Body Repairs

Chapter overview

• Technical data
  1
• 1 Basic instructions
  1
• 2 Vehicle identification data
  2
• 2.1 Vehicle identification number
  2
• 2.2 Type plate
  3
• 2.3 Vehicle data sticker
  3
• 3 Safety information
  4
• 4 Moulded foam inserts
  5
• 5 Galvanized body parts, high/higher-strength and hot-formed body panels
  7
• 5.1 Installing
  7
• 6 Laser welding
  11
• 7 Gaps/shut lines
  12
• 7.1 Body - front
  12
• 7.2 Body - centre
  13
• 7.3 Body - rear
  14
• 8 Body dimensions
  15
• 8.1 Body - front
  15
• 8.2 Body - centre
  16
• 8.3 Body - rear
  21
• 8.4 Floor panel - front
  22
• 8.5 Floor panel - centre
  23
• 8.6 Floor panel - rear
  24
• 9 Alignment jig
  25
• 9.1 Overview
  25
• 10 Portal gauge
  26
• Body - front
  27
• 1 Renewing mounting bracket for subframe
  27
• 1.1 Tools
  28
• 1.2 Removing
  28
• 1.3 Installing
  29
• 2 Renewing front bumper bracket
  31
• 2.1 Tools
  32
• 2.2 Removing
  32
• 2.3 Installing
  33
• 3 Renewing upper wheel housing longitudinal member
  36
• 3.1 Tools
  37
• 3.2 Removing
  37
• 3.3 Installing
  38
• 4 Renewing front wheel housing
  41
• 4.1 Tools
  42
• 4.2 Removing
  42
• 4.3 Installing
  43
• 5 Repairing threads for securing subframe
  45
• 5.1 Contents of thread repair kit
  47
• 5.2 Repairing threads
  47
• 6 Renewing front longitudinal member
  51
• 6.1 Tools
  52
• 6.2 Removing
  52
• 6.3 Installing
  53
• 7 Renewing front longitudinal member (left part section)
  57
• 7.1 Tools
  58
• 7.2 Removing
  58
• 7.3 Installing when using complete longitudinal member assembly
  60
• 7.4 Installing when using individual components of longitudinal member
  63
• 7.5 Renewing studs
  66
• 8 Renewing front longitudinal member (right part section)
  68
• 8.1 Tools
  69
• 8.2 Removing
  69
• 8.3 Installing when using complete longitudinal member assembly
  71
• 8.4 Installing when using individual components of longitudinal member
  74
• 8.5 Renewing studs
  77
• Body - centre
  79
• 1 Renewing roof
  79
• 1.1 Tools
  80
• 1.2 Removing
  80
• 1.3 Installing
  82
• 2 Renewing A-pillar
  93
• 2.1 Tools
  94
• 2.2 Removing
  94
• 2.3 Installing
  96
• 3 Renewing A-pillar reinforcement (part section)
  102
• 3.1 Tools
  103
• 3.2 Removing
  103
• 3.3 Installing
  104
• 4 Renewing B-pillar
  108
• 4.1 Tools
  109
• 4.2 Removing
  109
• 4.3 Installing
  110
• 5 Renewing outer side member (4-door)
  114
• 5.1 Tools
  115
• 5.2 Removing
  115
• 5.3 Installing
  116
• Body - rear
  121
• 1 Renewing rear cross panel
  121
• 1.1 Tools
  122
• 1.2 Removing
  123
• 1.3 Installing
  124
• 2 Renewing corner reinforcing
  128
• 2.1 Tools
  129
• 2.2 Removing
  129
• 2.3 Installing
  130
• 3 Renewing tail light mounting
  133
• 3.1 Tools
  134
• 3.2 Removing
  134
• 3.3 Installing
  135
• 4 Renewing cross panel member
  139
• 4.1 Tools
  140
• 4.2 Removing
  140
• 4.3 Installing
  141
• 5 Renewing luggage compartment floor
  145
• 5.1 Tools
  146
• 5.2 Removing
  147
• 5.3 Installing
  148
• 6 Renewing C-pillar reinforcement (part section)
  152
• 6.1 Tools
  153
• 6.2 Removing
  153
• 6.3 Installing
  154
• 7 Renewing rear longitudinal member (part section)
  157
• 7.1 Tools
  158
• 7.2 Removing
  158
• 7.3 Installing
  159
• 8 Renewing side panel
  162
• 8.1 Tools
  163
• 8.2 Removing
  163
• 8.3 Installing
  165
• 9 Renewing wheel housing - 4-door
  171
• 9.1 Tools
  171
• 9.2 Removing
  171
• 9.3 Installing
  173
• 10 Renewing outer wheel housing liner
  176
• 10.1 Tools
  177
• 10.2 Removing
  177
• 10.3 Installing
  179