General body repairs, exterior

Kapitelübersicht

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety precautions when working in the vicinity of high-voltage components
  1
• 1.2 Safety precautions when working on high-voltage system
  1
• 1.3 Safety measures when working on vehicles with a start/stop system
  2
• 1.5 Safety precautions when working on the cooling system
  3
• 2 Repair instructions
  4
• 2.1 General repair instructions
  4
• 2.2 Contact corrosion
  4
• 2.3 Routing and attachment of lines
  5
• 2.4 Nuts and bolts
  5
• 3 Hazard classification for the high-voltage system
  6
• Body - front
  7
• 1 Lock carrier
  7
• 1.1 Assembly overview – lock carrier
  7
• 1.2 Removing and installing lock carrier
  10
• 1.3 Moving to and back from service position
  15
• 1.4 Removing and installing air duct
  23
• 1.5 Removing and installing lock carrier struts
  29
• 2 Wings
  32
• 2.1 Assembly overview – wing
  32
• 2.2 Removing and installing wing
  33
• 3 Bulkhead
  40
• 3.1 Assembly overview – plenum chamber cover
  40
• 3.2 Removing and installing plenum chamber cover
  43
• 4 Carrier frames for high-voltage components
  50
• 4.1 Assembly overview – carrier frames for high-voltage components
  50
• 4.2 Removing and installing carrier frame
  50
• Body - centre
  55
• 1 Carrier frame for high-voltage battery 1 AX2
  55
• 1.1 Assembly overview - carrier frame for high-voltage battery 1 AX2
  55
• 1.2 Removing and installing carrier frame for high-voltage battery 1 AX2
  57
• 2 Deformation elements
  58
• 2.1 Assembly overview - deformation elements
  58
• 2.2 Removing and installing deformation elements
  58
• Bonnet, rear lid
  60
• 1 Bonnet
  60
• 1.1 Assembly overview – bonnet
  60
• 1.2 Assembly overview – Bowden cable
  63
• 1.3 Removing and installing bonnet
  64
• 1.4 Adjusting bonnet
  67
• 1.5 Removing and installing rear lid lock
  70
• 1.6 Removing and installing bonnet lock operating lever
  72
• 1.7 Removing and installing striker pin
  72
• 1.8 Removing and installing hinges
  73
• 1.9 Removing and installing insulation
  75
• 1.10 Removing and installing Bowden cable
  76
• 1.11 Removing and installing bonnet stay
  78
• 2 Tank flap unit
  81
• 2.1 Assembly overview – tank flap unit
  81
• 2.2 Removing and installing fuel tank flap
  82
• Front doors, door components, central locking
  85
• 1 Door
  85
• 1.1 Assembly overview – door
  85
• 1.2 Assembly overview - door seals
  87
• 1.3 Removing and installing inner door seal
  90
• 1.4 Removing and installing door
  93
• 1.5 Adjusting door
  95
• 1.6 Adjusting striker pin
  97
• 1.7 Removing and installing door hinge
  98
• 1.8 Removing and installing door arrester
  99
• 2 Door components
  101
• 2.1 Assembly overview – door components
  101
• 2.2 Assembly overview – window regulator
  102
• 2.3 Assembly overview – door handle and door lock
  103
• 2.4 Assembly overview - window channels and window slot (aperture) seals
  104
• 2.5 Removing and installing window regulator motor
  105
• 2.6 Removing and installing window regulator
  106
• 2.7 Removing and installing inner door cover
  108
• 2.8 Removing and installing striker pin
  109
• 2.9 Removing and installing door handle
  110
• 2.10 Removing and installing mounting bracket
  112
• 2.11 Removing and installing door lock
  113
• 2.12 Removing and installing window channel
  116
• 2.13 Removing and installing lock cylinder
  117
• 2.14 Removing and installing cap on door handle
  119
• 2.15 Removing and installing window slot inner seal
  120
• 2.16 Removing and installing window slot outer seal
  121
• 3 Central locking
  123
• 3.1 Overview of fitting locations – central locking system
  123
• 3.3 Removing and installing ignition key battery
  126
• 3.4 Removing and installing cap on ignition key
  127
• 3.5 Removing and installing bonnet contact switch F266
  128
• Rear doors, door components
  129
• 1 Door
  129
• 1.1 Assembly overview – door
  129
• 1.2 Assembly overview - door seals
  129
• 1.3 Removing and installing door
  130
• 1.4 Adjusting door
  132
• 1.5 Adjusting striker pin
  133
• 1.6 Removing and installing door hinges
  136
• 1.7 Removing and installing door arrester
  138
• 1.8 Removing and installing inner door seal
  141
• 2 Door components
  143
• 2.1 Assembly overview – door handle and door lock
  143
• 2.2 Removing and installing door components
  150
• 2.3 Removing and installing striker pin
  160
• 2.4 Removing and installing door handle
  162
• 2.5 Removing and installing mounting bracket
  164
• 2.6 Removing and installing door lock
  167
• 2.7 Removing and installing cap on door handle
  177
• 2.8 Removing and installing lock cylinder
  179
• 3 Sliding door
  182
• 3.1 Assembly overview – sliding door
  182
• 3.2 Assembly overview - door seals
  186
• 3.3 Removing and installing sliding door
  186
• 3.4 Adjusting sliding door
  189
• 3.5 Removing and installing add-on parts
  196
• 3.6 Removing and installing inner door seal
  202
• 3.7 Removing and installing rear right door control unit J389
  204
• 4 Wing door
  205
• 4.1 Assembly overview - wing door
  205
• 4.2 Assembly overview - door seals
  209
• 4.3 Removing and installing wing door
  209
• 4.4 Adjusting wing door
  210
• 4.5 Removing and installing hinges
  212
• 4.6 Removing and installing door attachments, wing door
  214
• 4.7 Removing and installing outer door seal
  221
• 4.8 Removing and installing inner door seal
  222
• Bumpers
  224
• 1 Bumper, front
  224
• 1.1 Assembly overview – bumper cover
  224
• 1.2 Removing and installing bumper cover
  226
• 1.3 Removing and installing bumper carrier
  229
• 1.4 Removing and installing add-on parts
  232
• 1.5 Repairing bumper cover
  235
• 2 Bumper, rear
  240
• 2.1 Assembly overview – bumper cover
  240
• 2.2 Assembly overview – bumper carrier
  241
• 2.3 Removing and installing bumper cover
  244
• 2.4 Removing and installing bumper carrier
  248
• 2.5 Removing and installing add-on parts
  250
• 2.6 Installing sender retainer for parking aid
  252
• Glazing
  255
• 1 Repair notes
  255
• 1.1 Minimum drying times for bonded windows
  255
• 1.2 Window repair
  255
• 1.3 Installation instructions for bonded windows
  256
• 1.4 Preparing old undamaged windows for installing
  258
• 1.5 Preparing new windows for installing
  260
• 1.6 Preparing body flange for installing
  261
• 1.7 Cleaning off excess adhesive
  262
• 2 Windscreen
  263
• 2.1 Assembly overview – windscreen
  263
• 2.2 Removing and installing windscreen
  263
• 3 Rear windscreen
  269
• 3.1 Assembly overview – rear window
  269
• 3.2 Removing and installing rear window
  271
• 4 Side windows
  286
• 4.1 Assembly overview - front side window
  286
• 4.2 Assembly overview - rear side windows
  287
• 4.3 Removing and installing front side window
  289
• 4.4 Removing and installing rear side window
  297
• 5 Door windows
  301
• 5.1 Assembly overview - rear door window
  301
• 5.2 Removing and installing front door window
  301
• 5.3 Removing and installing fixed front door window
  302
• 5.4 Removing and installing rear door window
  304
• 5.5 Removing and installing movable side window for sliding window
  307
• Exterior equipment
  311
• 1 Radiator grille and front trim
  311
• 1.1 Assembly overview – radiator grille
  311
• 1.2 Removing and installing radiator grille
  312
• 2 Mouldings, trims, extensions
  313
• 2.1 Assembly overview – covers
  313
• 2.2 Assembly overview – wheel arch covers
  314
• 2.3 Removing and installing cover
  315
• 2.4 Removing and installing trim strip
  330
• 2.5 Removing and installing B-pillar trim
  332
• 2.6 Removing and installing wheel arch covers
  333
• 3 Noise insulation
  335
• 3.1 Assembly overview - noise insulation
  335
• 3.2 Removing and installing noise insulation
  336
• 4 Underbody cladding
  340
• 4.1 Overview of fitting locations - underbody cladding
  340
• 4.2 Assembly overview – underbody cladding
  343
• 4.3 Removing and installing front underbody cladding
  344
• 4.4 Removing and installing rear centre underbody cladding
  350
• 4.5 Removing and installing centre underbody cladding
  353
• 4.6 Removing and installing rear underbody cladding
  356
• 5 Roof rails for roof load carrier
  362
• 5.1 Assembly overview - roof rails for roof load carrier
  362
• 6 Exterior mirror
  363
• 6.1 Assembly overview – exterior mirror
  363
• 6.2 Removing and installing exterior mirror
  365
• 6.3 Removing and installing mirror glass
  367
• 6.4 Removing and installing mirror cover
  368
• 6.5 Removing and installing mirror frame
  370
• 7 Wheel housing liner
  372
• 7.1 Assembly overview – front wheel housing liner
  372
• 7.2 Removing and installing front wheel housing liner
  372
• 8 Lettering and emblems
  376
• 8.1 Assembly overview – lettering and badges
  376
• 8.2 Dimensions - lettering and emblems on rear
  381
• 8.3 Dimensions – lettering and emblems on sides
  384
• 8.4 Renewing lettering and badges at rear
  386
• 8.5 General information on renewal of badges and lettering
  390
• 8.6 Removing and installing lettering and emblems for radiator grille
  391
• 9 Towing bracket
  395
• 9.1 Assembly overview – towing bracket
  395
• 9.2 Removing and installing towing bracket
  397
• 10 Spare wheel bracket
  403
• 10.1 Assembly overview - spare wheel bracket
  403
• 10.2 Removing and installing spare wheel bracket
  404
• 11 Mudflap
  409
• 11.1 Assembly overview - mudflap
  409
• 11.2 Removing and installing mudflaps
  409
• 12 Heat shields
  413
• 12.1 Assembly overview - heat shields
  413
• 12.2 Removing and installing front heat shield
  414
• 12.3 Removing and installing centre heat shield
  415
• 12.4 Removing and installing rear heat shield
  415
• 13 Load floor body
  417
• 13.1 Assembly overview – dropside bed
  417
• 13.2 Assembly overview - dropside body
  420
• 13.3 Assembly overview - rear cross member
  421
• 13.4 Assembly overview - carrier
  422
• 13.5 Assembly overview – skid plate
  423
• 13.6 Assembly overview - wheel housing
  424
• 13.7 Removing and installing dropside bed
  425
• 13.8 Removing and installing sideboard
  427
• 13.9 Removing and installing carrier
  428
• 13.10 Removing and installing side skid plate
  430
• 13.11 Removing and installing wheel housing
  431