Body Repairs

Chapter overview

• Technical data
  1
• 1 Basic instructions
  1
• 1.1 Original joint
  1
• 1.2 Used joining techniques
  1
• 2 Vehicle identification data
  2
• 2.1 Vehicle identification number
  2
• 2.2 Identification plate
  4
• 2.3 Vehicle data sticker
  5
• 3 Safety information
  6
• 4 Moulded foam inserts
  7
• 6 Laser welding
  12
• 7 Gaps/shut lines
  13
• 7.1 Front body
  13
• 7.2 Body, centre
  15
• 7.3 Body - rear
  18
• 8 Body dimensions
  20
• 8.1 Front body
  20
• 8.2 Body, centre
  22
• 8.3 Body - rear
  27
• 8.4 Floor panel - front
  28
• 8.5 Floor panel - centre
  29
• 8.6 Floor panel - rear
  30
• 9 Alignment bracket set
  31
• 9.1 Setup overview of complete body
  31
• 10 Portal gauge
  33
• 10.1 Setup overview of complete body
  33
• Body - front
  35
• 1 Overview of parts
  35
• 2 Renewing right bracket
  36
• 2.1 Tools
  37
• 2.2 Removing
  37
• 2.3 Installing
  38
• 3 Repairing threads for securing subframe
  41
• 3.1 Contents of thread repair kit
  42
• 3.2 Repairing threads
  42
• 4 Renewing mounting bracket for subframe
  46
• 4.1 Tools
  47
• 4.2 Removing
  47
• 4.3 Installing
  48
• 5 Renewing cross panel for front longitudinal member
  52
• 5.1 Tools
  53
• 5.2 Removing
  53
• 5.3 Installing
  54
• 6 Renewing upper wheel housing longitudinal member
  57
• 6.1 Tools
  58
• 6.2 Removing
  58
• 6.3 Installing
  59
• 7 Renewing upper inner wheel housing longitudinal member
  63
• 7.1 Tools
  64
• 7.2 Removing
  64
• 7.3 Installing
  65
• 8 Renewing front wheel housing
  68
• 8.1 Tools
  69
• 8.2 Removing
  69
• 8.3 Installing
  71
• 9 Renewing front longitudinal member
  76
• 9.1 Tools
  77
• 9.2 Removing
  77
• 9.3 Installing
  78
• 10 Renewing front longitudinal member (left part section)
  82
• 10.1 Tools
  83
• 10.2 Removing
  83
• 10.3 Installing when using complete longitudinal member assembly
  85
• 10.4 Installing when using individual components of longitudinal member
  89
• 11 Renewing front longitudinal member (right part section)
  92
• 11.1 Tools
  93
• 11.2 Removing
  93
• 11.3 Installing when using complete longitudinal member assembly
  95
• 11.4 Installing when using individual components of longitudinal member
  99
• 12 Renewing studs
  102
• Body - centre
  103
• 1 Overview of parts
  103
• 2 Renewing roof - vehicles with no panorama tilting sunroof
  104
• 2.1 Tools
  105
• 2.2 Removing
  105
• 2.3 Installing
  109
• 3 Renewing roof - vehicles with panorama tilting sunroof
  119
• 3.1 Tools
  120
• 3.2 Removing
  120
• 3.3 Installing
  123
• 4 Renewing A-pillar
  132
• 4.1 Tools
  133
• 4.2 Moulded foam inserts
  134
• 4.3 Removing
  134
• 4.4 Installing
  135
• 5 Renewing upper A-pillar reinforcement (part section)
  140
• 5.1 Tools
  141
• 5.2 Moulded foam inserts
  141
• 5.3 Removing
  141
• 5.4 Installing
  144
• 6 Renewing lower A-pillar reinforcement (part section)
  154
• 6.1 Tools
  155
• 6.2 Moulded foam inserts
  155
• 6.3 Removing
  155
• 6.4 Installing
  156
• 7 Renewing B-pillar
  160
• 7.1 Tools
  161
• 7.2 Identification plate
  161
• 7.3 Moulded foam inserts
  162
• 7.4 Removing
  162
• 7.5 Installing
  163
• 8 Renewing B-pillar reinforcement
  168
• 8.1 Tools
  169
• 8.2 Identification plate
  169
• 8.3 Moulded foam inserts
  170
• 8.4 Removing
  170
• 8.5 Installing
  171
• 9 Renewing B-pillar reinforcement (part section)
  177
• 9.1 Tools
  178
• 9.2 Identification plate
  178
• 9.3 Moulded foam inserts
  179
• 9.4 Removing
  179
• 9.5 Installing
  182
• 10 Renewing outer side member
  191
• 10.1 Tools
  192
• 10.2 Identification plate
  193
• 10.3 Moulded foam inserts
  194
• 10.4 Removing
  194
• 10.5 Installing
  195
• 11 Renewing side member cover plate
  200
• 11.1 Tools
  201
• 11.2 Removing
  201
• 11.3 Installing
  202
• Body - rear
  206
• 1 Overview of parts
  206
• 2 Renewing rear cross panel
  207
• 2.1 Tools
  208
• 2.2 Removing
  208
• 2.3 Installing
  212
• 3 Renewing cross panel member
  218
• 3.1 Tools
  219
• 3.2 Removing
  219
• 3.3 Installing
  220
• 4 Renewing lower corner part
  225
• 4.1 Tools
  226
• 4.2 Removing
  226
• 4.3 Installing
  227
• 5 Renewing luggage compartment floor
  231
• 5.1 Tools
  232
• 5.2 Moulded foam inserts
  232
• 5.3 Removing
  232
• 5.4 Installing
  234
• 6 Renewing rear longitudinal member (part section)
  237
• 6.1 Tools
  238
• 6.2 Moulded foam inserts
  238
• 6.3 Removing
  238
• 6.4 Installing
  240
• 7 Renewing rear longitudinal member (part section – second parting cut)
  244
• 7.1 Tools
  245
• 7.2 Moulded foam inserts
  245
• 7.3 Removing
  245
• 7.4 Installing
  251
• 8 Permitted parting cuts on side panel
  266
• 9 Renewing side panel (part section)
  267
• 9.1 Tools
  268
• 9.2 Moulded foam inserts
  269
• 9.3 Removing
  269
• 9.4 Installing
  271