Body Repairs

Chapter overview

• Technical data
  1
• 1 Basic instructions
  1
• 1.1 Original joint
  1
• 1.2 Used joining techniques
  1
• 2 Vehicle identification data
  3
• 2.1 Vehicle identification number
  3
• 2.2 Identification plate
  4
• 2.3 Vehicle data sticker
  5
• 3 Safety information
  7
• 4 Moulded foam inserts
  8
• 5 Galvanized body parts, high- and higher-strength and hot-formed body panels
  10
• 6 Laser welding
  13
• 7 Gaps/shut lines
  14
• 7.1 Front body
  14
• 7.2 Body, centre
  16
• 7.3 Body - rear
  19
• 8 Body dimensions
  22
• 8.1 Front body
  22
• 8.2 Body, centre
  24
• 8.3 Body - rear
  27
• 8.4 Body dimension for floor panel
  28
• 9 Alignment bracket set
  32
• 9.1 Setup overview of complete body
  32
• 10 Portal gauge
  34
• 10.1 Setup overview of complete body
  34
• Body - front
  36
• 1 Overview of parts
  36
• 2 Renewing right bracket
  37
• 2.1 Tools
  38
• 2.2 Removing
  38
• 2.3 Installing
  39
• 3 Repairing threads for securing subframe
  42
• 3.1 Contents of thread repair kit
  43
• 3.2 Repairing threads
  44
• 4 Renewing mounting bracket for subframe
  48
• 4.1 Tools
  49
• 4.2 Removing
  49
• 4.3 Installing
  50
• 5 Renewing cross panel for front longitudinal member
  54
• 5.1 Tools
  55
• 5.2 Removing
  55
• 5.3 Installing
  56
• 6 Renewing upper wheel housing longitudinal member
  59
• 6.1 Tools
  60
• 6.2 Removing
  60
• 6.3 Installing
  62
• 7 Renewing upper inner wheel housing longitudinal member
  66
• 7.1 Tools
  67
• 7.2 Removing
  67
• 7.3 Installing
  68
• 8.1 Tools
  73
• 8.2 Removing
  73
• 8.3 Installing
  75
• 9 Renewing front wheel housing
  81
• 9.1 Tools
  82
• 9.2 Removing
  82
• 9.3 Installing
  84
• 10 Renewing front wheel housing (part section)
  90
• 10.1 Tools
  91
• 10.2 Removing
  91
• 10.3 Installing
  92
• 11 Renewing front left longitudinal member
  96
• 11.1 Tools
  97
• 11.2 Removing
  97
• 11.3 Installing
  98
• 12 Renewing front right longitudinal member
  105
• 12.1 Tools
  106
• 12.2 Removing
  106
• 12.3 Installing
  107
• 13 Renewing front longitudinal member (left part section)
  114
• 13.1 Tools
  115
• 13.2 Removing
  115
• 13.3 Installing
  117
• 14 Renewing front longitudinal member (right part section)
  122
• 14.1 Tools
  123
• 14.2 Removing
  123
• 14.3 Installing
  125
• 15 Renewing studs
  130
• Body - centre
  131
• 1 Overview of parts
  131
• 2 Renewing roof - vehicles with no panorama tilting sunroof
  132
• 2.1 Tools
  133
• 2.2 Removing
  133
• 2.3 Installing
  137
• 3 Renewing roof - vehicles with panorama tilting sunroof
  147
• 3.1 Tools
  149
• 3.2 Removing
  149
• 3.3 Installing
  153
• 4 Renewing front cross member for roof
  163
• 4.1 Tools
  164
• 4.2 Removing
  164
• 4.3 Installing
  165
• 5 Renewing rear roof cross member
  168
• 5.1 Tools
  169
• 5.2 Removing
  169
• 5.3 Installing
  170
• 6 Renewing roof side member
  174
• 6.1 Tools
  175
• 6.2 Removing
  176
• 6.3 Installing
  179
• 7 Renewing A-pillar
  184
• 7.1 Tools
  185
• 7.2 Moulded foam inserts
  186
• 7.3 Removing
  186
• 7.4 Installing
  187
• 8 Renewing upper A-pillar reinforcement (part section)
  193
• 8.1 Tools
  194
• 8.2 Moulded foam inserts
  194
• 8.3 Removing
  194
• 8.4 Installing
  197
• 9 Renewing A-pillar reinforcement
  206
• 9.1 Tools
  207
• 9.2 Moulded foam inserts
  207
• 9.3 Removing
  207
• 9.4 Installing
  208
• 10 Renewing B-pillar
  213
• 10.1 Tools
  215
• 10.2 Identification plate
  215
• 10.3 Moulded foam inserts
  216
• 10.4 Removing
  216
• 10.5 Installing
  218
• 11 Renewing B-pillar reinforcement
  223
• 11.1 Tools
  224
• 11.2 Identification plate
  224
• 11.3 Moulded foam inserts
  225
• 11.4 Removing
  225
• 11.5 Installing
  227
• 12 Renewing B-pillar reinforcement (part section)
  232
• 12.1 Tools
  233
• 12.2 Identification plate
  233
• 12.3 Moulded foam inserts
  234
• 12.4 Removing
  234
• 12.5 Installing
  238
• 13 Renewing outer side member
  246
• 13.1 Tools
  247
• 13.2 Identification plate
  247
• 13.3 Moulded foam inserts
  248
• 13.4 Removing
  248
• 13.5 Installing
  250
• 14 Renewing side member reinforcement
  255
• 14.1 Tools
  256
• 14.2 Moulded foam inserts
  256
• 14.3 Removing
  256
• 14.4 Installing
  258
• 15 Renewing inner mounting for seat inner cross member
  263
• 15.1 Tools
  264
• 15.2 Removing
  264
• 15.3 Installing
  265
• 16 Renewing seat cross member
  268
• 16.1 Tools
  269
• 16.2 Removing
  269
• 16.3 Installing
  270
• 17 Renewing outer mounting for seat outer cross member
  273
• 17.1 Tools
  274
• 17.2 Removing
  274
• 17.3 Installing
  276
• Body - rear
  282
• 1 Overview of parts
  282
• 2 Renewing rear cross panel
  283
• 2.1 Tools
  284
• 2.2 Removing
  284
• 2.3 Installing
  285
• 3 Renewing rear cross member
  291
• 3.1 Tools
  292
• 3.2 Removing
  292
• 3.3 Installing
  293
• 4 Renewing tail light mounting
  298
• 4.1 Tools
  299
• 4.2 Removing
  299
• 4.3 Installing
  300
• 5 Renewing lower corner part
  305
• 5.1 Tools
  306
• 5.2 Removing
  306
• 5.3 Installing
  307
• 6 Renewing luggage compartment floor (front-wheel drive)
  311
• 6.1 Tools
  312
• 6.2 Moulded foam inserts
  312
• 6.3 Removing
  312
• 6.4 Installing
  313
• 7 Renewing luggage compartment floor (all-wheel drive)
  318
• 7.1 Tools
  319
• 7.2 Moulded foam inserts
  319
• 7.3 Removing
  319
• 7.4 Installing
  320
• 8 Renewing floor panel
  326
• 8.1 Tools
  327
• 8.2 Removing
  327
• 8.3 Installing
  328
• 9 Renewing rear end plate for longitudinal member
  331
• 9.1 Tools
  332
• 9.2 Removing
  332
• 9.3 Installing
  333
• 10 Renewing rear longitudinal member (part section)
  336
• 10.1 Tools
  337
• 10.2 Removing
  337
• 10.3 Installing
  339
• 11.1 Tools
  343
• 11.2 Moulded foam inserts
  343
• 11.3 Removing
  343
• 11.4 Installing
  345
• 12.1 Tools
  356
• 12.2 Moulded foam inserts
  356
• 12.3 Removing
  356
• 12.4 Installing
  359
• 13 Permitted parting cuts on side panel
  369
• 14 Renewing side panel (part section)
  370
• 14.1 Tools
  371
• 14.2 Moulded foam inserts
  372
• 14.3 Removing
  372
• 14.4 Installing
  374
• 15 Renewing outer wheel housing liner
  379
• 15.1 Tools
  380
• 15.2 Moulded foam inserts
  380
• 15.3 Removing
  380
• 15.4 Installing
  382
• 16 Renewing lock reinforcement
  387
• 16.1 Tools
  388
• 16.2 Removing
  388
• 16.3 Installing
  390