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
  2
• 2 Safety instructions
  3
• 3 Moulded foam elements
  4
• 4 Galvanized body parts
  5
• 5 High- and higher-strength body panels
  6
• 6 Hot-formed body panels
  7
• 7 Laser welding
  8
• 8 Body panel gaps/shut lines
  9
• 8.1 Body - front
  9
• 8.2 Body - centre
  10
• 8.3 Body - rear
  11
• 9 Body dimensions
  12
• 9.1 Body - front
  12
• 9.2 Body - centre
  14
• 9.3 Body - rear
  20
• 9.4 Floor group - front
  23
• 9.5 Floor group - centre
  25
• 9.6 Floor group - rear
  26
• 10 Alignment bracket set
  28
• 10.1 Tools
  28
• 10.2 Overview
  28
• 11 Portal gauge
  30
• 11.1 Tools
  30
• 11.2 Overview front door aperture
  30
• 11.3 Overview of middle door aperture
  31
• 11.4 Overview of rear door aperture
  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
  37
• 2.3 Installing
  39
• 3 Renewing retaining bracket (for subframe)
  42
• 3.1 Removing
  42
• 3.2 Installing
  43
• 4 Renewing bumper bracket
  46
• 4.1 Removing
  47
• 4.2 Installing
  48
• 5 Renewing upper wheel housing longitudinal member
  50
• 5.1 Tools
  50
• 5.2 Removing
  51
• 5.3 Installing
  54
• 6 Renewing front wheel housing
  60
• 6.1 Tools
  60
• 6.2 Removing
  61
• 6.3 Installing
  65
• 7 Renewing front longitudinal member
  68
• 7.1 Tools
  68
• 7.2 Removing
  69
• 7.3 Installing
  72
• 8 Renewing front longitudinal member - part section
  81
• 8.1 Tools
  81
• 8.2 Removing
  82
• 8.3 Installing
  85
• 9 Repairing threads for securing subframe (suspension subframe)
  91
• 9.1 Tools
  92
• 9.2 Contents of thread repair kit
  92
• 9.3 Repairing thread
  93
• 10 Renewing suspension strut mounting
  96
• 10.1 Tools
  97
• 10.2 Removing
  98
• 10.3 Installing
  99
• Body - centre
  109
• 1 Renewing roof - vehicles with no panorama tilting sunroof
  109
• 1.1 Tools
  109
• 1.2 Removing
  111
• 1.3 Installing
  113
• 2 Renewing roof, vehicles with panorama sliding sunroof
  126
• 2.1 Tools
  126
• 2.2 Removing
  128
• 2.3 Installing
  130
• 3 Renewing roof side member
  143
• 3.1 Tools
  143
• 3.2 Removing
  144
• 3.3 Installing
  146
• 4 Renewing front roof cross member
  154
• 4.1 Tools
  154
• 4.2 Removing
  155
• 4.3 Installing
  156
• 5 Renewing rear roof cross member
  158
• 5.1 Tools
  158
• 5.2 Removing
  159
• 5.3 Installing
  160
• 6 Renewing A-pillar
  163
• 6.1 Tools
  163
• 6.2 Removing
  164
• 6.3 Renewing wing retainer
  167
• 6.4 Installing
  171
• 7 Renewing A-pillar reinforcement
  178
• 7.1 Tools
  179
• 7.2 Removing
  179
• 7.3 Installing
  182
• 8 Renewing B-pillar
  187
• 8.1 Tools
  187
• 8.2 Removing
  189
• 8.3 Installing
  191
• 9 Renewing inner B-pillar
  198
• 9.1 Tools
  199
• 9.2 Removing
  199
• 9.3 Installing
  200
• 10 Renewing B-pillar reinforcement
  202
• 10.1 Tools
  203
• 10.2 Removing
  204
• 10.3 Installing
  206
• 11 Renewing side member
  216
• 11.1 Tools
  216
• 11.2 Removing
  217
• 11.3 Installing
  219
• 12 Renewing front side member reinforcement
  225
• 12.1 Tools
  225
• 12.2 Removing
  226
• 12.3 Installing
  227
• 13 Renewing rear side member reinforcement
  231
• 13.1 Tools
  231
• 13.2 Removing
  232
• 13.3 Installing
  233
• 14 Renewing outer mounting for seat outer cross member
  237
• 14.1 Tools
  238
• 14.2 Removing
  239
• 14.3 Installing
  240
• 15 Renewing inner mounting for seat inner cross member
  242
• 15.1 Tools
  243
• 15.2 Removing
  243
• 15.3 Installing
  244
• 16 Renewing seat middle cross member
  247
• 16.1 Tools
  247
• 16.2 Removing
  248
• 16.3 Installing
  249
• Body - rear
  252
• 1 Renewing cross panel
  252
• 1.1 Tools
  252
• 1.2 Removing
  253
• 1.3 Installing
  255
• 2 Renewing tail light mounting
  258
• 2.1 Tools
  258
• 2.2 Removing
  259
• 2.3 Installing
  260
• 3 Renewing lower corner part
  263
• 3.1 Tools
  263
• 3.2 Removing
  264
• 3.3 Installing
  265
• 4 Renewing cross panel member
  268
• 4.1 Tools
  268
• 4.2 Removing
  269
• 4.3 Installing
  270
• 5 Renewing rear luggage compartment floor
  273
• 5.1 Tools
  274
• 5.2 Removing
  274
• 5.3 Installing
  276
• 6 Renewing inner D-pillar
  280
• 6.1 Tools
  281
• 6.2 Removing
  282
• 6.3 Installing
  284
• 7 Renewing lower D-pillar reinforcement
  288
• 7.1 Tools
  289
• 7.2 Removing
  289
• 7.3 Installing
  290
• 8 Renewing rear longitudinal member - part section
  293
• 8.1 Tools
  294
• 8.2 Removing
  294
• 8.3 Installing
  295
• 9 Renewing side panel - part section
  298
• 9.1 Tools
  298
• 9.2 Removing
  299
• 9.3 Renewing lock reinforcement
  302
• 9.4 Installing
  306
• 10 Renewing sealing channel - part section
  312
• 10.1 Tools
  313
• 10.2 Removing
  313
• 10.3 Installing
  314
• 11 Renewing outer wheel housing
  317
• 11.1 Tools
  317
• 11.2 Removing
  318
• 11.3 Installing
  321