Body Repairs

Chapter overview

• Technical data
  1
• 1 Vehicle identification data
  1
• 1.1 Vehicle identification number
  1
• 1.2 Identification plate
  2
• 1.3 Vehicle data sticker
  2
• 2 Safety instructions
  4
• 3 Moulded foam elements
  5
• 4 Laser welding
  6
• 5 Galvanized body parts
  7
• 5.1 Body
  7
• 5.2 Floor group
  8
• 6 High strength body parts
  9
• 6.1 Body
  9
• 6.2 Floor group
  10
• 7 Body panel gaps/shut lines
  12
• 7.1 Body - front
  12
• 7.2 Body - centre
  14
• 7.3 Body - rear
  15
• 8 Body dimensions
  18
• 8.1 Body - front
  18
• 8.2 Body - centre
  23
• 8.3 Body - rear
  28
• 8.4 Floor group - front
  31
• 8.5 Floor group - centre
  34
• 8.6 Floor group - rear
  36
• 9 Alignment jig
  39
• 9.1 Overview
  40
• 9.2 Front alignment bracket
  41
• 9.3 Centre alignment bracket
  46
• 9.4 Rear alignment bracket
  48
• 10 Portal gauge
  50
• 10.1 Overview
  50
• Body - front
  52
• 1 Renewing right-hand bracket
  52
• 1.1 Removing
  52
• 1.2 Installing
  53
• 2 Renewing left console
  55
• 2.1 Removing
  56
• 2.2 Installing
  57
• 3 Renewing retaining bracket
  58
• 3.1 Removing
  58
• 3.2 Installing
  59
• 4 Renewing front bumper bracket
  61
• 4.1 Removing
  61
• 4.2 Installing
  62
• 5 Renewing upper wheel housing longitudinal member
  64
• 5.1 Removing
  65
• 5.2 Installing
  65
• 6 Renewing upper longitudinal member for wheel housing - partial renewal
  67
• 6.1 Removing
  67
• 6.2 Installing
  68
• 7 Renewing front wheel housing
  70
• 7.1 Removing
  70
• 7.2 Installing
  71
• 8 Repairing threads for securing subframe (suspension subframe)
  72
• 8.1 Contents of thread repair kit
  73
• 8.2 Repairing thread
  74
• 9 Renewing front longitudinal member
  77
• 9.1 Removing
  78
• 9.2 Installing
  80
• 10 Renewing front longitudinal member - partial replacement
  85
• 10.1 Removing
  86
• 10.2 Installing
  87
• Body - centre
  89
• 1 Renewing roof
  89
• 1.1 Removing
  90
• 1.2 Installing
  91
• 2 Renewing front roof cross member
  102
• 2.1 Removing
  102
• 2.2 Installing
  103
• 3 Renewing roof reinforcement
  105
• 3.1 Removing
  105
• 3.2 Installing
  106
• 4 Renewing rear roof cross member
  107
• 4.1 Removing
  107
• 4.2 Installing
  108
• 5 Renewing A-pillar - partial renewal
  110
• 5.1 Removing
  112
• 5.2 Installing
  113
• 6 Renewing A-pillar reinforcement
  116
• 6.1 Removing
  118
• 6.2 Installing
  119
• 7 Renewing B-pillar
  122
• 7.1 Removing
  125
• 7.2 Installing
  127
• 8 Renewing B-pillar reinforcement
  132
• 8.1 Removing
  134
• 8.2 Installing
  137
• 9 Renewing side member
  145
• 9.1 Removing
  147
• 9.2 Installing
  148
• 10 Renewing side member reinforcement
  154
• 10.1 Removing
  156
• 10.2 Installing
  157
• 11 Renewing side member reinforcement
  159
• 11.1 Removing
  160
• 11.2 Installing
  160
• 12 Renewing seat cross member mounting
  162
• 12.1 Removing
  163
• 12.2 Installing
  164
• 13 Renewing seat cross member mounting
  165
• 13.1 Removing
  166
• 13.2 Installing
  167
• 14 Renewing seat cross member
  168
• 14.1 Removing
  169
• 14.2 Installing
  169
• Body - rear
  170
• 1 Renewing cross panel
  170
• 1.1 Removing
  171
• 1.2 Installing
  172
• 2 Renewing mounting plate
  182
• 2.1 Removing
  183
• 2.2 Installing
  183
• 3 Renewing luggage compartment floor
  186
• 3.1 Removing
  187
• 3.2 Installing
  189
• 4 Renewing longitudinal member - partial renewal
  193
• 4.1 Removing
  194
• 4.2 Installing
  195
• 5 Renewing rear longitudinal member end piece
  197
• 5.1 Removing
  198
• 5.2 Installing
  199
• 6 Renewing side panel - partial replacement
  201
• 6.1 Removing
  203
• 6.2 Installing
  205
• 7 Renewing C-pillar reinforcement
  210
• 7.1 Removing
  211
• 7.2 Installing
  212
• 8 Renewing outer wheel housing liner
  213
• 8.1 Removing
  215
• 8.2 Installing
  217
• 9 Renewing spare wheel well - partial renewal
  220
• 9.1 Removing
  220
• 9.2 Installing
  221