Body Repairs

Chapter overview

• Technical data
  1
• 1 Basic instructions
  1
• 1.1 Original joint
  1
• 1.2 Joining techniques
  1
• 2 Vehicle identification data
  3
• 2.1 Vehicle identification number (VIN) - localization
  3
• 2.2 Identification plate
  3
• 2.3 Vehicle data – PR number
  4
• 3 Safety indications
  5
• 4 Moulded foam inserts
  6
• 6 Laser welding
  11
• 7 Clearance measurements
  12
• 7.1 Front body section
  12
• 7.2 Central body section
  13
• 7.3 Rear body section
  15
• 8 Body dimensions
  18
• 8.1 Front body section
  18
• 8.2 Central body section
  20
• 8.3 Rear body section
  24
• 8.4 Body measurements of the floor panel
  25
• Body - front
  29
• 1 Overview of parts
  29
• 2 Console (right-hand side) - replace
  30
• 2.1 Tools
  31
• 2.2 Remove
  31
• 2.3 Install
  32
• 3 Repair the assembly mountings fastening thread
  36
• 3.1 M12x1.5 Heli-coil thread repair set VAS 6058
  37
• 3.2 Thread - repair
  38
• 4 Front bumper support - replace
  42
• 4.1 Tools
  43
• 4.2 Remove
  43
• 4.3 Install
  44
• 5 Bonnet hinge support - replace
  47
• 5.1 Tools
  48
• 5.2 Remove
  48
• 5.3 Install
  49
• 6 Studs - replace
  52
• Body - centre
  54
• 1 Overview of parts
  54
• 2 Roof - replace
  55
• 2.1 Tools
  56
• 2.2 Remove
  56
• 2.3 Install
  60
• 3 Front roof cross member - replace
  71
• 3.1 Tools
  72
• 3.2 Remove
  72
• 3.3 Install
  73
• 4 Rear roof cross member - replace
  76
• 4.1 Tools
  77
• 4.2 Remove
  77
• 4.3 Install
  78
• 5 Roof cross member - replace
  82
• 5.1 Tools
  83
• 5.2 Remove
  84
• 5.3 Install
  85
• 6 Pillar A - replace
  90
• 6.1 Tools
  91
• 6.2 Moulded foam inserts
  92
• 6.3 Remove
  92
• 6.4 Install
  93
• 7 Replace the upper A-pillar reinforcement (partial part)
  98
• 7.1 Tools
  99
• 7.2 Moulded foam inserts
  99
• 7.3 Remove
  99
• 7.4 Install
  102
• 8 A-pillar reinforcement - replace
  112
• 8.1 Tools
  113
• 8.2 Moulded foam inserts
  113
• 8.3 Remove
  113
• 8.4 Install
  114
• 9 B-pillar - replace
  119
• 9.1 Tools
  121
• 9.2 Identification plate
  121
• 9.3 Moulded foam inserts
  122
• 9.4 Remove
  122
• 9.5 Install
  123
• 10 B-pillar reinforcement - replace
  128
• 10.1 Tools
  129
• 10.2 Identification plate
  129
• 10.3 Moulded foam inserts
  130
• 10.4 Remove
  130
• 10.5 Install
  132
• 11 B-pillar reinforcement (section) - replace
  136
• 11.1 Tools
  137
• 11.2 Identification plate
  137
• 11.3 Moulded foam inserts
  138
• 11.4 Remove
  138
• 11.5 Install
  140
• 12 External lower longitudinal member - replace
  150
• 12.1 Tools
  151
• 12.2 Identification plate
  151
• 12.3 Moulded foam inserts
  153
• 12.4 Remove
  153
• 12.5 Install
  154
• 13 Lower longitudinal member reinforcement - replace
  159
• 13.1 Tools
  160
• 13.2 Moulded foam inserts
  160
• 13.3 Remove
  160
• 13.4 Install
  162
• 14 Inner seat cross member housing - replace
  167
• 14.1 Tools
  168
• 14.2 Remove
  168
• 14.3 Install
  169
• 15 Outer seat cross member housing - replace
  172
• 15.1 Tools
  173
• 15.2 Remove
  173
• 15.3 Install
  174
• Body - rear
  180
• 1 Overview of parts
  180
• 2 Rear cover - replace
  181
• 2.1 Tools
  182
• 2.2 Remove
  182
• 2.3 Install
  184
• 3 Final cross member - replace
  190
• 3.1 Tools
  191
• 3.2 Remove
  191
• 3.3 Install
  192
• 4 Tail light cluster housing - replace
  197
• 4.1 Tools
  198
• 4.2 Remove
  198
• 4.3 Install
  199
• 5 Luggage compartment - replace
  204
• 5.1 Tools
  205
• 5.2 Moulded foam inserts
  205
• 5.3 Remove
  205
• 5.4 Install
  207
• 6 Floor plate - replace
  211
• 6.1 Tools
  212
• 6.2 Remove
  212
• 6.3 Install
  213
• 7 Rear side member end plate - replace
  217
• 7.1 Tools
  218
• 7.2 Remove
  218
• 7.3 Install
  219
• 8 Front longitudinal member (partial part) - replace
  222
• 8.1 Tools
  223
• 8.2 Remove
  223
• 8.3 Install
  224
• 9 Rear side member (partial part - second separating cut) - replace
  228
• 9.1 Tools
  229
• 9.2 Moulded foam inserts
  229
• 9.3 Remove
  229
• 9.4 Install
  231
• 10 Permitted separating cuts in the side panel
  241
• 11 Side panel (partial part) - replace
  242
• 11.1 Tools
  243
• 11.2 Moulded foam inserts
  244
• 11.3 Remove
  244
• 11.4 Install
  246
• 12 External wheel housing liner - replace
  251
• 12.1 Tools
  252
• 12.2 Moulded foam inserts
  252
• 12.3 Remove
  252
• 12.4 Install
  253
• 13 Lock reinforcement - replace
  258
• 13.1 Tools
  259
• 13.2 Remove
  259
• 13.3 Install
  260