Body Repairs

Chapter overview

• Technical data
  1
• 1 Vehicle identification data
  1
• 1.1 Vehicle identification number
  1
• 1.2 Type plate
  3
• 1.3 Vehicle data sticker
  4
• 2 Safety instructions
  5
• 3 Gaps/shut lines
  7
• 3.1 Body - front
  7
• 3.2 Body - centre
  8
• 3.3 Body - rear
  9
• 4 Body dimensions
  11
• 4.1 Body - front
  11
• 4.2 Body - centre
  12
• 4.3 Body - rear
  13
• 5 Measurement and alignment system
  14
• 6 Repair checklist
  15
• 6.1 Introduction, preliminary work
  15
• 6.2 Primary areas of focus at front
  18
• 6.3 Primary areas of focus at centre
  23
• 6.4 Primary areas of focus at rear
  24
• 6.5 Damage to add-on parts at front
  26
• 6.6 Damage to add-on parts at side
  29
• 6.7 Damage to add-on parts at rear
  32
• 6.8 Damage to underbody
  35
• 6.9 Damage to interior components
  36
• 6.10 Indicators
  37
• Body - front
  38
• 1 Monocoque - front
  38
• 1.1 Notes on corrosion protection at contact points of monocoque, front
  39
• 2 Renewing longitudinal member (crash reinforcement)
  41
• 2.1 Removing
  41
• 2.2 Installing
  44
• Body - centre
  47
• 1 Monocoque - centre
  47
• 2 Renewing roof
  48
• 2.1 Removing
  49
• 2.2 Installing
  51
• 3 Renewing plenum chamber
  56
• 3.1 Removing
  57
• 3.2 Installing
  59
• 4 Renewing B-pillar end plate
  62
• 4.1 Removing
  63
• 4.2 Installing
  64
• 5 Bonding studs to monocoque
  67
• 5.1 Overview of fitting locations - front
  68
• 5.2 Overview of fitting locations - centre
  69
• 5.3 Overview of fitting locations - rear
  71
• 5.4 Repairing studs
  74
• 6 Threaded inserts on monocoque
  77
• 6.1 Repairing anchor nuts on monocoque
  77
• 6.2 Repairing Time-Sert on monocoque
  80
• 6.3 Repairing Keensert on monocoque
  82
• 6.4 Repairing pop rivet nuts on monocoque
  84
• 6.5 Repairing Helicoil thread insert on monocoque
  95
• 6.6 Repairing Tophead on monocoque
  100
• 6.7 Preparing bonding surfaces for repair
  105
• Body - rear
  107
• 1 Monocoque - rear
  107
• 1.1 Notes on corrosion protection at contact points of monocoque, rear
  108
• 2 Renewing plenum chamber with luggage compartment floor and cross member
  110
• 2.1 Bonding plenum chamber to luggage compartment floor and cross member
  111