Body Repairs

Chapter overview

• Technical data
  1
• 1 Vehicle identification data
  1
• 1.1 Vehicle identification number
  1
• 1.2 Identification plate
  3
• 1.3 Vehicle data sticker
  4
• 2 Safety instructions
  5
• 3 Moulded foam elements
  6
• 4 Galvanized body parts
  7
• 4.1 Body
  7
• 4.2 Platform
  7
• 5 Laser welding
  8
• 6 Body panel gaps/shut lines
  9
• 6.1 Body - front
  9
• 6.2 Body - rear
  10
• 7 Body dimensions
  11
• 7.1 Body - front
  11
• 7.2 Body - centre
  17
• 7.3 Body - rear
  22
• 7.4 Floor group - front
  23
• 7.5 Floor group - centre
  25
• 7.6 Floor group - rear
  26
• 8 Alignment bracket set
  27
• 8.1 Overview
  27
• 9 Portal gauge
  28
• 9.1 Overview
  28
• Body - front
  30
• 1 Renewing wing connecting plate
  30
• 1.1 Removing
  31
• 1.2 Installing
  31
• 2 Renewing upper longitudinal member - partial renewal
  32
• 2.1 Removing
  32
• 2.2 Installing
  33
• 3 Renewing bumper bracket
  34
• 3.1 Removing
  35
• 3.2 Installing
  36
• 4 Renewing front suspension strut mounting
  38
• 4.1 Removing
  38
• 4.2 Installing
  39
• 5 Repairing threads for securing subframe (suspension subframe)
  41
• 5.1 Contents of thread repair kit
  42
• 5.2 Repairing thread
  43
• 6 Renewing front longitudinal member
  46
• 6.1 Removing
  46
• 6.2 Installing
  48
• 7 Renewing front longitudinal member - partial replacement
  53
• 7.1 Removing
  54
• 7.2 Installing
  55
• Body - centre
  58
• 1 Renewing roof
  58
• 1.1 Removing
  59
• 1.2 Installing
  61
• 2 Renewing front roof cross member
  74
• 2.1 Removing
  74
• 2.2 Installing
  75
• 3 Renewing rear roof cross member
  78
• 3.1 Removing
  78
• 3.2 Installing
  80
• 4 Renewing A-pillar
  83
• 4.1 Removing
  87
• 4.2 Installing
  88
• 5 Renewing A-pillar reinforcement
  92
• 5.1 Removing
  93
• 5.2 Installing
  95
• 6 Renewing B-pillar
  98
• 6.1 Removing
  103
• 6.2 Installing
  104
• 7 Renewing B-pillar reinforcement
  106
• 7.1 Removing
  107
• 7.2 Installing
  109
• 8 Renewing outer side member
  111
• 8.1 Removing
  112
• 8.2 Installing
  114
• 9 Renewing inner side member - partial renewal
  115
• 9.1 Removing
  116
• 9.2 Installing
  118
• 10 Renewing side member reinforcement (reinforcement pipe)
  120
• 10.1 Removing
  120
• 10.2 Installing
  121
• 11 Renewing front floor panel - partial renewal
  123
• 11.1 Removing
  124
• 11.2 Installing
  125
• 12 Renewing rear floor panel - partial renewal
  127
• 12.1 Removing
  129
• 12.2 Installing
  130
• 13 Replacing battery compartment
  132
• 13.1 Removing
  133
• 13.2 Installing
  133
• Body - rear
  135
• 1 Renewing cross panel
  135
• 1.1 Removing
  136
• 1.2 Installing
  137
• 2 Renewing rear cross panel
  138
• 2.1 Removing
  139
• 2.2 Installing
  139
• 3 Renewing lock carrier
  141
• 3.1 Removing
  141
• 3.2 Installing
  143
• 4 Renewing D-pillar reinforcement
  146
• 4.1 Removing
  146
• 4.2 Installing
  147
• 5 Renewing tail light mounting
  149
• 5.1 Removing
  149
• 5.2 Installing
  150
• 6 Renewing tow bar mounting
  152
• 6.1 Removing
  152
• 6.2 Installing
  154
• 7 Renewing rear longitudinal member - partial replacement
  157
• 7.1 Removing
  157
• 7.2 Installing
  159
• 8 Renewing side panel
  163
• 8.1 Removing
  166
• 8.2 Installing
  168
• 9 Renewing outer wheel housing liner
  170
• 9.1 Removing
  171
• 9.2 Installing
  175
• 10 Renewing spare wheel holder reinforcement
  179
• 10.1 Removing
  179
• 10.2 Installing
  182
• 11 Renewing spare wheel well
  184
• 11.1 Removing
  185
• 11.2 Installing
  188