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 Moulded foam elements
  5
• 4.1 Body
  7
• 4.2 2-door
  9
• 4.3 4-door
  12
• 5 Laser welding
  15
• 6 Body panel gaps/shut lines
  16
• 6.1 Body - front
  16
• 6.2 Body - centre
  17
• 6.3 Body - rear
  19
• 7 Body dimensions
  20
• 7.1 Body - front
  20
• 7.2 Body - centre
  23
• 7.3 Body - rear
  33
• 7.4 Floor group - front
  36
• 7.5 Floor group - centre
  38
• 7.6 Floor group - rear
  39
• 8 Tools
  40
• 9 Alignment jig
  41
• 9.1 Overview
  41
• 10 Portal gauge
  42
• 10.1 2-door
  42
• 10.2 4-door
  43
• Body - front
  45
• 1 Renewing right engine mounting bracket
  45
• 1.1 Tools
  45
• 1.2 Removing
  45
• 1.3 Installing
  47
• 2 Renewing retaining bracket for subframe
  49
• 2.1 Tools
  49
• 2.2 Removing
  49
• 2.3 Installing
  50
• 3 Renewing front bumper bracket
  53
• 3.1 Tools
  54
• 3.2 Removing
  54
• 3.3 Installing
  55
• 4 Renewing upper wheel housing longitudinal member
  57
• 4.1 Tools
  58
• 4.2 Removing
  58
• 4.3 Installing
  60
• 5 Renewing front wheel housing
  65
• 5.1 Tools
  66
• 5.2 Removing
  66
• 5.3 Installing
  67
• 6 Repairing threads for securing subframe
  69
• 6.1 Contents of thread repair kit
  71
• 6.2 Repairing threads
  71
• 7 Renewing front left longitudinal member
  75
• 7.1 Tools
  76
• 7.2 Removing
  76
• 7.3 Installing
  78
• 8 Renewing front left longitudinal member - part section
  82
• 8.1 Tools
  83
• 8.2 Removing
  83
• 8.3 Installing
  84
• 9 Renewing front right longitudinal member
  87
• 9.1 Tools
  88
• 9.2 Removing
  88
• 9.3 Installing
  90
• 10 Renewing front right longitudinal member - part section
  95
• 10.1 Tools
  96
• 10.2 Removing
  96
• 10.3 Installing
  97
• Body - centre
  100
• 1 Renewing roof
  100
• 1.1 Tools
  101
• 1.2 Removing
  102
• 1.3 Installing
  105
• 2 Renewing front roof cross member
  116
• 2.1 Tools
  116
• 2.2 Removing
  116
• 2.3 Installing
  118
• 3 Renewing roof reinforcement
  120
• 3.1 Tools
  120
• 3.2 Removing
  120
• 3.3 Installing
  122
• 4 Renewing rear roof cross member
  125
• 4.1 Tools
  125
• 4.2 Removing
  125
• 4.3 Installing
  127
• 5 Renewing A-pillar
  130
• 5.1 Tools
  131
• 5.2 Removing
  131
• 5.3 Installing
  133
• 6 Renewing A-pillar reinforcement
  141
• 6.1 Tools
  142
• 6.2 Removing
  142
• 6.3 Installing
  145
• 7 Renewing B-pillar – 4-door
  151
• 7.1 Tools
  152
• 7.2 Removing
  152
• 7.3 Installing
  153
• 8 Renewing B-pillar reinforcement – 4-door
  161
• 8.1 Tools
  162
• 8.2 Removing
  162
• 8.3 Installing
  165
• 9 Renewing B-pillar reinforcement – 2-door
  175
• 9.1 Tools
  176
• 9.2 Removing
  176
• 9.3 Installing
  178
• 10 Renewing outer side member – 4-door
  190
• 10.1 Tools
  191
• 10.2 Removing
  191
• 10.3 Installing
  193
• 11 Renewing outer side member – 2-door
  202
• 11.1 Tools
  203
• 11.2 Removing
  204
• 11.3 Installing
  205
• 12 Renewing gusset plate
  211
• 12.1 Tools
  211
• 12.2 Removing
  211
• 12.3 Installing
  212
• 13 Renewing seat cross member
  215
• 13.1 Tools
  215
• 13.2 Removing
  215
• 13.3 Installing
  217
• Body - rear
  220
• 1 Renewing rear cross panel
  220
• 1.1 Tools
  221
• 1.2 Removing
  221
• 1.3 Installing
  222
• 2 Renewing tail light mounting
  225
• 2.1 Tools
  226
• 2.2 Removing
  226
• 2.3 Installing
  227
• 3 Renewing cross panel member
  230
• 3.1 Tools
  231
• 3.2 Removing
  231
• 3.3 Installing
  232
• 4 Renewing luggage compartment floor
  235
• 4.1 Tools
  236
• 4.2 Removing
  236
• 4.3 Installing
  237
• 5 Renewing rear longitudinal member - part section
  240
• 5.1 Tools
  241
• 5.2 Removing
  241
• 5.3 Installing
  243
• 6 Renewing side panel, part section – 4-door
  246
• 6.1 Tools
  247
• 6.2 Removing
  247
• 6.3 Installing
  249
• 7 Renewing side panel – 2-door
  257
• 7.1 Tools
  258
• 7.2 Removing
  258
• 7.3 Installing
  260
• 8 Renewing outer wheel housing liner - part section
  269
• 8.1 Tools
  270
• 8.2 Removing
  270
• 8.3 Installing
  271