Body Repairs

Chapter overview

• Technical data
  1
• 1 Basic instructions
  1
• 2 Vehicle identification data
  2
• 2.1 Vehicle identification number
  2
• 2.2 Type plate
  2
• 2.3 Vehicle data sticker
  3
• 3 Safety information
  5
• 4 Moulded foam inserts
  6
• 5 Galvanized body parts, high- and higher-strength and hot-formed body panels
  8
• 5.1 Installing
  8
• 5.2 2-door models
  9
• 5.3 4-door models
  12
• 6 Laser welding
  16
• 7 Body panel gaps/shut lines
  17
• 7.1 Body - front
  17
• 7.2 Body - centre
  18
• 7.3 Body - rear
  19
• 8 Body dimensions
  21
• 8.1 Body - front
  21
• 8.2 Body - centre
  24
• 8.3 Body - rear
  34
• 8.4 Floor panel - front
  37
• 8.5 Floor panel - centre
  39
• 8.6 Floor panel - rear
  40
• 9 Tools
  42
• 10 Alignment jig
  43
• 10.1 Overview
  43
• 11 Portal gauge
  44
• 11.1 2-door models
  44
• 11.2 4-door models
  44
• Body - front
  47
• 1 Renewing right engine mounting bracket
  47
• 1.1 Tools
  47
• 1.2 Removing
  47
• 1.3 Installing
  49
• 2 Renewing mounting bracket for subframe
  51
• 2.1 Tools
  51
• 2.2 Removing
  51
• 2.3 Installing
  53
• 3 Renewing front bumper bracket
  55
• 3.1 Tools
  56
• 3.2 Removing
  56
• 3.3 Installing
  57
• 4 Renewing upper wheel housing longitudinal member
  59
• 4.1 Tools
  60
• 4.2 Removing
  60
• 4.3 Installing
  62
• 5 Renewing front wheel housing
  67
• 5.1 Tools
  68
• 5.2 Removing
  68
• 5.3 Installing
  69
• 6 Repairing threads for securing subframe
  71
• 6.1 Contents of thread repair kit
  72
• 6.2 Repairing threads
  73
• 7 Renewing front left longitudinal member
  77
• 7.1 Tools
  78
• 7.2 Removing
  78
• 7.3 Installing
  80
• 8 Renewing front left longitudinal member - part section
  84
• 8.1 Tools
  86
• 8.2 Removing
  86
• 8.3 Installing
  87
• 9 Renewing front right longitudinal member
  90
• 9.1 Tools
  91
• 9.2 Removing
  91
• 9.3 Installing
  93
• 10 Renewing front right longitudinal member - part section
  98
• 10.1 Tools
  99
• 10.2 Removing
  100
• 10.3 Installing
  101
• Body - centre
  104
• 1 Renewing roof
  104
• 1.1 Tools
  105
• 1.2 Removing
  106
• 1.3 Installing
  109
• 2 Renewing front cross member for roof
  121
• 2.1 Tools
  121
• 2.2 Removing
  121
• 2.3 Installing
  123
• 3 Renewing roof reinforcement
  125
• 3.1 Tools
  125
• 3.2 Removing
  125
• 3.3 Installing
  127
• 4 Renewing rear roof cross member
  130
• 4.1 Tools
  130
• 4.2 Removing
  130
• 4.3 Installing
  132
• 5 Renewing A-pillar
  135
• 5.1 Tools
  136
• 5.2 Removing
  136
• 5.3 Installing
  138
• 6 Renewing A-pillar reinforcement
  146
• 6.1 Tools
  147
• 6.2 Removing
  147
• 6.3 Installing
  151
• 7 Renewing B-pillar - 4-door
  157
• 7.1 Tools
  159
• 7.2 Removing
  159
• 7.3 Installing
  161
• 8 Renewing B-pillar reinforcement - 4-door
  166
• 8.1 Tools
  167
• 8.2 Removing
  167
• 8.3 Installing
  169
• 9 Renewing B-pillar reinforcement, 4-door model, part section
  175
• 9.1 Tools
  176
• 9.2 Removing
  176
• 9.3 Installing
  180
• 10 Renewing B-pillar reinforcement - 2-door
  189
• 10.1 Tools
  190
• 10.2 Removing
  190
• 10.3 Installing
  192
• 11 Renewing outer side member - 4-door
  204
• 11.1 Tools
  206
• 11.2 Removing
  206
• 11.3 Installing
  208
• 12 Renewing outer side member - 2-door
  217
• 12.1 Tools
  219
• 12.2 Removing
  219
• 12.3 Installing
  220
• 13 Renewing gusset plate
  226
• 13.1 Tools
  226
• 13.2 Removing
  226
• 13.3 Installing
  228
• 14 Renewing seat cross member
  230
• 14.1 Tools
  230
• 14.2 Removing
  230
• 14.3 Installing
  232
• Body - rear
  235
• 1 Renewing rear cross panel
  235
• 1.1 Tools
  236
• 1.2 Removing
  236
• 1.3 Installing
  237
• 2 Renewing tail light mounting
  240
• 2.1 Tools
  241
• 2.2 Removing
  241
• 2.3 Installing
  242
• 3 Renewing cross panel member
  245
• 3.1 Tools
  246
• 3.2 Removing
  246
• 3.3 Installing
  247
• 4 Renewing luggage compartment floor
  250
• 4.1 Tools
  251
• 4.2 Removing
  251
• 4.3 Installing
  252
• 5 Renewing rear longitudinal member - part section
  255
• 5.1 Tools
  256
• 5.2 Removing
  256
• 5.3 Installing
  258
• 6 Renewing side panel, part section – 4-door
  261
• 6.1 Tools
  262
• 6.2 Removing
  262
• 6.3 Installing
  264
• 7 Renewing side panel - 2-door
  272
• 7.1 Tools
  273
• 7.2 Removing
  273
• 7.3 Installing
  275
• 8 Renewing outer wheel housing liner - part section
  284
• 8.1 Tools
  285
• 8.2 Removing
  285
• 8.3 Installing
  287