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
  3
• 2 Safety instructions
  4
• 3 Basic instructions
  5
• 4 Body panel gaps/shut lines
  6
• 4.1 Body - front
  6
• 4.2 Body - centre
  7
• 4.3 Body - rear
  8
• 5 Body dimensions
  9
• 5.1 Body - front
  10
• 5.2 Body - centre
  13
• 5.3 Body - rear
  16
• 5.4 Floor group - front
  17
• 5.5 Floor group - centre
  19
• 5.6 Floor group - rear
  20
• 6 Tools
  21
• 7 Moulded foam elements
  22
• 8 Galvanised body parts, high/higher-strength and hot-formed body panels
  24
• 8.1 Body
  24
• 8.2 Overview
  26
• 9 Corrosion protection measures
  29
• 10 Bonded joints
  30
• 10.1 Checking and repairing spot welded/bonded joints
  30
• 10.2 Repair remedies for partial repairs
  30
• 11 Alignment bracket set
  31
• 11.1 Overview
  31
• 12 Portal gauge
  32
• Body - front
  33
• 1 Renewing right console
  33
• 1.1 Tools
  33
• 1.2 Removing
  34
• 1.3 Installing
  35
• 2 Renewing left console
  37
• 2.1 Tools
  37
• 2.2 Removing
  38
• 2.3 Installing
  40
• 3 Renewing retaining bracket for subframe
  42
• 3.1 Tools
  42
• 3.2 Removing
  43
• 3.3 Installing
  44
• 4 Renewing bumper bracket
  46
• 4.1 Tools
  47
• 4.2 Removing
  47
• 4.3 Installing
  48
• 5 Renewing upper wheel housing longitudinal member
  50
• 5.1 Tools
  51
• 5.2 Removing
  51
• 5.3 Installing
  53
• 6 Renewing front wheel housing
  58
• 6.1 Tools
  59
• 6.2 Removing
  59
• 6.3 Installing
  61
• 7 Renewing front longitudinal member
  69
• 7.1 Tools
  70
• 7.2 Removing
  70
• 7.3 Installing
  72
• 8 Renewing front longitudinal member - part section
  77
• 8.1 Tools
  78
• 8.2 Removing
  78
• 8.3 Installing
  80
• 9 Renewing front right longitudinal member
  82
• 9.1 Tools
  83
• 9.2 Removing
  83
• 9.3 Installing
  85
• 10 Renewing front right longitudinal member - part section
  90
• 10.1 Tools
  91
• 10.2 Removing
  91
• 10.3 Installing
  93
• 11 Repairing threads for attachment of subframe
  98
• 11.1 Contents of thread repair kit
  100
• 11.2 Repairing thread
  100
• Body - centre
  104
• 1 Replacing front upper roof cross member
  104
• 1.1 Tools
  105
• 1.2 Removing
  105
• 1.3 Installing
  106
• 2 Renewing roof cross member
  108
• 2.1 Tools
  109
• 2.2 Removing
  109
• 3 Renewing windscreen frame
  114
• 3.1 Tools
  115
• 3.2 Removing
  115
• 3.3 Installing
  116
• 4 Renewing A-pillar
  121
• 4.1 Tools
  122
• 4.2 Removing
  122
• 4.3 Installing
  123
• 5 Renewing A-pillar reinforcement
  131
• 5.1 Tools
  132
• 5.2 Removing
  132
• 5.3 Installing
  135
• 6 Renewing A-pillar reinforcement - part section
  142
• 6.1 Tools
  143
• 6.2 Removing
  143
• 6.3 Installing
  145
• 7 Renewing B-pillar reinforcement
  151
• 7.1 Tools
  152
• 7.2 Removing
  152
• 7.3 Installing
  156
• 8 Renewing side member reinforcement on outside
  164
• 8.1 Tools
  165
• 8.2 Removing
  165
• 8.3 Installing
  167
• Body - rear
  173
• 1 Renewing cross panel
  173
• 1.1 Tools
  174
• 1.2 Removing
  174
• 1.3 Installing
  177
• 2 Renewing tail light mounting
  181
• 2.1 Tools
  182
• 2.2 Removing
  182
• 2.3 Installing
  183
• 3 Renewing tail light mounting - part section
  187
• 3.1 Tools
  188
• 3.2 Removing
  188
• 3.3 Installing
  189
• 4 Renewing cross panel member
  193
• 4.1 Tools
  194
• 4.2 Removing
  194
• 4.3 Installing
  195
• 5 Renewing rear part of luggage compartment floor
  198
• 5.1 Tools
  199
• 5.2 Removing
  200
• 5.3 Installing
  201
• 6 Renewing rear longitudinal member - part section
  205
• 6.1 Tools
  206
• 6.2 Removing
  206
• 6.3 Installing
  207
• 7 Renewing side panel - part section
  210
• 7.1 Tools
  211
• 7.2 Removing
  211
• 7.3 Installing
  213
• 8 Renewing outer wheel housing
  218
• 8.1 Tools
  219
• 8.2 Removing
  219
• 8.3 Installing
  220