Body Repairs

Chapter overview

• Technical data
  1
• 1 Notice for vehicle converted by ABT e-Line GmbH
  1
• 2 Basic instructions
  2
• 2.1 Original joint
  2
• 2.2 Used joining techniques
  2
• 3 Key vehicle data
  3
• 3.1 Vehicle identification number
  3
• 3.2 Identification plate
  5
• 3.3 Vehicle data sticker
  6
• 4 Safety information
  8
• 4.1 Safety precautions when working with moulded foam inserts
  8
• 5 Moulded foam inserts
  9
• 6 Galvanised body parts and high-/higher-strength body panels
  10
• 7 Laser welding
  14
• 8 Tools
  15
• 9 Gaps/shut lines
  16
• 9.1 Body - front
  16
• 9.2 Body, rear
  17
• 10 Body dimensions
  23
• 10.1 Body - front
  23
• 10.2 Body, centre
  24
• 10.3 Body, rear
  29
• 10.4 Floor panel, front
  32
• 10.5 Floor panel, centre
  33
• 10.6 Floor panel, rear
  35
• 11 Straightening bracket set
  38
• 11.1 Alignment bracket set, Caddy
  38
• 11.2 Alignment jig Caddy »Maxi«
  39
• 11.3 Portal gauges overview, 2-door vehicles
  40
• 11.4 Portal gauges overview, 4-door vehicles
  41
• 12 Classification of dangers of high-voltage system
  43
• Body - front
  44
• 1 Notice for vehicle electrified by ABT e-Line
  44
• 2 Renewing suspension turret
  45
• 2.1 Tools
  46
• 2.2 Removing
  46
• 2.3 Installing
  47
• 3 Renewing engine/motor mounting bracket
  50
• 3.1 Removing
  50
• 3.2 Installing
  51
• 4 Renewing gearbox mounting bracket
  55
• 4.1 Removing
  55
• 4.2 Installing
  57
• 5 Renewing mounting bracket for subframe
  61
• 5.1 Removing
  61
• 5.2 Installing
  62
• 6 Renewing upper outer longitudinal member
  65
• 6.1 Removing
  65
• 6.2 Installing
  67
• 7 Renewing upper wheel housing longitudinal member
  72
• 7.1 Removing
  72
• 7.2 Installing
  76
• 8 Renewing upper wheel housing longitudinal member - part section
  81
• 8.1 Removing
  81
• 8.2 Installing
  82
• 9 Renewing front wheel housing
  85
• 9.1 Tools
  86
• 9.2 Removing
  86
• 9.3 Installing
  87
• 10 Repairing threads for securing subframe
  90
• 10.1 Contents of thread repair kit
  91
• 10.2 Repairing threads
  92
• 11 Renewing front longitudinal member
  96
• 11.1 Removing
  96
• 11.2 Installing
  99
• 12 Renewing front longitudinal member - part section
  107
• 12.1 Removing
  107
• 12.2 Installing
  110
• 13 Renewing front bumper carrier
  115
• 13.1 Removing
  115
• 13.2 Installing
  116
• Body - centre
  119
• 1 Notice for vehicle electrified by ABT e-Line
  119
• 2 Renewing roof
  120
• 2.1 Removing
  120
• 2.2 Installing
  125
• 3 Renewing roof »vehicles with ladder flap«
  139
• 3.1 Removing
  139
• 3.2 Installing
  143
• 4 Renewing roof »Caddy Maxi«
  156
• 4.1 Removing
  156
• 4.2 Installing
  159
• 5 Renewing front cross member for roof
  164
• 5.1 Removing
  164
• 5.2 Installing
  165
• 6 Renewing centre roof reinforcement
  169
• 6.1 Removing
  169
• 6.2 Installing
  170
• 7 Renewing rear roof cross member
  174
• 7.1 Tools
  174
• 7.2 Removing
  174
• 7.3 Installing
  177
• 8 Renewing rear roof cross member (vehicles with ladder flap)
  179
• 8.1 Tools
  179
• 8.2 Removing
  179
• 8.3 Installing
  181
• 9 Renewing D-pillar reinforcement
  183
• 9.1 Tools
  184
• 9.2 Removing
  184
• 9.3 Installing
  187
• 10 Renewing side panel
  195
• 10.1 Tools
  196
• 10.2 Removing
  196
• 10.3 Installing
  200
• 11 Renewing side panel - part section
  205
• 11.1 Tools
  206
• 11.2 Removing
  206
• 11.3 Installing
  208
• 12 Renewing complete side panel
  212
• 12.1 Tools
  213
• 12.2 Removing
  213
• 12.3 Installing
  216
• 13 Renewing side panel beneath guide rail
  222
• 13.1 Tools
  223
• 13.2 Removing
  223
• 13.3 Installing
  224
• 14 Renewing rear side panel - part section, »Caddy Maxi«
  228
• 14.1 Tools
  229
• 14.2 Removing
  229
• 14.3 Installing
  231
• 15 Renewing side panel beneath guide rail »Caddy Maxi«
  236
• 15.1 Tools
  237
• 15.2 Removing
  237
• 15.3 Installing
  239
• 16 Renewing hinge pillar (A-pillar) - part section
  244
• 16.1 Tools
  244
• 16.2 Removing
  244
• 16.3 Installing
  249
• 17 Renewing roof side member reinforcement - part section
  253
• 17.1 Tools
  254
• 17.2 Removing
  254
• 17.3 Installing
  256
• 18 Renewing inner hinge pillar (A-pillar)
  261
• 18.1 Tools
  262
• 18.2 Removing
  262
• 18.3 Installing
  265
• 19 Renewing upper hinge pillar reinforcement
  270
• 19.1 Tools
  271
• 19.2 Removing
  271
• 19.3 Installing
  272
• 20 Renewing lower hinge pillar reinforcement - part section
  275
• 20.1 Tools
  275
• 20.2 Removing
  275
• 20.3 Installing
  277
• 21 Renewing middle pillar
  281
• 21.1 Tools
  282
• 21.2 Removing
  282
• 21.3 Installing
  284
• 22 Renewing centre pillar
  287
• 22.1 Tools
  287
• 22.2 Removing
  287
• 22.3 Installing
  290
• 23 Renewing side member (sliding door side)
  293
• 23.1 Overview of parting cuts »Caddy«
  293
• 23.2 Overview of parting cuts »Caddy Maxi«
  294
• 23.3 Tools
  295
• 23.4 Removing
  296
• 23.5 Installing
  297
• 24 Renewing side member reinforcement
  301
• 24.1 Tools
  302
• 24.2 Removing
  302
• 24.3 Installing
  303
• 25 Renewing inner side member reinforcement - part section
  307
• 25.1 Tools
  307
• 25.2 Removing
  307
• 25.3 Installing
  308
• 26 Renewing connecting piece for floor panel - part section
  310
• 26.1 Tools
  310
• 26.2 Removing
  311
• 26.3 Installing
  312
• Body - rear
  315
• 1 Notice for vehicle electrified by ABT e-Line
  315
• 2 Renewing rear cross panel
  316
• 2.1 Tools
  316
• 2.2 Removing
  316
• 2.3 Installing
  318
• 3 Renewing lock carrier
  321
• 3.1 Tools
  322
• 3.2 Removing
  322
• 3.3 Installing
  323
• 4 Renewing tail light mounting
  326
• 4.1 Tools
  326
• 4.2 Removing
  326
• 4.3 Installing
  328
• 5 Renewing rear cross member
  331
• 5.1 Tools
  331
• 5.2 Removing
  331
• 5.3 Installing
  333
• 6 Renewing luggage compartment floor - part section
  335
• 6.1 Tools
  336
• 6.2 Removing
  336
• 6.3 Installing
  338
• 7 Renewing D-pillar
  341
• 7.1 Tools
  342
• 7.2 Removing
  342
• 7.3 Installing
  343
• 8 Renewing bumper mounting
  346
• 8.1 Tools
  347
• 8.2 Removing
  347
• 8.3 Installing
  348
• 9 Renewing rear longitudinal member
  351
• 9.1 Tools
  352
• 9.2 Removing
  352
• 9.3 Installing
  353
• 10 Renewing leaf spring mounting bracket
  357
• 10.1 Removing
  357
• 10.2 Installing
  359
• 11 Renewing wheel housing liner
  363
• 11.1 Tools
  365
• 11.2 Removing
  365
• 11.3 Installing
  366
• 12 Renewing cross member
  370
• 12.1 Tools
  371
• 12.2 Removing
  371
• 12.3 Installing
  371