
  212
• 10.2 Removing
  212
• 10.3 Installing
  214
• 11 Renewing side panel reinforcement (crash bar)
  218
• 11.1 Tools
  219
• 11.2 Removing
  219
• 11.3 Installing
  221
• Body - rear
  225
• 1 Renewing rear cross panel
  225
• 1.1 Tools
  226
• 1.2 Removing
  226
• 1.3 Installing
  228
• 2 Renewing rear cross member
  232
• 2.1 Tools
  233
• 2.2 Removing
  233
• 2.3 Installing
  234
• 3 Renewing rear floor cross member
  238
• 3.1 Tools
  239
• 3.2 Removing
  239
• 3.3 Installing
  241
• 4 Renewing centre floor panel (part section)
  245
• 4.1 Tools
  246
• 4.2 Removing
  246
• 4.3 Installing
  248
• 5 Renewing rear floor panel
  252
• 5.1 Tools
  253
• 5.2 Removing
  253
• 5.3 Installing
  255
• 6 Renewing longitudinal member cover plate
  259
• 6.1 Tools
  260
• 6.2 Removing
  260
• 6.3 Installing
  262
• 7 Renewing rear longitudinal member (part section)
  266
• 7.1 Tools
  267
• 7.2 Removing
  267
• 7.3 Installing
  269
• 8 Renewing rear longitudinal member (second part section)
  273
• 8.1 Tools
  274
• 8.2 Removing
  274
• 8.3 Installing
  277
• 9 Permitted parting cuts on side panel
  283
• 10 Renewing side panel (part section)
  284
• 10.1 Tools
  286
• 10.2 Removing
  286
• 10.3 Installing
  288
• 11 Renewing floor panel reinforcement
  294
• 11.1 Tools
  295
• 11.2 Removing
  295
• 11.3 Installing
  296
• 12 Renewing outer wheel housing liner
  299
• 12.1 Tools
  300
• 12.2 Removing
  300
• 12.3 Installing
  303