Body Repairs

Chapter overview

• Technical data
  1
• 1 Vehicle identification data
  1
• 1.1 Identification plate
  1
• 1.2 Vehicle data plate
  1
• 1.3 Vehicle identification number
  1
• 2 Body dimensions
  2
• 2.1 Floor group - front
  2
• 2.2 Floor group - rear
  3
• 2.3 Body - front
  5
• 2.4 Body - centre
  8
• 2.5 Body - rear
  12
• 3 Body panel gaps/shutlines
  14
• 3.1 Body - front
  14
• 3.2 Body - centre
  16
• 3.3 Body - rear
  17
• 4 Alignment jig
  19
• 4.1 Overview
  19
• Body - front
  28
• 1 Renewing front cross member
  28
• 1.1 Removing
  28
• 1.2 Installing
  30
• 2 Renewing wheel housing cover (floor pan corner) - partial renewal
  32
• 2.1 Removing
  32
• 2.2 Installing
  33
• 3 Renewing reinforcement for wheel housing
  35
• 3.1 Removing
  35
• 3.2 Installing
  36
• 4 Renewing front wheel housing
  37
• 4.1 Removing
  37
• 4.2 Installing
  38
• 5 Renewing front inner longitudinal member - partial renewal
  40
• 5.1 Removing
  40
• 5.2 Installing
  41
• 6 Renewing battery console
  43
• 6.1 Removing
  43
• 6.2 Installing
  43
• Body - centre
  45
• 1 Renewing high roof
  45
• 1.1 Removing
  45
• 1.2 Installing
  46
• 2 Renewing roof (dropside)
  47
• 2.1 Removing
  47
• 2.2 Installing
  48
• 3 Renewing high roof (front part)
  49
• 3.1 Removing
  49
• 3.2 Installing
  50
• 4 Renewing high roof cross member, front
  51
• 4.1 Removing
  51
• 4.2 Installing
  51
• 5 Renewing high roof reinforcement
  52
• 5.1 Removing
  52
• 5.2 Installing
  53
• 6 Renewing high roof cross member, rear
  54
• 6.1 Removing
  54
• 6.2 Installing
  55
• 7 Renewing dropside backwall (with rear window)
  57
• 7.1 Removing
  57
• 7.2 Installing
  58
• 8 Renewing dropside backwall (without rear window)
  60
• 8.1 Removing
  60
• 8.2 Installing
  61
• 9 Renewing high roof rear part
  63
• 9.1 Removing
  63
• 9.2 Installing
  64
• 10 Renewing intermediate gusset plate (step)
  66
• 10.1 Removing
  66
• 10.2 Installing
  67
• 11 Renewing rear side panel (panel van)
  68
• 11.1 Removing
  68
• 11.2 Installing
  69
• 12 Renewing rear side panel (sliding door side/panel van)
  71
• 12.1 Removing
  71
• 12.2 Installing
  72
• 13 Renewing rear side panel (Kombi)
  74
• 13.1 Removing
  74
• 13.2 Installing
  75
• 14 Renewing rear side panel (sliding door side/Kombi)
  77
• 14.1 Removing
  77
• 14.2 Installing
  78
• 15 Renewing rear side panel lower part
  80
• 15.1 Removing
  80
• 15.2 Installing
  81
• 16 Renewing rear side panel lower part (sliding door side)
  83
• 16.1 Removing
  83
• 16.2 Installing
  84
• 17 Renewing rear side panel - partial renewal, front
  86
• 17.1 Removing
  86
• 17.2 Installing
  87
• 18 Renewing rear side panel - partial renewal, front (sliding door side)
  89
• 18.1 Removing
  89
• 18.2 Installing
  90
• 19 Renewing rear side panel - partial renewal, rear
  92
• 19.1 Removing
  92
• 19.2 Installing
  93
• 20 Renewing front side panel (panel van)
  95
• 20.1 Removing
  95
• 20.2 Installing
  96
• 21 Renewing front side panel - partial renewal (Kombi)
  97
• 21.1 Removing
  97
• 21.2 Installing
  98
• 22 Renewing front side panel lower part
  100
• 22.1 Removing
  100
• 22.2 Installing
  101
• 23 Renewing hinge pillar (A-pillar) - partial renewal
  103
• 23.1 Removing
  103
• 23.2 Installing
  104
• 24 Renewing lock pillar (B-pillar) with reinforcement
  106
• 24.1 Removing
  106
• 24.2 Installing
  107
• 25 Renewing lock pillar (B-pillar) with reinforcement (dropside)
  111
• 25.1 Removing
  111
• 25.2 Installing
  112
• 26 Renewing lock pillar (B-pillar) with reinforcement (sliding door side)
  116
• 26.1 Removing
  116
• 26.2 Installing
  117
• 27 Renewing side member (sliding door frame)
  121
• 27.1 Removing
  121
• 27.2 Installing
  122
• 28 Renewing outer side member - partial renewal
  123
• 28.1 Removing
  123
• 28.2 Installing
  124
• 29 Renewing floor panel - partial renewal
  125
• 29.1 Removing
  125
• 29.2 Installing
  127
• Body - rear
  129
• 1 Renewing cross panel
  129
• 1.1 Removing
  129
• 1.2 Installing
  130
• 2 Renewing backwall corner part
  132
• 2.1 Removing
  132
• 2.2 Installing
  133
• 3 Renewing luggage compartment floor - partial renewal
  138
• 3.1 Removing
  138
• 3.2 Installing
  139
• 4 Renewing cross panel member
  141
• 4.1 Removing
  141
• 4.2 Installing
  142
• 5 Renewing rear longitudinal member
  144
• 5.1 Removing
  144
• 5.2 Installing
  145
• 6 Renewing rear outer wheel housing liner
  148
• 6.1 Removing
  148
• 6.2 Installing
  149
• 7 Renewing rear inner wheel housing liner
  151
• 7.1 Removing
  151
• 7.2 Installing
  152
• 8 Renewing rear cross member
  154
• 8.1 Removing
  154
• 8.2 Installing
  155