Body Repairs

Chapter overview

• Technical data
  1
• 1 Vehicle identification data
  1
• 1.1 Vehicle identification number
  1
• 1.2 Type plate
  2
• 1.3 Type plate
  3
• 1.4 Vehicle data sticker
  3
• 2 Safety information
  4
• 3 Moulded foam inserts
  5
• 4 Galvanised body parts
  7
• 5 Laser welding
  8
• 6 Gaps/shut lines
  9
• 6.1 Body, front
  9
• 6.2 Body, centre
  11
• 6.3 Body centre, cab door
  12
• 6.4 Body - rear
  13
• 7 Body dimensions
  15
• 7.1 Floor panel - front
  15
• 7.2 Floor panel - rear
  16
• 7.3 Body, front
  17
• 7.4 Body, centre
  20
• 7.5 Body - rear
  24
• 8 Alignment jig
  28
• 8.1 Tools
  28
• 8.2 Converting the alignment jig
  28
• 8.3 Support trolley VAS 6404 set-up
  30
• 8.4 Front repairs
  31
• 8.5 Rear repairs
  34
• 8.6 Overview of alignment bracket positions
  37
• 9 Body builder guidelines
  44
• 9.1 Planning the bodies
  44
• 9.2 Technical limit values for planning
  45
• 9.3 Prevention of damage
  48
• 9.4 Modifications to the base vehicle
  49
• 9.5 Body designs
  64
• 9.6 Electrical/electronic system
  78
• Body - front
  81
• 1 Renewing reinforcing for front wheel housing
  81
• 1.1 Removing
  81
• 1.2 Installing
  83
• 2 Renewing front wheel housing (subpart)
  85
• 2.1 Removing
  85
• 2.2 Installing
  87
• 3 Renewing front longitudinal member complete
  90
• 3.1 Removing
  90
• 3.2 Installing
  94
• 4 Renewing front longitudinal member (part section)
  98
• 4.1 Removing
  98
• 4.2 Installing
  99
• Body - centre
  102
• 1 Renewing the GRP high roof
  102
• 1.1 Removing
  103
• 1.2 Installing
  106
• 2 Renewing front section of high roof
  117
• 2.1 Removing
  117
• 2.2 Installing
  118
• 3.1 Removing (vehicles with and without sliding door for load compartment)
  122
• 3.2 Installing (vehicles with and without sliding door for load compartment)
  126
• 4 Renewing rear roof panelling (high roof with no sliding door for load compartment)
  130
• 4.1 Removing
  130
• 4.2 Installing
  133
• 5 Renewing rear roof panelling (high roof with sliding door for load compartment)
  137
• 5.1 Removing
  137
• 5.2 Installing
  139
• 6 Renewing front roof panelling (flat roof)
  142
• 6.1 Removing
  142
• 6.2 Installing
  144
• 7 Renewing rear roof panelling (flat roof, double cab)
  147
• 7.1 Removing
  147
• 7.2 Installing
  149
• 8.1 Removing
  151
• 8.2 Installing
  154
• 9.1 Removing
  157
• 9.2 Installing
  159
• 10 Renewing front roof frame (only installed in GRP high roof)
  162
• 10.1 Removing
  162
• 10.2 Installing
  163
• 11 Renewing front cross member for roof
  164
• 11.1 Removing
  164
• 11.2 Installing
  165
• 12 Renewing roof reinforcement (high roof)
  166
• 12.1 Removing
  166
• 12.2 Installing
  167
• 13 Renewing rear outer roof cross member
  169
• 13.1 Removing
  169
• 13.2 Installing
  170
• 14 Renewing rear roof inner cross member
  172
• 14.1 Removing
  172
• 14.2 Installing
  173
• 15 Renewing rear window frame, complete (dropside and double cab)
  175
• 15.1 Removing
  175
• 15.2 Installing
  177
• 16 Renewing rear window frame, part section (dropside and double cab)
  190
• 16.1 Removing
  190
• 16.2 Installing
  192
• 17 Renewing middle section of high roof
  202
• 17.1 Removing
  202
• 17.2 Installing
  203
• 18 Renewing cowl panel
  206
• 18.1 Removing
  206
• 18.2 Installing
  207
• 19 Renewing rear section of high roof
  209
• 19.1 Removing
  209
• 19.2 Installing
  210
• 20.1 Removing
  212
• 20.2 Installing
  215
• 21.1 Removing
  222
• 21.2 Installing
  224
• 22 Renewing rear side panel (part section, Kombi with no sliding door for load compartment)
  229
• 22.1 Removing
  229
• 22.2 Installing
  231
• 23 Renewing front side panel lower part
  235
• 23.1 Removing
  235
• 23.2 Installing
  236
• 24.1 Removing
  238
• 24.2 Installing
  240
• 25 Renewing rear lower side panel after wheel arch
  243
• 25.1 Removing
  243
• 25.2 Installing
  244
• 26 Renewing inner part of side panel (part section, Kombi)
  247
• 26.1 Removing
  247
• 26.2 Installing
  250
• 27 Renewing complete inner part of side panel (panel van and Kombi)
  256
• 27.1 Removing
  256
• 27.2 Installing
  259
• 28 Renewing inner front side panel at bottom
  264
• 28.1 Removing
  264
• 28.2 Installing
  267
• 29 Renewing complete front door frame (high roof, panel van and Kombi)
  270
• 29.1 Removing
  271
• 29.2 Installing
  273
• 30 Renewing complete front side panel (high roof, panel van and Kombi)
  277
• 30.1 Removing
  277
• 30.2 Installing
  279
• 31 Renewing front side panel (part section, Kombi)
  282
• 31.1 Removing
  282
• 31.2 Installing
  284
• 32.1 Removing
  288
• 32.2 Installing
  291
• 33.1 Removing
  298
• 33.2 Installing
  300
• 34.1 Removing
  305
• 34.2 Installing
  307
• 35.1 Removing
  311
• 35.2 Installing
  312
• 36 Renewing hinge pillar (A-pillar) (part section)
  315
• 36.1 Removing
  316
• 36.2 Installing
  318
• 37 Renewing hinge pillar (A-pillar) reinforcement
  322
• 37.1 Removing
  322
• 37.2 Installing
  323
• 38 Renewing lock column, C-pillar, double cab
  325
• 38.1 Removing
  325
• 38.2 Installing
  327
• 39 Renewing front step complete
  330
• 39.1 Removing
  330
• 39.2 Installing
  332
• 40 Renewing step of load compartment sliding door completely
  338
• 40.1 Removing
  338
• 40.2 Installing
  341
• 41 Renewing rear step (double cab)
  346
• 41.1 Removing
  346
• 41.2 Installing
  347
• 42.1 Removing
  350
• 42.2 Installing
  352
• 43.1 Removing
  355
• 43.2 Installing
  356
• 44.1 Removing
  359
• 44.2 Installing
  360
• 45 Renewing outer side member
  362
• 45.1 Removing
  362
• 45.2 Installing
  364
• 46.1 Removing
  366
• 46.2 Installing
  368
• 47.1 Removing
  371
• 47.2 Installing
  373
• 48 Renewing rear side member (double cab)
  375
• 48.1 Removing
  375
• 48.2 Installing
  376
• 49 Renewing side member section for sliding door frame - part section
  378
• 49.1 Removing
  378
• 49.2 Installing
  380
• 50 Renewing rear inner side member (double cab)
  382
• 50.1 Removing
  382
• 50.2 Installing
  384
• 51.1 Removing
  386
• 51.2 Installing
  388
• 52 Renewing C-pillar reinforcement (vehicles with sliding door for load compartment)
  391
• 52.1 Removing
  391
• 52.2 Installing
  392
• 53 Renewing C-pillar reinforcement (double cab)
  395
• 53.1 Removing
  395
• 53.2 Installing
  396
• Body - rear
  398
• 1 Renewing rear apron
  398
• 1.1 Removing
  398
• 1.2 Installing
  400
• 2 Renewing rear crash box
  402
• 2.1 Removing
  402
• 2.2 Installing
  402
• 3 Renewing rear lock carrier
  404
• 3.1 Removing
  404
• 3.2 Installing
  407
• 4 Renewing rear panel upper corner piece complete
  411
• 4.1 Removing
  411
• 4.2 Installing
  414
• 5 Renewing rear panel lower outer corner piece
  419
• 5.1 Removing
  419
• 5.2 Installing
  420
• 6 Renewing rear lower door hinge mounting
  423
• 6.1 Removing
  423
• 6.2 Installing
  424
• 7 Renewing bearing bracket for rear leaf spring mounting (panel van and Kombi)
  426
• 7.1 Removing
  426
• 7.2 Installing
  428
• 8 Renewing bearing bracket for rear leaf spring mounting (dropside body)
  431
• 8.1 Removing
  431
• 8.2 Installing
  433
• 9 Renewing rear cross panel carrier
  438
• 9.1 Removing
  438
• 9.2 Installing
  440
• 10 Renewing rear inner wheel housing liner
  443
• 10.1 Removing
  443
• 10.2 Installing
  444
• 11 Renewing rear outer wheel housing liner
  446
• 11.1 Removing
  446
• 11.2 Installing
  447
• 12 Repairing hinge bearing for drop side
  450
• 12.1 Removing
  450
• 12.2 Installing
  451
• 13 Renewing longitudinal member
  453