Body Repairs

Chapter overview

• Technical data
  1
• 1 Basic instructions
  1
• 2 Vehicle identification data
  2
• 2.1 Vehicle identification number
  2
• 2.2 Identification plate/safety certificate
  4
• 2.3 Vehicle data sticker
  5
• 3 Safety information
  6
• 4 Moulded foam inserts
  7
• 6 Laser welding
  15
• 7 Gaps/shut lines
  16
• 7.1 Body - front
  16
• 7.2 Body - centre
  17
• 7.3 Body - rear
  20
• 8 Body dimensions
  21
• 8.1 Body - front
  21
• 8.2 Body - centre
  22
• 8.3 Body - rear
  29
• 8.4 Floor panel - front
  30
• 8.5 Floor panel - centre
  31
• 8.6 Floor panel - rear
  32
• 9 Alignment bracket set
  33
• 9.1 Setup overview of complete body
  33
• 10 Portal gauge
  35
• 10.1 Setup overview of complete body
  35
• Body - front
  37
• 1 Renewing right bracket
  37
• 1.1 Tools
  37
• 1.2 Removing
  37
• 1.3 Installing
  39
• 2 Renewing mounting bracket for subframe
  42
• 2.1 Tools
  43
• 2.2 Removing
  43
• 2.3 Installing
  44
• 3 Renewing front bumper bracket
  47
• 3.1 Tools
  48
• 3.2 Removing
  48
• 3.3 Installing
  49
• 4 Renewing upper wheel housing longitudinal member
  52
• 4.1 Tools
  53
• 4.2 Removing
  53
• 4.3 Installing
  54
• 5 Renewing upper inner wheel housing longitudinal member
  57
• 5.1 Tools
  58
• 5.2 Removing
  58
• 5.3 Installing
  59
• 6 Renewing front wheel housing
  62
• 6.1 Tools
  63
• 6.2 Removing
  63
• 6.3 Installing
  65
• 7 Renewing front wheel housing (part section)
  69
• 7.1 Tools
  70
• 7.2 Removing
  70
• 7.3 Installing
  72
• 8 Repairing threads for securing subframe
  76
• 8.1 Contents of thread repair kit
  78
• 8.2 Repairing threads
  78
• 9 Renewing front longitudinal member
  82
• 9.1 Tools
  83
• 9.2 Removing
  83
• 9.3 Installing
  84
• 10 Renewing front longitudinal member (left part section)
  87
• 10.1 Tools
  88
• 10.2 Removing
  88
• 10.3 Installing when using complete longitudinal member assembly
  90
• 10.4 Installing when using individual components of longitudinal member
  93
• 10.5 Renewing studs
  96
• 11 Renewing front longitudinal member (right part section)
  98
• 11.1 Tools
  99
• 11.2 Removing
  99
• 11.3 Installing when using complete longitudinal member assembly
  101
• 11.4 Installing when using individual components of longitudinal member
  104
• 11.5 Renewing studs
  107
• Body - centre
  109
• 1 Renewing roof - vehicles with no panorama tilting sunroof
  109
• 1.1 Tools
  110
• 1.2 Removing
  110
• 1.3 Installing
  112
• 2 Renewing roof - vehicles with panorama tilting sunroof
  123
• 2.1 Tools
  124
• 2.2 Removing
  124
• 2.3 Installing
  126
• 3 Renewing A-pillar
  137
• 3.1 Tools
  138
• 3.2 Removing
  139
• 3.3 Installing
  140
• 4 Renewing A-pillar reinforcement (part section)
  145
• 4.1 Tools
  146
• 4.2 Removing
  146
• 4.3 Installing
  147
• 5 Renewing B-pillar - 4-door
  151
• 5.1 Tools
  152
• 5.2 Type plate
  152
• 5.3 Moulded foam inserts
  153
• 5.4 Removing
  153
• 5.5 Installing
  155
• 6 Renewing B-pillar reinforcement - 4-door
  159
• 6.1 Tools
  160
• 6.2 Type plate
  161
• 6.3 Moulded foam inserts
  162
• 6.4 Removing
  162
• 6.5 Installing
  164
• 7 Renewing B-pillar reinforcement (2-door models)
  172
• 7.1 Tools
  173
• 7.2 Type plate
  174
• 7.3 Moulded foam inserts
  175
• 7.4 Removing
  175
• 7.5 Installing
  177
• 8 Renewing inner B-pillar
  185
• 8.1 Tools
  186
• 8.2 Moulded foam inserts
  187
• 8.3 Removing
  187
• 8.4 Installing
  188
• 9 Renewing outer side member - 4-door
  191
• 9.1 Tools
  192
• 9.2 Removing
  192
• 9.3 Installing
  193
• 10 Renewing outer side member - 2-door
  198
• 10.1 Tools
  199
• 10.2 Removing
  199
• 10.3 Installing
  200
• 11 Renewing inner side member
  205
• 11.1 Tools
  206
• 11.2 Moulded foam inserts
  207
• 11.3 Removing
  207
• 11.4 Installing
  208
• Body - rear
  213
• 1 Renewing rear cross panel
  213
• 1.1 Tools
  214
• 1.2 Removing
  215
• 1.3 Installing
  216
• 2 Renewing corner reinforcing
  220
• 2.1 Tools
  221
• 2.2 Removing
  221
• 2.3 Installing
  222
• 3 Renewing tail light mounting
  225
• 3.1 Tools
  226
• 3.2 Removing
  226
• 3.3 Installing
  227
• 4 Renewing cross panel member
  231
• 4.1 Tools
  232
• 4.2 Removing
  232
• 4.3 Installing
  233
• 5 Renewing luggage compartment floor
  237
• 5.1 Tools
  238
• 5.2 Removing
  239
• 5.3 Installing
  240
• 6 Renewing rear longitudinal member (part section)
  244
• 6.1 Tools
  245
• 6.2 Removing
  245
• 6.3 Installing
  247
• 7 Renewing side panel (4-door)
  250
• 7.1 Tools
  251
• 7.2 Removing
  251
• 7.3 Installing
  253
• 8 Renewing side panel - 2-door
  259
• 8.1 Tools
  260
• 8.2 Moulded foam inserts
  261
• 8.3 Removing
  261
• 8.4 Installing
  263
• 9 Renewing wheel housing - 4-door
  269
• 9.1 Tools
  269
• 9.2 Removing
  269
• 9.3 Installing
  271
• 10 Renewing wheel housing - 2-door
  274
• 10.1 Tools
  274
• 10.2 Removing
  274
• 10.3 Installing
  276
• 11 Renewing outer wheel housing liner
  279
• 11.1 Tools
  280
• 11.2 Removing
  281
• 11.3 Installing
  283