Body Repairs

Chapter overview

• Technical data
  1
• 1 Vehicle identification data
  1
• 1.1 Vehicle identification number
  1
• 1.2 Identification plate
  1
• 1.3 Vehicle data sticker
  1
• 2 Safety instructions
  2
• 3 Body foam insulation
  3
• 4 Galvanized body parts
  4
• 5 Strengthened steel body panels
  5
• 6 Body panel gaps/shut lines
  6
• 6.1 Body - front
  6
• 6.2 Body - rear
  7
• 7 Body dimensions
  9
• 7.1 Body - front
  9
• 7.2 Body - centre
  12
• 7.3 Body - rear
  15
• 7.4 Floor group - front
  18
• 7.5 Floor group - centre
  19
• 7.6 Floor group - rear
  20
• 8 Alignment jig
  21
• 8.1 Overview
  21
• 8.2 Portal gauge
  32
• Body - front
  34
• 1 Removing and installing engine bracket
  34
• 1.1 Removing
  34
• 1.2 Installing
  35
• 2 Removing and installing intermediate piece
  36
• 2.1 Removing
  36
• 2.2 Installing
  37
• 3 Removing and installing wing connecting plate
  38
• 3.1 Removing
  38
• 3.2 Installing
  39
• 4 Removing and installing headlight mounting
  40
• 4.1 Removing
  40
• 4.2 Installing
  41
• 5 Removing and installing longitudinal member for upper wheel housing
  42
• 5.1 Removing
  42
• 5.2 Installing
  43
• 6 Removing and installing front wheel housing
  44
• 6.1 Removing
  44
• 6.2 Installing
  45
• 7 Removing and installing front wheel housing - part section
  46
• 7.1 Removing
  46
• 7.2 Installing
  47
• 8 Removing and installing front longitudinal member
  48
• 8.1 Removing
  48
• 8.2 Installing
  49
• 9 Removing and installing front longitudinal member - part section
  50
• 9.1 Removing
  50
• 9.2 Installing
  51
• 10 Removing and installing front part of longitudinal member
  52
• 10.1 Removing
  52
• 10.2 Installing
  53
• Body - centre
  55
• 1 Renewing roof
  55
• 1.1 Removing
  55
• 1.2 Installing
  56
• 2 Renewing front roof cross member
  58
• 2.1 Removing
  58
• 2.2 Installing
  59
• 3 Renewing middle roof cross member
  60
• 3.1 Removing
  60
• 3.2 Installing
  61
• 4 Renewing rear roof cross member
  62
• 4.1 Removing
  62
• 4.2 Installing
  63
• 5 Removing and installing A-pillar
  64
• 5.1 Removing
  64
• 5.2 Installing
  65
• 6 Removing and installing A-pillar reinforcement
  67
• 6.1 Removing
  67
• 6.2 Installing
  68
• 7 Removing and installing B-pillar reinforcement
  70
• 7.1 Removing
  70
• 7.2 Installing
  71
• 8 Removing and installing outer side member
  73
• 8.1 Removing
  73
• 8.2 Installing
  74
• 9 Removing and installing middle side member
  76
• 9.1 Removing
  76
• 9.2 Installing
  77
• 10 Removing and installing side member reinforcement - part section
  79
• 10.1 Removing
  79
• 10.2 Installing
  80
• 11 Removing and installing floor panel - part section
  82
• 11.1 Removing
  82
• 11.2 Installing
  83
• Body - rear
  84
• 1 Removing and installing rear cross panel
  84
• 1.1 Removing
  84
• 1.2 Installing
  85
• 2 Removing and installing corner reinforcement
  87
• 2.1 Removing
  87
• 2.2 Installing
  88
• 3 Removing and installing rear lock carrier
  89
• 3.1 Removing
  89
• 3.2 Installing
  90
• 4 Removing and installing lower corner part
  91
• 4.1 Removing
  91
• 4.2 Installing
  92
• 5 Removing and installing cover plate
  94
• 5.1 Removing
  94
• 5.2 Installing
  95
• 6 Removing and installing rear longitudinal member - part section
  96
• 6.1 Removing
  96
• 6.2 Installing
  97
• 7 Removing and installing side panel - part section
  98
• 7.1 Removing
  98
• 7.2 Installing
  99
• 8 Removing and installing spare wheel well
  101
• 8.1 Removing
  101
• 8.2 Installing
  102
• 9 Removing and installing spare wheel well - part section
  103
• 9.1 Removing
  103
• 9.2 Installing
  104