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
  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 Body - front
  14
• 7.2 Body, centre
  16
• 7.3 Body, rear
  19
• 8 Body dimensions
  22
• 8.1 Body - front
  22
• 8.2 Body, centre
  23
• 8.3 Body, rear
  28
• 8.4 Floor panel, front
  29
• 8.5 Floor panel, centre
  30
• 8.6 Floor panel, rear
  31
• 9 Straightening 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 Overview of parts - LWB, MEX
  37
• 2 Overview of parts - LWB, EU
  38
• 3 Renewing bracket - LWB, MEX, right side
  39
• 3.1 Tools
  40
• 3.2 Removing
  40
• 3.3 Installing
  41
• 4 Renewing bracket - LWB, EU, right side
  44
• 4.1 Tools
  45
• 4.2 Removing
  45
• 4.3 Installing
  46
• 5 Repairing threads for securing subframe
  49
• 5.1 Contents of thread repair kit
  50
• 5.2 Repairing threads
  51
• 6 Renewing mounting bracket for subframe
  55
• 6.1 Tools
  56
• 6.2 Removing
  56
• 6.3 Installing
  58
• 7 Renewing front longitudinal member end plate – LWB-MEX
  62
• 7.1 Tools
  63
• 7.2 Removing
  63
• 7.3 Installing
  64
• 8 Renewing front longitudinal member end plate – LWB-EU
  67
• 8.1 Tools
  68
• 8.2 Removing
  68
• 8.3 Installing
  69
• 9 Renewing upper wheel housing longitudinal member
  72
• 9.1 Tools
  73
• 9.2 Removing
  73
• 9.3 Installing
  75
• 10 Renewing upper inner wheel housing longitudinal member
  79
• 10.1 Tools
  80
• 10.2 Removing
  80
• 10.3 Installing
  81
• 11 Renewing front wheel housing - LWB, MEX
  85
• 11.1 Tools
  86
• 11.2 Removing
  86
• 11.3 Installing
  88
• 12 Renewing front wheel housing - LWB, EU
  93
• 12.1 Tools
  94
• 12.2 Removing
  94
• 12.3 Installing
  96
• 13 Renewing front wheel housing - LWB, MEX, part section
  100
• 13.1 Tools
  101
• 13.2 Removing
  101
• 13.3 Installing
  103
• 14 Renewing front wheel housing - LWB, EU, part section
  108
• 14.1 Tools
  109
• 14.2 Removing
  109
• 14.3 Installing
  111
• 15 Renewing front longitudinal member - LWB, MEX
  116
• 15.1 Tools
  117
• 15.2 Removing
  117
• 15.3 Installing
  118
• 16 Renewing front longitudinal member - LWB, EU
  122
• 16.1 Tools
  123
• 16.2 Removing
  123
• 16.3 Installing
  124
• 17 Renewing front longitudinal member - LWB, MEX, part section, left side
  128
• 17.1 Tools
  129
• 17.2 Removing
  129
• 17.3 Installing
  132
• 17.4 Renewing studs
  136
• 18 Renewing front longitudinal member - LWB, EU, part section, left side
  138
• 18.1 Tools
  139
• 18.2 Removing
  139
• 18.3 Installing when using complete longitudinal member assembly
  142
• 18.4 Installing when using individual components of longitudinal member
  145
• 18.5 Renewing studs
  149
• 19 Renewing front longitudinal member - LWB, MEX, part section, right side
  150
• 19.1 Tools
  151
• 19.2 Removing
  151
• 19.3 Installing
  154
• 19.4 Renewing studs
  158
• 20 Renewing front longitudinal member - LWB, EU, part section, right side
  160
• 20.1 Tools
  161
• 20.2 Removing
  161
• 20.3 Installing when using complete longitudinal member assembly
  164
• 20.4 Installing when using individual components of longitudinal member
  167
• 20.5 Renewing studs
  171
• Body - centre
  173
• 1 Overview of parts - LWB, MEX
  173
• 2 Overview of parts - LWB, EU
  174
• 3 Renewing roof - vehicles with no panorama tilting sunroof
  175
• 3.1 Tools
  176
• 3.2 Removing
  176
• 3.3 Installing
  180
• 4 Renewing roof - vehicles with panorama tilting sunroof
  191
• 4.1 Tools
  192
• 4.2 Removing
  193
• 4.3 Installing
  196
• 5 Renewing A-pillar
  206
• 5.1 Tools
  208
• 5.2 Removing
  208
• 5.3 Installing
  210
• 6 Renewing A-pillar reinforcement - LWB, EU, part section
  215
• 6.1 Tools
  216
• 6.2 Removing
  216
• 6.3 Installing
  217
• 7 Renewing upper A-pillar reinforcement - LWB, EU, part section
  222
• 7.1 Tools
  223
• 7.2 Removing
  223
• 7.3 Installing
  226
• 8 Renewing B-pillar
  235
• 8.1 Tools
  237
• 8.2 Type plate
  237
• 8.3 Removing
  238
• 8.4 Installing
  240
• 9 Renewing B-pillar reinforcement
  245
• 9.1 Tools
  246
• 9.2 Type plate
  246
• 9.3 Removing
  247
• 9.4 Installing
  249
• 10 Renewing B-pillar reinforcement - LWB, EU, part section
  254
• 10.1 Tools
  255
• 10.2 Type plate
  255
• 10.3 Removing
  256
• 10.4 Installing
  259
• 11 Renewing outer side member
  267
• 11.1 Tools
  268
• 11.2 Type plate
  268
• 11.3 Removing
  269
• 11.4 Installing
  270
• 12 Renewing side member reinforcement - LWB MEX
  275
• 12.1 Tools
  276
• 12.2 Type plate
  277
• 12.3 Removing
  277
• 12.4 Installing
  279
• Body - rear
  284
• 1 Overview of parts - LWB, MEX
  284
• 2 Overview of parts - LWB, EU
  285
• 3 Renewing rear cross panel
  286
• 3.1 Tools
  287
• 3.2 Removing
  287
• 3.3 Installing
  289
• 4 Renewing lower corner part
  293
• 4.1 Tools
  294
• 4.2 Removing
  294
• 4.3 Installing
  295
• 5 Renewing rear cross member
  299
• 5.1 Tools
  300
• 5.2 Removing
  300
• 5.3 Installing
  301
• 6 Renewing luggage compartment floor
  306
• 6.1 Tools
  307
• 6.2 Removing
  307
• 6.3 Installing
  309
• 7 Renewing rear longitudinal member - LWB, MEX, part section
  314
• 7.1 Tools
  315
• 7.2 Removing
  315
• 7.3 Installing
  317
• 8 Renewing rear longitudinal member - LWB, EU, part section
  320
• 8.1 Tools
  321
• 8.2 Removing
  321
• 8.3 Installing
  323
• 9 Renewing rear longitudinal member - LWB (second parting cut - part section)
  326
• 9.1 Tools
  327
• 9.2 Removing
  328
• 9.3 Installing
  331
• 10 Renewing side panel (part section)
  342
• 10.1 Tools
  344
• 10.2 Removing
  344
• 10.3 Installing
  348
• 11 Renewing outer wheel housing liner
  354
• 11.1 Tools
  355
• 11.2 Moulded foam inserts
  355
• 11.3 Removing
  355
• 11.4 Installing
  357
• 12 Renewing rear wheel housing
  362
• 12.1 Tools
  363
• 12.2 Removing
  363
• 12.3 Installing
  365