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
  2
• 3 Gas vehicles
  3
• 4 Moulded foam inserts
  4
• 5 Galvanised body parts
  5
• 5.1 Installing
  5
• 5.2 Platform
  6
• 6 Strengthened steel body panels
  7
• 6.1 Installing
  7
• 6.2 Platform
  8
• 7 Laser welding
  11
• 8 Body panel gaps/shut lines
  12
• 8.1 Body - front
  12
• 8.2 Body - rear
  15
• 8.3 Body - rear (Variant)
  17
• 9 Body dimensions
  19
• 9.1 Body - front
  19
• 9.2 Body - centre
  23
• 9.3 Body - centre (Variant)
  29
• 9.4 Body - rear
  32
• 9.5 Body - rear (Variant)
  34
• 9.6 Floor panel - front
  36
• 9.7 Floor panel, centre
  38
• 9.8 Floor panel - rear
  39
• 10 Alignment bracket set
  41
• 10.1 Overview
  41
• 11 Portal gauge
  43
• 11.1 Overview
  43
• Body - front
  45
• 1 Renewing right bracket
  45
• 1.1 Tools
  45
• 1.2 Removing
  45
• 1.3 Installing
  47
• 2 Renewing left bracket
  49
• 2.1 Tools
  49
• 2.2 Removing
  49
• 2.3 Installing
  51
• 3 Renewing retaining bracket (for subframe)
  53
• 3.1 Removing
  53
• 3.2 Installing
  54
• 4 Renewing bumper bracket
  56
• 4.1 Removing
  57
• 4.2 Installing
  58
• 5 Renewing upper wheel housing longitudinal member
  59
• 5.1 Tools
  60
• 5.2 Removing
  61
• 5.3 Installing
  63
• 6 Renewing front wheel housing
  66
• 6.1 Tools
  66
• 6.2 Removing
  67
• 6.3 Installing
  68
• 7 Renewing front longitudinal member
  75
• 7.1 Tools
  75
• 7.2 Removing
  76
• 7.3 Installing
  78
• 8 Renewing front longitudinal member - part section
  85
• 8.1 Tools
  85
• 8.2 Removing
  86
• 8.3 Installing
  89
• 9 Repairing threads for securing subframe (suspension subframe)
  91
• 9.1 Tools
  91
• 9.2 Contents of thread repair kit
  92
• 9.3 Repairing thread
  92
• Body - centre
  96
• 1 Renewing roof
  96
• 1.1 Tools
  96
• 1.2 Removing
  98
• 1.3 Installing
  99
• 2 Renewing roof (Variant)
  109
• 2.1 Tools
  109
• 2.2 Removing
  111
• 2.3 Installing
  112
• 3 Renewing roof side member
  120
• 3.1 Tools
  120
• 3.2 Removing
  121
• 3.3 Installing
  124
• 3.4 Foam treating roof side member
  127
• 4 Renewing front cross member for roof
  129
• 4.1 Tools
  129
• 4.2 Removing
  130
• 4.3 Installing
  131
• 5 Renewing roof reinforcement, vehicles with no sliding/tilting sunroof
  132
• 5.1 Tools
  132
• 5.2 Removing
  133
• 5.3 Installing
  134
• 6 Renewing rear roof cross member
  135
• 6.1 Tools
  135
• 6.2 Removing
  136
• 6.3 Installing
  137
• 7 Renewing rear roof cross member (Variant)
  138
• 7.1 Tools
  138
• 7.2 Removing
  139
• 7.3 Installing
  140
• 8 Renewing A-pillar
  143
• 8.1 Tools
  143
• 8.2 Removing
  144
• 8.3 Installing
  145
• 9 Renewing A-pillar reinforcement
  150
• 9.1 Tools
  150
• 9.2 Removing
  151
• 9.3 Installing
  152
• 10 Renewing B-pillar
  157
• 10.1 Tools
  157
• 10.2 Removing
  157
• 10.3 Installing
  160
• 11 Renewing inner B-pillar
  167
• 11.1 Tools
  167
• 11.2 Removing
  168
• 11.3 Installing
  169
• 12 Renewing B-pillar reinforcement
  171
• 12.1 Tools
  172
• 12.2 Removing
  172
• 12.3 Installing
  175
• 13 Renewing side member
  184
• 13.1 Tools
  184
• 13.2 Removing
  185
• 13.3 Installing
  186
• 14 Renewing front side member reinforcement
  193
• 14.1 Tools
  193
• 14.2 Removing
  194
• 14.3 Installing
  195
• 15 Renewing rear side member reinforcement
  200
• 15.1 Tools
  200
• 15.2 Removing
  201
• 15.3 Installing
  202
• Body - rear
  204
• 1 Renewing cross panel
  204
• 1.1 Tools
  205
• 1.2 Removing
  206
• 1.3 Installing
  207
• 2 Renewing cross panel (Variant)
  211
• 2.1 Tools
  211
• 2.2 Removing
  212
• 2.3 Installing
  214
• 3 Renewing lock carrier
  218
• 3.1 Tools
  218
• 3.2 Removing
  218
• 3.3 Installing
  219
• 4 Renewing tail light mounting
  221
• 4.1 Tools
  221
• 4.2 Removing
  221
• 4.3 Installing
  222
• 5 Renewing tail light mounting (Variant)
  225
• 5.1 Tools
  225
• 5.2 Removing
  226
• 5.3 Installing
  227
• 6 Renewing C-pillar reinforcement (Variant)
  229
• 6.1 Tools
  229
• 6.2 Removing
  230
• 6.3 Installing
  231
• 7 Renewing D-pillar reinforcement - part section
  234
• 7.1 Tools
  234
• 7.2 Removing
  235
• 7.3 Installing
  236
• 8 Renewing inner D-pillar
  238
• 8.1 Tools
  238
• 8.2 Removing
  239
• 8.3 Installing
  240
• 9 Renewing rear longitudinal member - part section
  242
• 9.1 Tools
  242
• 9.2 Removing
  243
• 9.3 Installing
  245
• 10 Renewing side panel - part section
  248
• 10.1 Tools
  248
• 10.2 Removing
  249
• 10.3 Installing
  251
• 11 Renewing side panel - part section (Variant)
  256
• 11.1 Tools
  256
• 11.2 Removing
  257
• 11.3 Installing
  259
• 12 Renewing outer wheel housing liner
  264
• 12.1 Tools
  264
• 12.2 Removing
  265
• 12.3 Installing
  266
• 13 Renewing outer wheel housing liner (Variant)
  269
• 13.1 Tools
  269
• 13.2 Removing
  270
• 13.3 Installing
  272
• 14 Renewing spare wheel well
  275
• 14.1 Removing
  276
• 14.2 Installing
  277