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
  2
• 2.1 Vehicle identification number
  2
• 2.2 Type plate
  4
• 2.3 Vehicle data sticker
  5
• 3 Safety information
  6
• 4 Moulded foam inserts
  7
• 6 Laser welding
  12
• 7 Gaps/shut lines
  13
• 7.1 Body, front
  13
• 7.2 Body, centre
  15
• 7.3 Body - rear
  17
• 8 Body dimensions
  19
• 8.1 Body, front
  19
• 8.2 Body, centre
  22
• 8.3 Body - rear
  26
• 8.4 Body dimension for floor panel
  27
• 9 Alignment bracket set
  30
• 9.1 Setup overview of complete body
  30
• 10 Portal gauge
  32
• 10.1 Setup overview of complete body
  32
• Body - front
  34
• 1 Overview of parts
  34
• 2 Renewing right bracket
  35
• 2.1 Tools
  36
• 2.2 Removing
  36
• 2.3 Installing
  37
• 3 Repairing threads for securing subframe
  40
• 3.1 Contents of thread repair kit
  41
• 3.2 Repairing threads
  41
• 4 Renewing mounting bracket for subframe
  45
• 4.1 Tools
  46
• 4.2 Removing
  46
• 4.3 Installing
  47
• 5 Renewing cross panel for front longitudinal member
  51
• 5.1 Tools
  52
• 5.2 Removing
  52
• 5.3 Installing
  53
• 6 Renewing upper wheel housing longitudinal member
  56
• 6.1 Tools
  57
• 6.2 Removing
  57
• 6.3 Installing
  58
• 7 Renewing hinge reinforcement for bonnet
  62
• 7.1 Tools
  63
• 7.2 Removing
  63
• 7.3 Installing
  64
• 8 Renewing upper inner wheel housing longitudinal member
  67
• 8.1 Tools
  68
• 8.2 Removing
  68
• 8.3 Installing
  69
• 9 Renewing front wheel housing
  73
• 9.1 Tools
  74
• 9.2 Removing
  75
• 9.3 Installing
  76
• 10 Renewing front wheel housing (part section)
  82
• 10.1 Tools
  83
• 10.2 Removing
  83
• 10.3 Installing
  84
• 11 Renewing front longitudinal member
  87
• 11.1 Tools
  88
• 11.2 Removing
  88
• 11.3 Installing
  91
• 12 Renewing front longitudinal member (left part section)
  97
• 12.1 Tools
  98
• 12.2 Removing
  98
• 12.3 Installing
  99
• 13 Renewing front longitudinal member (right part section)
  102
• 13.1 Tools
  103
• 13.2 Removing
  103
• 13.3 Installing
  104
• 14 Renewing studs
  107
• Body - centre
  109
• 1 Overview of parts
  109
• 2 Renewing roof
  110
• 2.1 Tools
  111
• 2.2 Removing
  111
• 2.3 Installing
  115
• 3 Renewing front cross member for roof
  125
• 3.1 Tools
  126
• 3.2 Removing
  126
• 3.3 Installing
  127
• 4 Renewing rear roof cross member
  130
• 4.1 Tools
  131
• 4.2 Removing
  131
• 4.3 Installing
  132
• 5 Renewing roof side member
  136
• 5.1 Tools
  137
• 5.2 Removing
  138
• 5.3 Installing
  139
• 6 Renewing A-pillar
  144
• 6.1 Tools
  145
• 6.2 Moulded foam inserts
  145
• 6.3 Removing
  145
• 6.4 Installing
  147
• 7 Renewing upper A-pillar reinforcement (part section repair)
  152
• 7.1 Tools
  153
• 7.2 Moulded foam inserts
  153
• 7.3 Removing
  153
• 7.4 Installing
  155
• 8 Renewing A-pillar reinforcement
  164
• 8.1 Tools
  165
• 8.2 Moulded foam inserts
  165
• 8.3 Removing
  165
• 8.4 Installing
  166
• 9 Renewing B-pillar
  170
• 9.1 Tools
  171
• 9.2 Type plate
  172
• 9.3 Moulded foam inserts
  173
• 9.4 Removing
  173
• 9.5 Installing
  174
• 10 Renewing B-pillar reinforcement
  179
• 10.1 Tools
  180
• 10.2 Type plate
  180
• 10.3 Moulded foam inserts
  181
• 10.4 Removing
  181
• 10.5 Installing
  182
• 11 Renewing B-pillar reinforcement (part section)
  186
• 11.1 Tools
  187
• 11.2 Type plate
  187
• 11.3 Moulded foam inserts
  188
• 11.4 Removing
  188
• 11.5 Installing
  190
• 12 Renewing outer side member
  200
• 12.1 Tools
  201
• 12.2 Type plate
  202
• 12.3 Moulded foam inserts
  203
• 12.4 Removing
  203
• 12.5 Installing
  204
• 13 Renewing side member reinforcement
  209
• 13.1 Tools
  210
• 13.2 Moulded foam inserts
  211
• 13.3 Removing
  211
• 13.4 Installing
  212
• 14 Renewing inner mounting for seat inner cross member
  217
• 14.1 Tools
  218
• 14.2 Removing
  218
• 14.3 Installing
  219
• 15 Renewing outer mounting for seat outer cross member
  222
• 15.1 Tools
  223
• 15.2 Removing
  223
• 15.3 Installing
  224
• Body - rear
  230
• 1 Overview of parts
  230
• 2 Renewing rear cross panel
  231
• 2.1 Tools
  232
• 2.2 Removing
  232
• 2.3 Installing
  234
• 3 Renewing rear cross member
  239
• 3.1 Tools
  240
• 3.2 Removing
  240
• 3.3 Installing
  241
• 4 Renewing tail light mounting
  246
• 4.1 Tools
  247
• 4.2 Removing
  247
• 4.3 Installing
  248
• 5 Renewing luggage compartment floor
  252
• 5.1 Tools
  253
• 5.2 Moulded foam inserts
  253
• 5.3 Removing
  253
• 5.4 Installing
  254
• 6 Renewing left floor panel
  258
• 6.1 Tools
  259
• 6.2 Removing
  259
• 6.3 Installing
  260
• 7 Renewing rear end plate for longitudinal member
  263
• 7.1 Tools
  264
• 7.2 Removing
  264
• 7.3 Installing
  265
• 8 Renewing rear longitudinal member (part section)
  268
• 8.1 Tools
  269
• 8.2 Removing
  269
• 8.3 Installing
  270
• 9 Renewing rear longitudinal member (part section – second parting cut)
  273
• 9.1 Tools
  274
• 9.2 Moulded foam inserts
  274
• 9.3 Removing
  274
• 9.4 Installing
  276
• 10 Permitted parting cuts on side panel
  285
• 11 Renewing side panel (part section)
  286
• 11.1 Tools
  287
• 11.2 Moulded foam inserts
  288
• 11.3 Removing
  288
• 11.4 Installing
  290
• 12 Renewing outer wheel housing liner
  295
• 12.1 Tools
  296
• 12.2 Moulded foam inserts
  296
• 12.3 Removing
  296
• 12.4 Installing
  297
• 13 Renewing lock reinforcement
  302
• 13.1 Tools
  303
• 13.2 Removing
  303
• 13.3 Installing
  304