Body Repairs

Chapter overview

• Technical data
  1
• 1 Vehicle identification data
  1
• 1.1 Vehicle identification number
  1
• 1.2 Type plate
  1
• 1.3 Vehicle data sticker
  1
• 2 Safety information
  4
• 3 Gas vehicles
  5
• 4 Moulded foam inserts
  6
• 5 Galvanized panels
  7
• 6 High strength body parts
  8
• 7 Laser welding
  11
• 8 Body panel gaps/shut lines
  12
• 8.1 Body - front
  12
• 8.2 Body - rear
  14
• 9 Body dimensions
  17
• 9.1 Body - front
  17
• 9.2 Body - centre
  24
• 9.3 Body - rear
  31
• 9.4 Floor panel - front
  34
• 9.5 Floor panel - centre
  35
• 9.6 Floor panel - rear
  36
• 10 Alignment jig
  37
• 10.1 Overview - alignment bracket for Touran VAS 6240
  37
• 11 Portal gauge
  39
• 11.1 Front portal gauge
  39
• 11.2 Rear portal gauge
  41
• Body - front
  42
• 1 Renewing suspension strut mounting
  42
• 1.1 Tools
  42
• 1.2 Removing
  42
• 1.3 Installing
  43
• 2 Renewing right bracket
  46
• 2.1 Tools
  46
• 2.2 Removing
  46
• 2.3 Installing
  48
• 3 Renewing left console
  50
• 3.1 Tools
  50
• 3.2 Removing
  51
• 3.3 Installing
  52
• 4 Renewing mounting bracket for subframe
  54
• 4.1 Tools
  54
• 4.2 Removing
  54
• 4.3 Installing
  56
• 5 Renewing front bumper carrier
  58
• 5.1 Tools
  58
• 5.2 Removing
  58
• 5.3 Installing
  60
• 6 Renewing upper outer longitudinal member
  62
• 6.1 Tools
  62
• 6.2 Removing
  62
• 6.3 Installing
  63
• 7 Renewing upper outer longitudinal member, model year 2011 >
  64
• 7.1 Tools
  64
• 7.2 Removing
  64
• 7.3 Installing
  66
• 8 Renewing upper wheel housing longitudinal member
  70
• 8.1 Tools
  70
• 8.2 Removing
  70
• 8.3 Installing
  71
• 9 Renewing front wheel housing - part section
  72
• 9.1 Tools
  72
• 9.2 Removing
  72
• 9.3 Installing
  74
• 10 Repairing threads for securing subframe (suspension subframe)
  75
• 10.1 Contents of thread repair kit
  77
• 10.2 Repairing threads
  78
• 11 Renewing front longitudinal member
  81
• 11.1 Tools
  81
• 11.2 Removing
  82
• 11.3 Installing
  83
• 12 Renewing front longitudinal member - part section
  90
• 12.1 Tools
  90
• 12.2 Removing
  90
• 12.3 Installing
  93
• Body - centre
  95
• 1 Renewing roof
  95
• 1.1 Tools
  95
• 1.2 Removing
  97
• 1.3 Installing
  99
• 2 Renewing roof - vehicles with panorama sunroof -
  107
• 2.1 Tools
  107
• 2.2 Removing
  110
• 2.3 Installing
  113
• 3 Renewing roof side member
  123
• 3.1 Tools
  126
• 3.2 Removing
  127
• 3.3 Installing
  129
• 4 Renewing front cross member for roof
  135
• 4.1 Tools
  135
• 4.2 Removing
  135
• 4.3 Installing
  137
• 5 Renewing roof reinforcement
  138
• 5.1 Tools
  138
• 5.2 Removing
  138
• 5.3 Installing
  140
• 6 Renewing rear roof cross member
  141
• 6.1 Tools
  141
• 6.2 Removing
  141
• 6.3 Installing
  143
• 7 Renewing A-pillar
  144
• 7.1 Tools
  145
• 7.2 Removing
  146
• 7.3 Installing
  147
• 8 Renewing A-pillar reinforcement
  152
• 8.1 Tools
  152
• 8.2 Removing
  153
• 8.3 Installing
  154
• 9 Renewing A-pillar reinforcement - part section
  156
• 9.1 Tools
  156
• 9.2 Removing
  156
• 9.3 Installing
  157
• 10 Renewing inner A-pillar
  158
• 10.1 Tools
  158
• 10.2 Removing
  159
• 10.3 Installing
  159
• 11 Renewing B-pillar
  161
• 11.1 Tools
  161
• 11.2 Removing
  162
• 11.3 Installing
  162
• 12 Renewing B-pillar reinforcement
  165
• 12.1 Tools
  165
• 12.2 Removing
  166
• 12.3 Installing
  166
• 13 Renewing inner panel of B-pillar
  168
• 13.1 Tools
  168
• 13.2 Removing
  169
• 13.3 Installing
  170
• 14 Renewing outer side member
  173
• 14.1 Tools
  173
• 14.2 Removing
  173
• 14.3 Installing
  175
• 15 Renewing web plate for side member - part section
  177
• 15.1 Tools
  177
• 15.2 Removing
  177
• 15.3 Installing
  178
• 16 Renewing web plate for side member - part section
  179
• 16.1 Tools
  179
• 16.2 Removing
  180
• 16.3 Installing
  180
• 17 Renewing reinforcement for side member - part section
  182
• 17.1 Tools
  182
• 17.2 Removing
  182
• 17.3 Installing
  183
• 18 Renewing connecting piece for floor panel - part section
  184
• 18.1 Tools
  184
• 18.2 Removing
  184
• 18.3 Installing
  185
• Body - rear
  188
• 1 Renewing cross panel
  188
• 1.1 Tools
  188
• 1.2 Removing
  188
• 1.3 Installing
  190
• 2 Renewing tail light mounting
  191
• 2.1 Tools
  191
• 2.2 Removing
  191
• 2.3 Installing
  192
• 3 Renewing rear cross member
  195
• 3.1 Tools
  195
• 3.2 Removing
  195
• 3.3 Installing
  196
• 4 Removing and installing rear pillars
  200
• 4.1 Tools
  200
• 4.2 Removing
  200
• 4.3 Installing
  201
• 5 Renewing bumper bracket
  202
• 5.1 Tools
  202
• 5.2 Removing
  202
• 5.3 Installing
  204
• 6 Renewing longitudinal member - part section
  205
• 6.1 Tools
  205
• 6.2 Removing
  205
• 6.3 Installing
  206
• 7 Renewing side panel - part section
  207
• 7.1 Tools
  208
• 7.2 Removing
  209
• 7.3 Installing
  211
• 8 Renewing C-pillar reinforcement
  216
• 8.1 Tools
  216
• 8.2 Removing
  216
• 8.3 Installing
  217
• 9 Renewing inner wheel housing liner - part section
  218
• 9.1 Tools
  218
• 9.2 Removing
  218
• 9.3 Installing
  222
• 10 Renewing inner side panel - part section
  223
• 10.1 Tools
  223
• 10.2 Removing
  224
• 10.3 Installing
  224
• 11 Renewing outer wheel housing liner - part section
  226
• 11.1 Tools
  226
• 11.2 Removing
  227
• 11.3 Installing
  227
• 12 Renewing rear luggage compartment floor
  229
• 12.1 Tools
  229
• 12.2 Removing
  229
• 12.3 Installing
  230
• 13 Renewing rear spare wheel well - part section
  235
• 13.1 Tools
  235
• 13.2 Removing
  235
• 13.3 Installing
  236
• 14 Renewing floor panel - vehicles powered by natural gas
  237
• 14.1 Removing
  238
• 14.2 Installing
  239