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 Moulded foam elements
  3
• 4 Galvanized body parts
  4
• 4.1 Body
  4
• 4.2 Platform
  5
• 5 Strengthened steel body panels
  6
• 5.1 Body
  7
• 5.2 Platform
  8
• 6 Laser welding
  9
• 7 Body panel gaps/shut lines
  10
• 7.1 Body - front
  10
• 7.2 Body - rear
  13
• 8 Body dimensions
  16
• 8.1 Body - front
  16
• 8.2 Body - centre
  19
• 8.3 Body - rear
  26
• 8.4 Floor group - front
  29
• 8.5 Floor group - centre
  31
• 8.6 Floor group - rear
  32
• 9 Alignment bracket set
  36
• 9.1 Overview
  36
• 10 Portal / convertible roof gauge
  37
• 10.1 Overview - portal gauge
  37
• 10.2 Overview - convertible roof gauge
  38
• Body - front
  39
• 1 Renewing right console
  39
• 1.1 Tools
  39
• 1.2 Removing
  40
• 1.3 Installing
  41
• 2 Renewing left console
  43
• 2.1 Tools
  43
• 2.2 Removing
  44
• 2.3 Installing
  45
• 3 Renewing retaining bracket (for subframe)
  47
• 3.1 Tools
  47
• 3.2 Removing
  48
• 3.3 Installing
  49
• 4 Renewing bumper bracket
  51
• 4.1 Tools
  51
• 4.2 Removing
  51
• 4.3 Installing
  52
• 5 Renewing upper wheel housing longitudinal member
  54
• 5.1 Tools
  55
• 5.2 Removing
  55
• 5.3 Installing
  57
• 6 Renewing front wheel housing
  60
• 6.1 Tools
  60
• 6.2 Removing
  61
• 6.3 Installing
  63
• 7 Renewing front longitudinal member
  70
• 7.1 Tools
  70
• 7.2 Removing
  71
• 7.3 Installing
  73
• 8 Renewing front longitudinal member - partial renewal
  78
• 8.1 Tools
  78
• 8.2 Removing
  79
• 8.3 Installing
  81
• 9 Repairing threads for securing subframe (suspension subframe)
  83
• 9.1 Tools
  84
• 9.2 Contents of thread repair kit
  84
• 9.3 Repairing thread
  85
• Body - centre
  88
• 1 Renewing windscreen frame
  88
• 1.1 Tools
  88
• 1.2 Removing
  89
• 1.3 Installing
  89
• 2 Renewing A-pillar
  91
• 2.1 Tools
  91
• 2.2 Removing
  92
• 2.3 Installing
  93
• 3 Renewing left and right upper A-pillars
  99
• 3.1 Tools
  99
• 3.2 Removing
  100
• 3.3 Installing
  101
• 4 Renewing A-pillar reinforcement
  107
• 4.1 Tools
  107
• 4.2 Removing
  108
• 4.3 Installing
  113
• 5 Renewing B-pillar reinforcement
  121
• 5.1 Tools
  122
• 5.2 Removing
  122
• 5.3 Installing
  124
• 6 Renewing outer side member
  128
• 6.1 Tools
  128
• 6.2 Removing
  129
• 6.3 Installing
  130
• 7 Renewing side member reinforcement
  134
• 7.1 Tools
  134
• 7.2 Removing
  135
• 7.3 Installing
  136
• Body - rear
  139
• 1 Renewing rear cross panel
  139
• 1.1 Tools
  140
• 1.2 Removing
  140
• 1.3 Installing
  142
• 2 Renewing tail light mounting
  144
• 2.1 Tools
  144
• 2.2 Removing
  145
• 2.3 Installing
  147
• 3 Renewing rear longitudinal member - partial renewal
  151
• 3.1 Tools
  151
• 3.2 Removing
  152
• 3.3 Installing
  153
• 4 Renewing side panel
  155
• 4.1 Tools
  156
• 4.2 Removing
  156
• 4.3 Installing
  158
• 5 Renewing wheel housing liner
  165
• 5.1 Tools
  165
• 5.2 Removing
  166
• 5.3 Installing
  167
• 6 Renewing window lifter mounting
  172
• 6.1 Tools
  172
• 6.2 Removing
  172
• 6.3 Installing
  173
• 7 Renewing spare wheel well
  176
• 7.1 Tools
  176
• 7.2 Removing
  177
• 7.3 Installing
  180