Body Repairs

Chapter overview

• Technical data
  1
• 1 Induction training/staff qualifications
  1
• 1.1 Qualification
  1
• 2 Vehicle identification data
  2
• 2.1 Vehicle identification number
  2
• 2.2 Type plate
  3
• 2.3 Vehicle data sticker
  4
• 3 Safety information
  6
• 4 Body work for which HV electrical system must be de-energised
  7
• 4.1 The following body work requires the HV electrical system to be de-energised
  7
• 5 Moulded foam inserts
  8
• 6.1 Aluminium panels
  11
• 7 Laser welding
  16
• 8 Body panel gaps/shut lines
  17
• 8.1 Body, front
  17
• 8.2 Body, centre
  18
• 8.3 Body, rear
  19
• 9 Body dimensions
  20
• 9.1 Body, front
  20
• 9.2 Body, centre
  22
• 9.3 Body, rear
  27
• 9.4 Floor panel, front
  28
• 9.5 Floor panel, centre
  29
• 9.6 Floor panel, rear
  30
• 10 Straightening bracket set
  32
• 10.1 Setup overview of complete body
  32
• 11 Portal gauge
  34
• 11.1 Setup overview of complete body
  34
• 12 Repair kit for flow-drill screws
  36
• 13 Extraction technology for multi-material body workplaces
  37
• 14 Rivets accessible from one side
  38
• 15 Overview of press tool insert combinations
  39
• 16 Overview of rivets for repairs
  40
• Body - front
  41
• 1 Renewing upper wheel housing longitudinal member - part section
  41
• 1.1 Tools
  42
• 1.2 Removing
  42
• 1.3 Installing
  45
• 2 Renewing upper wheel housing longitudinal member
  53
• 2.1 Tools
  54
• 2.2 Removing
  54
• 2.3 Installing
  56
• 3 Renewing front wheel housing
  62
• 3.1 Tools
  63
• 3.2 Removing
  63
• 3.3 Installing
  65
• 4 Renewing front longitudinal member
  69
• 4.1 Tools
  70
• 4.2 Removing
  70
• 4.3 Installing
  78
• 5 Renewing front longitudinal member (part section)
  86
• 5.1 Tools
  87
• 5.2 Removing
  87
• 5.3 Installing
  89
• 6 Renewing upper footwell cross member
  100
• 6.1 Tools
  101
• 6.2 Removing
  101
• 6.3 Installing
  103
• 7 Renewing outer footwell cross member
  107
• 7.1 Tools
  108
• 7.2 Removing
  108
• 7.3 Installing
  111
• Body - centre
  116
• 1 Renewing roof - vehicles with no panorama tilting sunroof
  116
• 1.1 Tools
  117
• 1.2 Removing
  117
• 1.3 Installing
  121
• 2 Renewing roof - vehicles with panorama tilting sunroof
  133
• 2.1 Tools
  134
• 2.2 Removing
  134
• 2.3 Installing
  139
• 3 Renewing roof side member
  152
• 3.1 Tools
  153
• 3.2 Removing
  153
• 3.3 Installing
  155
• 4 Renewing front cross member for roof
  161
• 4.1 Tools
  162
• 4.2 Removing
  162
• 4.3 Installing
  164
• 5 Renewing rear roof cross member
  167
• 5.1 Tools
  168
• 5.2 Removing
  168
• 5.3 Installing
  170
• 6 Renewing A-pillar
  173
• 6.1 Tools
  174
• 6.2 Removing
  174
• 6.3 Installing
  176
• 7 Renewing A-pillar reinforcement
  183
• 7.1 Tools
  184
• 7.2 Removing
  184
• 7.3 Installing
  186
• 8 Renewing upper A-pillar reinforcement (part section)
  191
• 8.1 Tools
  192
• 8.2 Removing
  192
• 8.3 Installing
  196
• 9 Renewing B-pillar
  206
• 9.1 Tools
  208
• 9.2 Identification plate
  208
• 9.3 Removing
  209
• 9.4 Installing
  211
• 10 Renewing B-pillar reinforcement
  217
• 10.1 Tools
  218
• 10.2 Type plate
  218
• 10.3 Removing
  219
• 10.4 Installing
  222
• 11 Renewing outer side member
  226
• 11.1 Tools
  227
• 11.2 Identification plate
  227
• 11.3 Removing
  228
• 11.4 Installing
  230
• 12 Renewing front seat cross member
  237
• 12.1 Tools
  238
• 12.2 Removing
  239
• 12.3 Installing
  241
• 13 Renewing rear seat cross member
  244
• 13.1 Tools
  245
• 13.2 Removing
  245
• 13.3 Installing
  247
• 14 Renewing centre tunnel
  250
• 14.1 Tools
  251
• 14.2 Removing
  251
• 14.3 Installing
  254
• Body - rear
  258
• 1 Renewing cross panel
  258
• 1.1 Tools
  259
• 1.2 Removing
  259
• 1.3 Installing
  261
• 2 Renewing rear longitudinal member (part section)
  267
• 2.1 Tools
  268
• 2.2 Removing
  268
• 2.3 Installing
  273
• 3 Renewing cross panel reinforcement
  281
• 3.1 Tools
  282
• 3.2 Removing
  282
• 3.3 Installing
  286
• 4 Renewing side panel
  299
• 4.1 Tools
  300
• 4.2 Removing
  300
• 4.3 Installing
  303
• 5 Renewing C-pillar reinforcement
  310
• 5.1 Tools
  311
• 5.2 Removing
  311
• 5.3 Installing
  313
• 6 Renewing rear inner wheel housing
  318
• 6.1 Tools
  319
• 6.2 Removing
  319
• 6.3 Installing
  322
• 7 Renewing rear outer wheel housing
  328
• 7.1 Tools
  329
• 7.2 Removing
  329
• 7.3 Installing
  331
• 8 Renewing rear part of luggage compartment floor
  336
• 8.1 Tools
  337
• 8.2 Removing
  337
• 8.3 Installing
  340
• 9 Renewing rear luggage compartment floor (part section)
  347
• 9.1 Tools
  348
• 9.2 Removing
  348
• 9.3 Installing
  350