Body Repairs

Chapter overview

• Technical data
  1
• 1 Vehicle identification data
  1
• 1.1 Vehicle identification number
  1
• 1.2 Identification plate
  1
• 1.3 Vehicle data sticker
  1
• 2 Body dimensions
  2
• 2.1 Body - front
  2
• 2.2 Body - centre
  5
• 2.3 Body - rear
  12
• 2.4 Floor group - front
  14
• 2.5 Floor group - rear
  16
• 3 Moulded foam elements
  18
• 4 Galvanized body parts
  19
• 5 Strengthened steel body panels
  20
• 6 Laser welding
  21
• 7 Body panel gaps/shut lines
  22
• 7.1 Body - front
  22
• 7.2 Body - rear
  24
• 8 Alignment jig
  26
• 8.1 Overview
  26
• Body - front
  37
• 1 Renewing engine console (right)
  37
• 1.1 Tools
  37
• 1.2 Removing
  38
• 1.3 Installing
  39
• 2 Renewing wing connecting plate
  40
• 2.1 Tools
  40
• 2.2 Removing
  41
• 2.3 Installing
  42
• 3 Renewing upper wheel housing longitudinal member ►02.2005
  43
• 3.1 Tools
  43
• 3.2 Removing
  43
• 3.3 Installing
  45
• 4 Renewing upper wheel housing longitudinal member 03.2005 ►
  46
• 4.1 Tools
  46
• 4.2 Removing
  47
• 4.3 Installing
  49
• 5 Renewing front wheel housing
  51
• 5.1 Tools
  51
• 5.2 Removing
  51
• 5.3 Installing
  52
• 6 Renewing front wheel housing - part section
  54
• 6.1 Tools
  54
• 6.2 Removing
  54
• 6.3 Installing
  56
• 7 Renewing front longitudinal member
  57
• 7.1 Tools
  58
• 7.2 Removing
  58
• 7.3 Installing
  59
• 8 Renewing front longitudinal member - part section
  63
• 8.1 Tools
  63
• 8.2 Removing
  63
• 8.3 Installing
  64
• 9 Renewing front section of longitudinal member
  66
• 9.1 Removing
  66
• 9.2 Installing
  67
• Body - centre
  69
• 1 Renewing roof
  69
• 1.1 Tools
  69
• 1.2 Installing
  71
• 2 Renewing roof with roof railing
  83
• 2.1 Tools
  83
• 2.2 Installing
  86
• 3 Renewing front roof cross member
  103
• 3.1 Tools
  103
• 3.2 Removing
  103
• 3.3 Installing
  104
• 4 Renewing roof reinforcement
  106
• 4.1 Removing
  106
• 4.2 Installing
  107
• 5 Renewing rear roof cross member
  108
• 5.1 Removing
  108
• 5.2 Installing
  109
• 6 Renewing A-pillar
  110
• 6.1 Tools
  110
• 6.2 Removing
  111
• 6.3 Installing
  113
• 7 Renewing inner A-pillar
  116
• 7.1 Tools
  116
• 7.2 Removing
  116
• 7.3 Installing
  119
• 8 Renewing B-pillar (4-door)
  121
• 8.1 Tools
  121
• 8.2 Removing
  122
• 8.3 Installing
  122
• 9 Renewing inner B-pillar (2-door)
  126
• 9.1 Tools
  126
• 9.2 Removing
  126
• 9.3 Installing
  128
• 10 Renewing inner B-pillar (4-door)
  130
• 10.1 Removing
  130
• 10.2 Installing
  132
• 11 Renewing outer side member (2-door)
  134
• 11.1 Tools
  134
• 11.2 Removing
  134
• 11.3 Installing
  135
• 12 Renewing outer side member (4-door)
  138
• 12.1 Tools
  138
• 12.2 Removing
  138
• 12.3 Installing
  139
• 13 Renewing side member reinforcement
  143
• 13.1 Tools
  143
• 13.2 Removing
  143
• 13.3 Installing
  145
• 14 Renewing floor panel - part section
  147
• 14.1 Tools
  147
• 14.2 Removing
  148
• 14.3 Installing
  149
• Body - rear
  152
• 1 Renewing rear cross panel
  152
• 1.1 Tools
  152
• 1.2 Removing
  152
• 1.3 Installing
  154
• 2 Renewing inner lock carrier
  155
• 2.1 Tools
  155
• 2.2 Removing
  155
• 2.3 Installing
  156
• 3 Renewing tail light mounting
  157
• 3.1 Tools
  157
• 3.2 Removing
  158
• 3.3 Installing
  159
• 4 Renewing towing eye
  160
• 4.1 Removing
  160
• 4.2 Installing
  161
• 5 Renewing rear longitudinal member - part section
  162
• 5.1 Removing
  162
• 5.2 Installing
  163
• 6 Renewing side panel - part section (2-door)
  165
• 6.1 Tools
  165
• 6.2 Removing
  166
• 6.3 Installing
  168
• 7 Renewing side panel - part section (4-door)
  171
• 7.1 Tools
  171
• 7.2 Removing
  172
• 7.3 Installing
  174
• 8 Renewing outer wheel housing liner - part section
  177
• 8.1 Tools
  177
• 8.2 Removing
  177
• 8.3 Installing
  178
• 9 Renewing spare wheel well
  180
• 9.1 Removing
  180
• 9.2 Installing
  181
• 10 Renewing spare wheel well - part section
  182
• 10.1 Removing
  182
• 10.2 Installing
  183