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 Type plate
  5
• 2.3 Vehicle data sticker
  6
• 3 Safety information
  7
• 4 Moulded foam inserts
  8
• 6 Laser welding
  13
• 7 Gaps/shut lines
  14
• 7.1 Body - front
  14
• 7.2 Body - centre
  17
• 7.3 Body - rear
  20
• 8 Body dimensions
  22
• 8.1 Body - front
  22
• 8.2 Body - centre
  25
• 8.3 Body - rear
  28
• 8.4 Body dimension for floor panel
  30
• 9 Alignment bracket set
  34
• 10 Portal gauge
  35
• 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
  44
• 3.2 Repairing threads
  45
• 4 Renewing mounting bracket for subframe
  50
• 4.1 Tools
  51
• 4.2 Removing
  51
• 4.3 Installing
  52
• 5 Renewing cross panel for front longitudinal member
  55
• 5.1 Tools
  56
• 5.2 Removing
  56
• 5.3 Installing
  57
• 6 Replacing upper wheel housing longitudinal member
  60
• 6.1 Tools
  61
• 6.2 Removing
  61
• 6.3 Installing
  62
• 7 Renewing hinge reinforcement for bonnet
  66
• 7.1 Tools
  67
• 7.2 Removing
  67
• 7.3 Installing
  68
• 8 Renewing upper inner wheel housing longitudinal member
  71
• 8.1 Tools
  72
• 8.2 Removing
  72
• 8.3 Installing
  73
• 9 Renewing front wheel housing
  77
• 9.1 Tools
  78
• 9.2 Removing
  78
• 9.3 Installing
  79
• 10 Renewing front wheel housing (part section)
  83
• 10.1 Tools
  84
• 10.2 Removing
  84
• 10.3 Installing
  85
• 11 Renewing front longitudinal member
  88
• 11.1 Tools
  89
• 11.2 Removing
  89
• 11.3 Installing
  90
• 12 Renewing front longitudinal member (left part section)
  94
• 12.1 Tools
  95
• 12.2 Removing
  96
• 12.3 Installing
  98
• 13 Renewing front longitudinal member (right part section)
  102
• 13.1 Tools
  103
• 13.2 Removing
  104
• 13.3 Installing
  106
• 14 Renewing studs
  110
• Body - centre
  112
• 1 Overview of parts
  112
• 2 Renewing roof - vehicles with no panorama tilting sunroof
  113
• 2.1 Tools
  114
• 2.2 Removing
  114
• 2.3 Installing
  116
• 3 Renewing roof - vehicles with panorama tilting sunroof
  127
• 3.1 Tools
  128
• 3.2 Removing
  128
• 3.3 Installing
  130
• 4 Renewing front cross member for roof
  141
• 4.1 Tools
  142
• 4.2 Removing
  142
• 4.3 Installing
  143
• 5 Renewing rear roof cross member
  147
• 5.1 Tools
  148
• 5.2 Removing
  148
• 5.3 Installing
  149
• 6 Renewing roof side member
  152
• 6.1 Tools
  153
• 6.2 Removing
  154
• 6.3 Installing
  155
• 7 Renewing A-pillar
  160
• 7.1 Tools
  161
• 7.2 Moulded foam inserts
  162
• 7.3 Removing
  162
• 7.4 Installing
  164
• 8 Renewing upper A-pillar reinforcement (part section)
  169
• 8.1 Tools
  170
• 8.2 Moulded foam inserts
  171
• 8.3 Removing
  171
• 8.4 Installing
  173
• 9 Renewing A-pillar reinforcement
  180
• 9.1 Tools
  181
• 9.2 Moulded foam inserts
  181
• 9.3 Removing
  181
• 9.4 Installing
  182
• 10 Renewing B-pillar
  187
• 10.1 Tools
  188
• 10.2 Type plate
  189
• 10.3 Moulded foam inserts
  190
• 10.4 Removing
  190
• 10.5 Installing
  192
• 11 Renewing B-pillar reinforcement
  196
• 11.1 Tools
  197
• 11.2 Type plate
  197
• 11.3 Moulded foam inserts
  198
• 11.4 Removing
  198
• 11.5 Installing
  200
• 12 Renewing outer side member
  207
• 12.1 Tools
  208
• 12.2 Type plate
  209
• 12.3 Moulded foam inserts
  210
• 12.4 Removing
  210
• 12.5 Installing
  211
• 13 Renewing side member reinforcement
  216
• 13.1 Tools
  217
• 13.2 Moulded foam inserts
  218
• 13.3 Removing
  218
• 13.4 Installing
  219
• 14 Renewing inner mounting for seat inner cross member
  223
• 14.1 Tools
  224
• 14.2 Removing
  224
• 14.3 Installing
  225
• 15 Renewing seat cross member
  228
• 15.1 Tools
  229
• 15.2 Removing
  229
• 15.3 Installing
  230
• 16 Renewing outer mounting for seat outer cross member
  233
• 16.1 Tools
  234
• 16.2 Removing
  234
• 16.3 Installing
  236
• Body - rear
  241
• 1 Overview of parts
  241
• 2 Renewing rear cross panel
  242
• 2.1 Tools
  243
• 2.2 Removing
  243
• 2.3 Installing
  245
• 3 Renewing cross panel member
  249
• 3.1 Tools
  250
• 3.2 Removing
  250
• 3.3 Installing
  251
• 4 Renewing tail light mounting
  255
• 4.1 Tools
  256
• 4.2 Removing
  256
• 4.3 Installing
  257
• 5 Renewing luggage compartment floor
  260
• 5.1 Tools
  261
• 5.2 Moulded foam inserts
  261
• 5.3 Removing
  261
• 5.4 Installing
  262
• 6 Renewing floor panel
  267
• 6.1 Tools
  268
• 6.2 Removing
  268
• 6.3 Installing
  269
• 7 Renewing rear end plate for longitudinal member
  272
• 7.1 Tools
  273
• 7.2 Removing
  273
• 7.3 Installing
  274
• 8 Renewing rear longitudinal member (part section)
  277
• 8.1 Tools
  278
• 8.2 Removing
  278
• 8.3 Installing
  279
• 9.1 Tools
  283
• 9.2 Moulded foam inserts
  283
• 9.3 Removing
  283
• 9.4 Installing
  286
• 10.1 Tools
  296
• 10.2 Moulded foam inserts
  296
• 10.3 Removing
  296
• 10.4 Installing
  299
• 11 Permitted parting cuts on side panel
  309
• 12 Renewing side panel (part section)
  310
• 12.1 Tools
  311
• 12.2 Moulded foam inserts
  312
• 12.3 Removing
  312
• 12.4 Installing
  314
• 13 Renewing outer wheel housing liner
  319
• 13.1 Tools
  320
• 13.2 Moulded foam inserts
  320
• 13.3 Removing
  320
• 13.4 Installing
  322
• 14 Renewing C-pillar reinforcement
  327
• 14.1 Tools
  328
• 14.2 Removing
  328
• 14.3 Installing
  329
• 15 Renewing lock reinforcement
  332
• 15.1 Tools
  333
• 15.2 Removing
  333
• 15.3 Installing
  335