General body repairs, exterior

Kapitelübersicht

• Body - front
  1
• 1 Lock carrier
  1
• 1.1 Tools
  1
• 1.2 Assembly overview - lock carrier, service position
  2
• 1.3 Service position
  2
• 1.4 Removing and installing lock carrier with attachments
  4
• 1.5 Assembly overview - air deflectors on lock carrier
  6
• 2 Wings
  7
• 2.1 Tools
  7
• 2.2 Assembly overview - wing
  7
• 2.3 Removing and installing wing
  8
• 2.4 Removing and installing wing bracket
  10
• 3 Noise insulation
  11
• 3.1 Tools
  11
• 3.2 Noise insulation
  11
• 4 Underbody cover
  13
• 4.1 Tools
  13
• 4.2 Underbody trim panels
  13
• 5 Plenum chamber bulkhead
  15
• 5.1 Tools
  15
• 5.2 Materials
  15
• 5.3 Assembly overview - bulkhead
  16
• 6 Bulkhead of plenum chamber
  17
• 6.1 Tools
  17
• 6.2 Assembly overview - plenum chamber bulkhead
  17
• 7 Radius rod
  18
• 7.1 Tools
  18
• 7.2 Assembly overview - radius rod
  18
• 8 Tunnel cross-piece
  20
• 8.1 Tools
  20
• 8.2 Assembly overview - tunnel cross-piece
  20
• Bonnet, rear lid
  21
• 1 Bonnet
  21
• 1.1 Tools
  21
• 1.2 Assembly overview - bonnet
  21
• 1.3 Removing and installing bonnet
  23
• 1.4 Removing gas strut
  25
• 1.5 Releasing gas from gas strut
  25
• 1.6 Removing and installing lid hinge
  25
• 1.7 Removing and installing insulation
  27
• 1.8 Assembly overview - bonnet lock and release components
  27
• 1.9 Removing and installing lid lock
  29
• 1.10 Bowden cable coupling
  31
• 1.11 Adjusting bonnet
  31
• 1.12 Removing and installing release lever
  33
• 2 Tailgate
  35
• 2.1 Tools
  35
• 2.2 Assembly overview - rear lid
  35
• 2.3 Removing and installing rear lid
  36
• 2.4 Adjusting rear lid
  38
• 2.5 Removing gas strut
  41
• 2.6 Releasing gas from gas strut
  41
• 2.7 Assembly overview - release element
  41
• 2.8 Removing and installing release element
  42
• 2.9 Removing and installing lid lock
  44
• 2.10 Removing and installing striker pin with power latching motor
  45
• 2.11 Removing and installing side striker pin
  46
• 2.12 Adjusting adjustment buffer
  47
• 2.13 Emergency release for rear lid
  48
• 2.14 Rear lid seal
  48
• 3 Tank flap unit
  51
• 3.1 Tools
  51
• 3.2 Assembly overview - tank flap unit and actuator
  51
• 3.3 Removing and installing tank flap unit
  53
• 3.4 Removing and installing actuator
  55
• Front doors, door components, central locking
  56
• 1 Rear door
  56
• 1.1 Tools
  56
• 1.2 Assembly overview - front door
  56
• 1.3 Assembly overview - door hinges
  58
• 1.4 Removing and installing door
  59
• 1.5 Adjusting door
  61
• 2 Door components
  63
• 2.1 Tools
  63
• 2.2 Assembly overview - assembly carrier
  65
• 2.3 Removing and installing subframe
  65
• 2.4 Assembly overview - door handle and door lock
  69
• 2.5 Removing and installing housing
  70
• 2.6 Removing and installing door handle
  71
• 2.7 Removing and installing door lock
  71
• 2.8 Removing and installing mounting plate
  72
• 2.9 Inner door seal
  73
• 2.10 Removing and installing inner door seal
  74
• 2.11 Removing and installing outer door seal
  75
• 2.12 Assembly overview - insulation
  76
• 3 Central locking
  78
• 3.1 Tool
  78
• 3.2 Fitting location overview - central locking components
  78
• 3.3 Adapting radio remote control ignition keys to the convenience system
  79
• 3.4 Adapting remote control keys to immobilizer
  80
• 3.5 Assembly overview - battery for folding key with remote control
  80
• 3.6 Battery for folding key with radio remote control
  81
• Rear doors, door components
  83
• Sunroof
  84
• 1 Externally guided sliding roof with glass panel
  84
• Convertible roof, hardtop, canopy
  85
• 1 Notes for working on the CSC roof
  85
• 1.1 Notes for safety and working on the CSC roof
  85
• 1.2 Rear lid service position
  86
• 1.3 Opening CSC roof without electrohydraulic system
  87
• 1.4 Closing CSC roof without electrohydraulic system
  91
• 1.5 Repairing seals with Sipiol coatings
  96
• 2 Sequence description
  100
• 3 Assembly overview - CSC roof
  106
• 4 Glass panel
  107
• 4.1 Tool
  107
• 4.2 Assembly overview - glass panel
  107
• 4.3 Removing glass panel
  109
• 4.4 Installing glass panel
  114
• 4.5 Adjusting glass panel
  116
• 4.6 Shut lines for glass panel
  117
• 4.7 Removing Bowden cables for glass panel
  119
• 4.8 Installing Bowden cables for glass panel
  125
• 4.9 Removing sliding sunroof motor
  127
• 4.10 Installing sliding sunroof motor
  128
• 4.11 Glass panel seal (> 07.2007)
  129
• 4.12 Cleaning water drainage hoses
  130
• 4.13 Removing guide rail
  131
• 4.14 Install guide rail
  137
• 4.15 Adjusting guide rail
  145
• 5 Roof
  146
• 5.1 Tool
  146
• 5.2 Removing centre roof section
  146
• 5.3 Install middle section of roof
  153
• 5.4 Adjusting centre roof section
  158
• 5.5 Removing seal for centre roof section
  159
• 5.6 Installing seal for centre roof section
  160
• 5.7 Shut lines for roof centre section
  162
• 6 Rear window frame
  163
• 6.1 Tool
  163
• 6.2 Assembly overview - rear window frame
  163
• 6.3 Removing rear window frame
  164
• 6.4 Installing rear window frame
  168
• 6.5 Adjusting rear window frame
  169
• 6.6 Shut lines for rear window frame
  170
• 6.7 Assembly overview - rear window frame seal
  172
• 6.8 Removing and installing rear window frame seal
  173
• 7 Roof member
  175
• 7.1 Tool
  175
• 7.2 Removing roof side member
  176
• 7.3 Installing roof side member
  184
• 7.4 Adjusting roof side member
  190
• 7.5 Roof side member shut lines
  191
• 7.6 Removing seal for roof side member
  193
• 7.7 Installing seal for roof side member
  196
• 7.8 Removing locking device for roof side member
  199
• 7.9 Installing locking device for roof side member
  200
• 7.10 Repairing water drain on roof side member
  201
• 7.11 Repairing water drain point on roof side member
  205
• 7.12 Assembly overview - lock fitting
  207
• 8 CSC roof
  208
• 8.1 Note on sender transferral when changing roof
  208
• 8.2 Tools
  208
• 8.3 Removing CSC roof
  210
• 8.4 Setting CSC roof down
  216
• 8.5 Removing new CSC roof from transportation box
  217
• 8.6 Installing CSC roof
  219
• 8.7 Basic settings for a newly installed CSC roof
  223
• 9 Interior trim
  232
• 9.1 Tool
  232
• 9.2 Assembly overview - interior trim
  232
• 9.3 Removing sliding headliner
  234
• 9.4 Installing sliding headliner
  237
• 9.5 Removing Bowden cables for sun visor
  240
• 9.6 Installing Bowden cables for sliding headliner
  243
• 9.7 Removing tensioned headlining
  245
• 9.8 Installing tensioned headlining
  248
• 9.9 Tensioning straps for tensioned headlining
  251
• 9.10 Removing bracing bow for tensioned headlining
  258
• 9.11 Installing bracing bow for tensioned headlining
  259
• 9.12 Trim for roof side member
  260
• 9.13 Preparing new trim for roof side member
  261
• 9.14 Tensioning straps for roof side member trim
  262
• 9.15 Lower trim for rear window frame
  266
• 9.16 Upper trim for rear window frame
  267
• 10 Roof side member flap
  268
• 10.1 Tool
  268
• 10.2 Assembly overview - trim for roof side member flap
  268
• 10.3 Assembly overview - roof side member flap mechanism
  269
• 10.4 Removing roof side member flap
  270
• 10.5 Installing roof side member flap
  273
• 10.6 Adjusting roof side member flaps
  274
• 11 Cover flaps
  275
• 11.1 Assembly overview - trim for cover flap
  275
• 11.2 Removing cover flaps
  276
• 11.3 Installing cover flaps
  277
• 11.4 Adjusting cover flap
  278
• 12 Rear shelf
  279
• 12.1 Assembly overview - rear shelf
  279
• 12.2 Removing rear shelf
  280
• 12.3 Installing rear shelf
  281
• 12.4 Installing stop buffer for rear shelf
  283
• 12.5 Removing and installing rear shelf protective strip
  284
• 12.6 Hinges for rear shelf with assembly frame
  286
• 12.7 Covers for assembly frame
  287
• 12.8 Repairing cables in assembly frame
  288
• 13 Hinge for rear shelf
  292
• 13.1 Assembly overview
  292
• 13.2 Removing
  293
• 13.3 Installing
  294
• 14 Securing bracket
  295
• 14.1 Assembly overview
  295
• 14.2 Removing
  296
• 14.3 Installing
  297
• 15 Windscreen frame seal
  298
• 15.1 Assembly overview - windscreen frame seal
  298
• 15.2 Removing windscreen frame seal
  299
• 15.3 Installing windscreen frame seal
  300
• 16 Wind deflector
  303
• 16.1 Assembly overview - wind deflector
  303
• 17 Electrical components
  304
• 17.1 Tool
  304
• 17.2 Assembly overview
  304
• 17.3 Front sender for position of roof side member (G556 / G557)
  306
• 17.4 Sender for roof side member locked (G558 / G559)
  307
• 17.5 Sender for rear window frame locked (G560 / G561)
  308
• 17.6 Sender for rear window frame open (G562)
  310
• 17.7 Sender roof side member flap open (G566 / G567)
  312
• 17.8 Sender for rear shelf locked (G563 / G564)
  313
• 17.9 Sender for roof stowed (G565) - vehicles > VIN 8V036221
  314
• 17.10 Senders for roof stowed (G565 and G672) - vehicles with VIN 8V036222 >
  315
• 17.11 Luggage cover contact switch (F364)
  316
• 17.12 Convertible roof actuation control unit (J256)
  317
• 17.13 Coding roof actuation control unit
  317
• 18 Hydraulic system
  319
• 18.1 Notes on hydraulic system
  319
• 18.2 Rules for cleanliness
  319
• 18.3 Filling and bleeding the hydraulic system
  320
• 18.4 Tool
  322
• 18.5 Assembly overview
  322
• 18.6 Assembly overview - hydraulic pump
  324
• 18.7 Hydraulic pump connection assignment
  325
• 18.8 Removing hydraulic oil reservoir
  330
• 18.9 Removing and installing hydraulic lines on hydraulic cylinder
  331
• 18.10 Hydraulic cylinder in roof side member
  332
• 18.11 Hydraulic cylinder in securing frame
  334
• 18.12 Hydraulic cylinder on hinge
  336
• 18.13 Hydraulic cylinder in main hinge
  337
• Bumpers
  339
• 1 Front bumper cover > 12.2010
  339
• 1.1 Tools
  339
• 1.2 Repairing front bumper cover
  339
• 1.3 Assembly overview - front bumper cover
  339
• 1.4 Removing and installing front bumper cover
  340
• 1.5 Front bumper cover add-on parts
  342
• 1.6 Front bumper cover substructure parts
  343
• 1.7 Assembly overview - front bumper carrier
  344
• 1.8 Assembly overview - front bumper carrier (USA)
  345
• 2 Front bumper cover 01.2011 >
  346
• 2.1 Tools
  346
• 2.2 Repairing front bumper cover
  346
• 2.3 Assembly overview - front bumper cover
  346
• 2.4 Removing and installing front bumper cover
  347
• 2.5 Front bumper cover add-on parts
  349
• 2.6 Front bumper cover substructure parts
  350
• 2.7 Assembly overview - front bumper carrier
  351
• 2.8 Assembly overview - front bumper carrier (USA)
  352
• 2.9 Number plate carrier
  353
• 3 Rear bumper cover > 12.2010
  354
• 3.1 Tools
  354
• 3.2 Repairing rear bumper cover
  354
• 3.3 Installing brackets for parking aid system
  354
• 3.4 Assembly overview - rear bumper cover
  359
• 3.5 Removing and installing rear bumper cover
  359
• 3.6 Rear bumper cover add-on parts
  361
• 3.7 Rear bumper cover substructure parts
  362
• 3.8 Assembly overview - rear bumper carrier
  363
• 3.9 Assembly overview - rear bumper carrier (USA)
  364
• 3.10 Assembly overview - towing bracket
  364
• 4 Rear bumper cover 01.2011 >
  366
• 4.1 Tools
  366
• 4.2 Repairing rear bumper cover
  366
• 4.3 Assembly overview - rear bumper cover
  366
• 4.4 Removing and installing rear bumper cover
  367
• 4.5 Rear bumper cover add-on parts
  369
• 4.6 Rear bumper cover substructure parts
  370
• 4.7 Assembly overview - rear bumper carrier
  371
• 4.8 Assembly overview - rear bumper carrier (USA)
  372
• 4.9 Assembly overview - towing bracket
  372
• Glazing
  374
• 1 Flush bonded windows
  374
• 1.1 Tools
  374
• 1.2 Materials
  376
• 1.3 Repairing windscreen
  376
• 1.4 Assembly overview - windscreen
  376
• 1.5 Plenum chamber cover
  378
• 1.6 Removing windscreen
  381
• 1.7 Installing windscreen
  381
• 1.8 Assembly overview - rear window
  381
• 1.9 Removing undamaged rear window
  383
• 1.10 Removing broken rear window
  385
• 1.11 Installing rear window
  386
• 1.12 Preparing old undamaged window for glazing
  386
• 1.13 Preparing new window for glazing
  386
• 1.14 Preparing body flange for glazing
  387
• 1.15 Fitting instructions
  389
• 1.16 Minimum curing period
  391
• 1.17 Touching up paint damage
  392
• 1.18 Cleaning in the event of dirt caused by adhesive sealing material
  392
• 2 Door window
  393
• 2.1 Tools
  393
• 2.2 Assembly overview - door window
  394
• 2.3 Removing door window
  395
• 2.4 Installing door window
  396
• 2.5 Adjusting door window
  397
• 2.6 Door window adjustment dimensions
  400
• 2.7 Removing window regulator motor
  401
• 2.8 Installing window regulator motor
  402
• 2.9 Removing window lifters
  403
• 2.10 Installing window lifters
  404
• 2.11 Basic settings for window regulator
  405
• 2.12 Removing window channel and window slot seal
  405
• 2.13 Installing window channel and window slot seal
  407
• 3 Side window
  408
• 3.1 Tools
  408
• 3.2 Assembly overview - side window
  408
• 3.3 Removing side window with window regulator
  409
• 3.4 Installing side window with window regulator
  410
• 3.5 Removing side window
  411
• 3.6 Installing side window
  412
• 3.7 Adjusting side window
  413
• 3.8 Side window adjustment dimensions
  416
• 3.9 Window regulator motor
  417
• 3.10 Assembly overview - window slot seals
  418
• 3.11 Assembly overview - intermediate plate
  419
• Exterior equipment
  420
• 1 Wheel housing liner
  420
• 1.1 Tools
  420
• 1.2 Assembly overview - front wheel housing liner
  420
• 1.3 Removing and installing front wheel housing liner
  421
• 1.4 Assembly overview - rear wheel housing liner
  423
• 1.5 Removing and installing rear wheel housing liner
  424
• 2 Exterior mirror > 05.2008
  426
• 2.1 Tools
  426
• 2.2 Assembly overview - exterior mirror
  427
• 2.3 Removing and installing mirror glass
  427
• 2.4 Removing and installing mirror housing
  428
• 2.5 Removing and installing trim
  430
• 2.6 Removing and installing turn signal repeater
  430
• 2.7 Removing and installing adjustment unit with motor
  431
• 2.8 Removing and installing entry light
  432
• 2.9 Removing and installing exterior mirror
  433
• 3 Exterior mirror 06.2008 >
  434
• 3.1 Tools
  434
• 3.2 Assembly overview - exterior mirror
  434
• 3.3 Removing and installing mirror glass
  435
• 3.4 Removing and installing mirror housing
  437
• 3.5 Removing and installing trim
  438
• 3.6 Removing and installing side turn signal and entry light in exterior mirror
  439
• 3.7 Removing and installing exterior mirror
  441
• 4 Radiator grille > 12.2010
  442
• 4.1 Assembly overview - radiator grille
  442
• 4.2 Removing and installing radiator grille
  443
• 4.3 Removing and installing emblem
  445
• 4.4 Assembly overview - number plate carrier
  445
• 4.5 Removing and installing number plate carrier
  447
• 5 Radiator grille 01.2011 >
  449
• 5.1 Removing radiator grille
  449
• 5.2 Installing radiator grille
  450
• 5.3 Removing and installing emblem
  451
• 6 Mouldings and trims
  453
• 6.1 Cover strip
  453
• 6.2 Wheel arch trim
  455
• 7 Lettering
  457
• 7.1 Tools
  457
• 7.2 Fitting instructions
  457
• 7.3 Rear lettering dimensions > 12.2010
  457
• 7.4 Rear lettering dimensions 01.2011 >
  459
• 7.5 Lettering on wing
  460