Body Repairs

Chapter overview

• Technical data
  1
• 1 Basic instructions
  1
• 1.1 Original joint
  1
• 1.2 Used joining techniques
  1
• 2 Key vehicle data
  3
• 2.1 Vehicle identification number
  3
• 2.2 Type plate
  5
• 2.3 Vehicle data sticker
  6
• 3 Safety information
  7
• 4 Moulded foam inserts
  8
• 5 Galvanised body parts
  10
• 6 Strengthened steel body panels
  11
• 6.1 Floor group
  11
• 6.2 Installing
  12
• 7 Laser welding
  13
• 8 Gaps/shut lines
  14
• 8.1 Body, front
  14
• 8.2 Body - centre and rear
  15
• 8.3 Rear body with rear wing doors
  16
• 9 Body dimensions
  17
• 9.1 Body dimensions, front
  17
• 9.2 Body dimensions - centre
  21
• 9.3 Body - rear
  26
• 9.4 Floor panel - front
  28
• 9.5 Floor panel - centre
  29
• 9.6 Floor panel - rear
  30
• 10 Alignment bracket set
  31
• 10.1 Overview
  31
• 11 Portal gauge
  44
• 11.1 Overview
  44
• Body - front
  48
• 1 Renewing suspension turret
  48
• 1.1 Tools
  49
• 1.2 Removing
  49
• 1.3 Installing
  52
• 2 Renewing battery carrier
  58
• 2.1 Tools
  58
• 2.2 Removing
  58
• 2.3 Installing
  60
• 3 Renewing towing eye mounting
  63
• 3.1 Tools
  64
• 3.2 Removing
  64
• 3.3 Installing
  65
• 4 Replacing intermediate piece/end plate for front wheel housing
  70
• 4.1 Tools
  70
• 4.2 Removing
  70
• 4.3 Installing
  71
• 5 Renewing bumper bracket
  73
• 5.1 Tools
  73
• 5.2 Removing
  73
• 5.3 Installing
  74
• 6 Renewing reinforcement for front wheel housing (part section)
  77
• 6.1 Tools
  77
• 6.2 Removing
  77
• 6.3 Installing
  78
• 7 Renewing front wheel housing
  80
• 7.1 Tools
  81
• 7.2 Removing
  81
• 7.3 Installing
  82
• 8 Repairing threads for securing subframe
  85
• 8.1 Contents of thread repair kit
  86
• 8.2 Repairing threads
  86
• 9 Renewing front part of longitudinal member (part section)
  90
• 9.1 Tools
  90
• 9.2 Removing
  90
• 9.3 Installing
  92
• 10 Renewing front rigger
  95
• 10.1 Tools
  95
• 10.2 Removing
  95
• 10.3 Installing
  96
• Body - centre
  99
• 1 Renewing high roof
  99
• 1.1 Removing
  99
• 1.2 Installing
  109
• 2 Renewing roof
  114
• 2.1 Tools
  115
• 2.2 Removing
  115
• 2.3 Installing
  119
• 3 Renewing roof (double cab)
  125
• 3.1 Tools
  126
• 3.2 Removing
  126
• 3.3 Installing
  128
• 4 Renewing front cross member for roof
  132
• 4.1 Tools
  132
• 4.2 Removing
  132
• 4.3 Installing
  133
• 5 Renewing roof reinforcement
  136
• 5.1 Tools
  136
• 5.2 Removing
  136
• 5.3 Installing
  137
• 6 Renewing rear roof cross member (double cab)
  140
• 6.1 Tools
  140
• 6.2 Removing
  140
• 6.3 Installing
  142
• 7 Renewing rear roof cross member
  144
• 7.1 Tools
  145
• 7.2 Removing
  145
• 7.3 Installing
  147
• 8 Renewing rear window frame (single and double cab)
  150
• 8.1 Tools
  151
• 8.2 Removing
  151
• 8.3 Installing
  153
• 9 Renewal of cross member (single and double cab)
  156
• 9.1 Tools
  156
• 9.2 Removing
  156
• 9.3 Installing
  158
• 10 Renewing front outer side section
  159
• 10.1 Tools
  160
• 10.2 Removing
  160
• 10.3 Installing
  163
• 11 Renewing rear outer side panel (double cab)
  169
• 11.1 Tools
  170
• 11.2 Removing
  170
• 11.3 Installing
  173
• 12 Renewing outer side panel completely (panel van)
  179
• 12.1 Tools
  180
• 12.2 Removing
  180
• 12.3 Installing
  184
• 13 Renewing outer side panel (window aperture of Kombi)
  189
• 13.1 Tools
  190
• 13.2 Removing
  190
• 13.3 Installing
  193
• 14 Renewing outer side panel (rear part section - Kombi)
  198
• 14.1 Tools
  199
• 14.2 Removing
  199
• 14.3 Installing
  201
• 15 Renewing side panel (part section, panel van and Kombi)
  207
• 15.1 Tools
  207
• 15.2 Removing
  207
• 15.3 Installing
  209
• 16 Renewing side panel on sliding door side (part section - Kombi)
  211
• 16.1 Tools
  212
• 16.2 Removing
  212
• 16.3 Installing
  213
• 17 Renewing outer side panel on sliding door side (part section, panel van)
  217
• 17.1 Tools
  218
• 17.2 Removing
  218
• 17.3 Installing
  221
• 18.1 Tools
  229
• 18.2 Removing
  229
• 18.3 Installing
  232
• 19 Renewing hinge pillar
  236
• 19.1 Tools
  237
• 19.2 Removing
  237
• 19.3 Installing
  239
• 20 Renewing reinforcement for hinge pillar (part section)
  242
• 20.1 Tools
  243
• 20.2 Removing
  243
• 20.3 Installing
  244
• 21 Renewing lock column, single cab
  248
• 21.1 Tools
  249
• 21.2 Removing
  249
• 21.3 Installing
  252
• 22 Renewing C-pillar (part section - double cab)
  257
• 22.1 Tools
  258
• 22.2 Removing
  258
• 22.3 Installing
  259
• 23 Renewing front step
  262
• 23.1 Tools
  263
• 23.2 Removing
  264
• 23.3 Installing
  266
• 24 Renewing rear step
  271
• 24.1 Tools
  272
• 24.2 Removing
  272
• 24.3 Installing
  276
• 25 Renewing rear step (double cab)
  281
• 25.1 Tools
  281
• 25.2 Removing
  281
• 25.3 Installing
  283
• 26 Renewing middle pillar (part section)
  287
• 26.1 Tools
  288
• 26.2 Removing
  288
• 26.3 Installing
  290
• 27 Renewing reinforcing for middle pillar
  294
• 27.1 Tools
  295
• 27.2 Removing
  295
• 27.3 Installing
  297
• 28 Renewing lower guide rail for sliding door
  300
• 28.1 Tools
  300
• 28.2 Removing
  300
• 28.3 Installing
  301
• 29 Renewing outer side member
  304
• 29.1 Tools
  305
• 29.2 Removing
  305
• 29.3 Installing
  306
• 30 Renewing centre section of side member (part section, double cab)
  308
• 30.1 Tools
  309
• 30.2 Removing
  309
• 30.3 Installing
  310
• 31 Renewing front side member reinforcement
  312
• 31.1 Tools
  313
• 31.2 Removing
  313
• 31.3 Installing
  314
• 32 Renewing gusset plate for roof side member
  316
• 32.1 Tools
  316
• 32.2 Removing
  316
• 32.3 Installing
  318
• 33 Renewing C-pillar reinforcement (part section, double cab)
  321
• 33.1 Tools
  322
• 33.2 Removing
  322
• 33.3 Installing
  323
• 34 Renewing C-pillar reinforcement (part section, Kombi)
  326
• 34.1 Tools
  327
• 34.2 Removing
  327
• 34.3 Installing
  329
• 35 Renewing floor panel (double cab)
  333
• 35.1 Tools
  334
• 35.2 Removing
  334
• 35.3 Installing
  335
• 36 Renewing threaded nut for fastening ring
  338
• 36.1 Tools
  339
• 36.2 Removing
  339
• 36.3 Installing
  340
• 37 Renewing centre floor panel
  343
• 37.1 Tools
  344
• 37.2 Removing
  344
• 37.3 Installing
  345
• 38 Renewing fastening ring for cargo bed
  348
• 38.1 Tools
  349
• 38.2 Removing
  349
• 38.3 Installing
  350
• 39 Renewing studs
  353
• Body - rear
  355
• 1 Renewing lower corner reinforcement
  355
• 1.1 Tools
  355
• 1.2 Removing
  355
• 1.3 Installing
  357
• 2 Renewing lock carrier
  359
• 2.1 Tools
  359
• 2.2 Removing
  359
• 2.3 Installing
  361
• 3 Renewing tail light mounting
  364
• 3.1 Tools
  364
• 3.2 Removing
  364
• 3.3 Installing
  366
• 4 Renewing cross panel member
  367
• 4.1 Tools
  367
• 4.2 Removing
  367
• 4.3 Installing
  368
• 5 Renewing rear part of luggage compartment floor
  371
• 5.1 Tools
  372
• 5.2 Removing
  372
• 5.3 Installing
  374
• 6 Renewing D-pillar reinforcement (part section)
  377
• 6.1 Tools
  378
• 6.2 Removing
  378
• 6.3 Installing
  379
• 7 Renewing D-pillar reinforcement
  382
• 7.1 Tools
  383
• 7.2 Removing
  383
• 7.3 Installing
  385
• 8 Renewal of rear cross panel member (single and double cab)
  390
• 8.1 Tools
  390
• 8.2 Removing
  390
• 8.3 Installing
  392
• 9 Renewing rear longitudinal member (part section, panel van and Kombi)
  394
• 9.1 Tools
  394
• 9.2 Removing
  394
• 9.3 Installing
  398
• 10 Renewal of rear longitudinal member (single and double cab)
  406
• 10.1 Tools
  406
• 10.2 Removing
  406
• 10.3 Installing
  408
• 11 Renewing rear outer wheel housing liner
  413
• 11.1 Tools
  414
• 11.2 Removing
  414
• 11.3 Installing
  416
• 12 Renewing cross member (double cab/dropside vehicle)
  418
• 12.1 Tools
  419
• 12.2 Removing
  419
• 12.3 Installing
  420