Body Repairs

Chapter overview

• Technical data
  1
• 1 Key vehicle data
  1
• 1.1 Vehicle identification number
  1
• 1.2 Type plate
  3
• 1.3 Vehicle data sticker
  4
• 2 Safety information
  5
• 3 Moulded foam inserts
  6
• 4 Galvanised body parts
  8
• 5 Strengthened steel body panels
  9
• 5.1 Platform
  9
• 5.2 Vehicle body
  10
• 6 Laser welding
  11
• 7 Tools
  12
• 8 Gaps/shut lines
  13
• 8.1 Body, front
  13
• 8.2 Body, centre
  18
• 8.3 Body - rear
  18
• 9 Body dimensions
  21
• 9.1 Body dimensions, front
  21
• 9.2 Body dimensions - centre
  22
• 9.3 Body - rear
  28
• 9.4 Floor panel - front
  30
• 9.5 Floor panel - centre
  31
• 9.6 Floor panel - rear
  32
• 10 Alignment bracket set
  33
• 10.1 Overview
  33
• 11 Portal gauge
  46
• 11.1 Overview
  46
• Body - front
  50
• 1 Renewing suspension turret
  50
• 1.1 Removing
  51
• 1.2 Installing
  54
• 2 Renewing battery carrier
  59
• 2.1 Removing
  59
• 2.2 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 Removing
  70
• 4.2 Installing
  71
• 5 Renewing front bumper bracket
  72
• 5.1 Removing
  72
• 5.2 Installing
  73
• 6 Renewing reinforcement for front wheel housing (part section)
  76
• 6.1 Removing
  76
• 6.2 Installing
  77
• 7 Renewing front wheel housing
  79
• 7.1 Removing
  80
• 7.2 Installing
  81
• 8 Repairing threads for securing subframe
  86
• 8.1 Contents of thread repair kit
  87
• 8.2 Repairing threads
  87
• 9 Renewing front part of longitudinal member (part section)
  91
• 9.1 Removing
  91
• 9.2 Installing
  93
• 10 Renewing front rigger
  95
• 10.1 Removing
  95
• 10.2 Installing
  96
• Body - centre
  99
• 1 Renewing roof
  99
• 1.1 Removing
  100
• 1.2 Installing
  103
• 2 Renewing roof (double cab)
  109
• 2.1 Removing
  110
• 2.2 Installing
  112
• 3 Renewing front cross member for roof
  116
• 3.1 Removing
  116
• 3.2 Installing
  117
• 4 Renewing roof reinforcement
  120
• 4.1 Removing
  120
• 4.2 Installing
  121
• 5 Renewing rear roof cross member (double cab)
  124
• 5.1 Removing
  124
• 5.2 Installing
  125
• 6 Renewing rear roof cross member
  128
• 6.1 Tools
  129
• 6.2 Removing
  129
• 6.3 Installing
  131
• 7 Renewing rear window frame (single and double cab)
  134
• 7.1 Tools
  135
• 7.2 Removing
  135
• 7.3 Installing
  137
• 8 Renewal of cross member (single and double cab)
  140
• 8.1 Tools
  140
• 8.2 Removing
  140
• 8.3 Installing
  142
• 9 Renewing front outer side section
  143
• 9.1 Removing
  144
• 9.2 Installing
  146
• 10 Renewing rear outer side panel (double cab)
  152
• 10.1 Tools
  153
• 10.2 Removing
  153
• 10.3 Installing
  156
• 11 Renewing outer side panel completely (panel van)
  162
• 11.1 Tools
  163
• 11.2 Removing
  163
• 11.3 Installing
  167
• 12.1 Tools
  173
• 12.2 Removing
  173
• 12.3 Installing
  176
• 13 Renewing outer side panel, rear part section (closed body versions)
  181
• 13.1 Tools
  182
• 13.2 Removing
  182
• 13.3 Installing
  184
• 14 Renewing side panel, part section (closed body versions)
  190
• 14.1 Tools
  190
• 14.2 Removing
  190
• 14.3 Installing
  192
• 15.1 Tools
  195
• 15.2 Removing
  195
• 15.3 Installing
  196
• 16 Renewing outer side panel on sliding door side (part section, panel van)
  200
• 16.1 Tools
  201
• 16.2 Removing
  201
• 16.3 Installing
  204
• 17 Renewing outer side panel – sliding door side, part section (closed body versions)
  211
• 17.1 Tools
  212
• 17.2 Removing
  212
• 17.3 Installing
  215
• 18 Renewing hinge pillar
  219
• 18.1 Tools
  220
• 18.2 Removing
  220
• 18.3 Installing
  222
• 19 Renewing reinforcement for hinge pillar (part section)
  225
• 19.1 Tools
  226
• 19.2 Removing
  226
• 19.3 Installing
  227
• 20 Renewing lock column, single cab
  231
• 20.1 Tools
  232
• 20.2 Removing
  232
• 20.3 Installing
  235
• 21 Renewing C-pillar (part section - double cab)
  240
• 21.1 Tools
  241
• 21.2 Removing
  241
• 21.3 Installing
  242
• 22 Renewing front step
  245
• 22.1 Tools
  246
• 22.2 Removing
  246
• 22.3 Installing
  248
• 23 Renewing rear step
  253
• 23.1 Tools
  254
• 23.2 Removing
  254
• 23.3 Installing
  258
• 24 Renewing rear step (double cab)
  263
• 24.1 Tools
  263
• 24.2 Removing
  263
• 24.3 Installing
  265
• 25 Renewing middle pillar (part section)
  269
• 25.1 Tools
  270
• 25.2 Removing
  270
• 25.3 Installing
  272
• 26 Renewing reinforcement for centre pillar
  276
• 26.1 Tools
  277
• 26.2 Removing
  277
• 26.3 Installing
  279
• 27 Renewing lower guide rail for sliding door
  282
• 27.1 Tools
  282
• 27.2 Removing
  282
• 27.3 Installing
  283
• 28 Renewing outer side member
  286
• 28.1 Tools
  287
• 28.2 Removing
  287
• 28.3 Installing
  288
• 29 Renewing centre section of side member (part section, double cab)
  290
• 29.1 Tools
  291
• 29.2 Removing
  291
• 29.3 Installing
  292
• 30 Renewing front side member reinforcement
  294
• 30.1 Tools
  295
• 30.2 Removing
  295
• 30.3 Installing
  296
• 31 Renewing gusset plate for roof side member
  298
• 31.1 Tools
  298
• 31.2 Removing
  298
• 31.3 Installing
  300
• 32 Renewing C-pillar reinforcement (part section, double cab)
  303
• 32.1 Tools
  304
• 32.2 Removing
  304
• 32.3 Installing
  305
• 33 Renewing C-pillar reinforcement, part section (closed body versions)
  308
• 33.1 Tools
  309
• 33.2 Removing
  309
• 33.3 Installing
  311
• 34 Renewing floor panel (double cab)
  315
• 34.1 Tools
  316
• 34.2 Removing
  316
• 34.3 Installing
  317
• 35 Renewing threaded nut for fastening ring
  320
• 35.1 Tools
  321
• 35.2 Removing
  321
• 35.3 Installing
  322
• 36 Renewing centre floor panel
  325
• 36.1 Tools
  326
• 36.2 Removing
  326
• 36.3 Installing
  327
• 37 Renewing fastening ring for cargo bed
  330
• 37.1 Tools
  331
• 37.2 Removing
  331
• 37.3 Installing
  332
• 38 Renewing studs
  335
• Body - rear
  337
• 1 Renewing lower corner reinforcement
  337
• 1.1 Tools
  337
• 1.2 Removing
  337
• 1.3 Installing
  339
• 2 Renewing lock carrier
  341
• 2.1 Tools
  341
• 2.2 Removing
  341
• 2.3 Installing
  342
• 3 Renewing tail light mounting
  345
• 3.1 Tools
  345
• 3.2 Removing
  345
• 3.3 Installing
  346
• 4 Renewing cross panel member
  348
• 4.1 Tools
  348
• 4.2 Removing
  348
• 4.3 Installing
  349
• 5 Renewing rear part of luggage compartment floor
  352
• 5.1 Tools
  353
• 5.2 Removing
  353
• 5.3 Installing
  355
• 6 Renewing D-pillar reinforcement (part section)
  358
• 6.1 Tools
  359
• 6.2 Removing
  359
• 6.3 Installing
  360
• 7 Renewing D-pillar reinforcement
  363
• 7.1 Tools
  364
• 7.2 Removing
  364
• 7.3 Installing
  366
• 8 Renewal of rear cross panel member (single and double cab)
  371
• 8.1 Tools
  371
• 8.2 Removing
  371
• 8.3 Installing
  373
• 9 Renewing rear longitudinal member, part section (closed body versions)
  375
• 9.1 Tools
  375
• 9.2 Removing
  375
• 9.3 Installing
  379
• 10 Renewal of rear longitudinal member (single and double cab)
  387
• 10.1 Tools
  387
• 10.2 Removing
  387
• 10.3 Installing
  389
• 11 Renewing rear outer wheel housing liner
  394
• 11.1 Tools
  395
• 11.2 Removing
  395
• 11.3 Installing
  397
• 12 Renewing cross member (double cab/dropside vehicle)
  399
• 12.1 Tools
  400
• 12.2 Removing
  400
• 12.3 Installing
  401