General body repairs, exterior

Chapter overview

• Body - front
  1
• 1 Lock carrier
  1
• 1.1 Tools
  1
• 1.2 Lock carrier - add-on parts
  1
• 1.3 Service position
  5
• 1.4 Removing and installing lock carrier with attachments
  8
• 1.5 Removing and installing pressure hoses
  11
• 2 Wings
  14
• 2.1 Tools
  14
• 2.2 Assembly overview - front wing
  14
• 2.3 Removing and installing front wing
  15
• 2.4 Insulation and foam elements for wing and wing end plate
  18
• 2.5 Wing end plate
  18
• 2.6 Removing and installing wing bracket
  19
• 3 Plenum chamber cover
  21
• 3.1 Assembly overview - plenum chamber cover
  21
• 3.2 Removing and installing plenum chamber covers
  21
• 4 Underbody cladding
  25
• 4.1 Tools
  25
• 4.2 Assembly overview - underbody cladding
  25
• 4.3 Rear right underbody cladding
  26
• 5 Bulkhead
  28
• 5.1 Tools
  28
• 5.2 Materials
  28
• 5.3 Assembly overview - bulkhead
  29
• 6 Tunnel cross-piece
  30
• 6.1 Tools
  30
• 6.2 Assembly overview - tunnel cross-piece
  30
• Bonnet, rear lid
  32
• 1 Bonnet
  32
• 1.1 Tools
  32
• 1.2 Assembly overview - bonnet
  32
• 1.3 Removing and installing bonnet
  33
• 1.4 Removing and installing bonnet hinge
  35
• 1.5 Removing and installing insulation
  37
• 1.6 Assembly overview - seals
  39
• 1.7 Removing and installing bonnet stay
  40
• 1.8 Assembly overview - bonnet lock and release components
  42
• 1.9 Removing and installing bonnet lock
  43
• 1.10 Removing and installing Bowden cable
  46
• 1.11 Removing and installing striker pin
  47
• 1.12 Removing and installing release lever
  49
• 1.13 Adjusting bonnet
  52
• 2 Rear lid
  55
• 2.1 Tools
  55
• 2.2 Assembly overview - rear lid
  55
• 2.3 Removing and installing rear lid
  56
• 2.4 Assembly overview - gas strut
  57
• 2.5 Removing and installing gas strut
  58
• 2.6 Releasing gas from gas strut
  60
• 2.7 Assembly overview - rear lid hinge
  61
• 2.8 Removing and installing rear lid hinge
  62
• 2.9 Removing and installing hinge covers
  63
• 2.10 Removing and installing striker plate
  65
• 2.11 Adjusting rear lid
  66
• 2.12 Removing and installing rear lid handle release button E234
  67
• 2.13 Removing and installing bonnet lock
  68
• 2.14 Rear lid seal
  70
• 2.15 Removing and installing rear lid seal
  71
• 2.16 Number plate carrier
  72
• 3 Tank flap unit
  74
• 3.1 Tools
  74
• 3.2 Assembly overview - tank flap unit
  74
• 3.3 Removing and installing tank flap unit
  75
• 3.4 Removing and installing tank filler flap locking motor V155
  78
• Front doors, door components, central locking
  80
• 1 Rear door
  80
• 1.1 Tools
  80
• 1.2 Assembly overview - door hinges
  81
• 1.3 Removing and installing door
  83
• 1.4 Installing after renewing A-pillar
  85
• 1.5 Door alignment
  86
• 2 Door components
  89
• 2.1 Tools
  89
• 2.2 Assembly overview - front door
  89
• 2.3 Removing and installing door cover
  91
• 2.4 Removing and installing door retaining strap
  93
• 2.5 Removing and installing striker pin
  94
• 2.6 Assembly overview - door handle and door lock
  95
• 2.7 Removing and installing lock cylinder cover cap
  97
• 2.8 Removing and installing lock cylinder
  98
• 2.9 Removing and installing cover cap (without lock cylinder)
  101
• 2.10 Removing and installing door handle
  104
• 2.11 Removing and installing door lock
  106
• 2.12 Removing and installing mounting bracket
  109
• 2.13 Removing and installing inner window slot seal
  111
• 2.14 Removing and installing outer window slot seal
  114
• 2.15 Removing and installing inner door seal
  115
• 2.16 Removing and installing outer door seal
  118
• 2.17 Assembly overview - insulation
  119
• 3 Central locking
  121
• 3.1 Fitting location overview - central locking components
  121
• 3.2 Adapting keys with remote control
  123
• 3.3 Assembly overview - battery for folding key with remote control
  123
• 3.4 Removing and installing battery for folding key with remote control
  124
• 3.5 Assembly overview - battery for folding key with cover cap
  126
• 3.6 Removing and installing battery for folding key with cover cap
  127
• Rear doors, door components
  129
• 1 Rear door
  129
• 1.1 Tools
  129
• 1.2 Assembly overview - door hinges
  130
• 1.3 Removing and installing door
  132
• 1.4 Installing after renewing B-pillar
  134
• 1.5 Door alignment
  135
• 2 Door components
  137
• 2.1 Tools
  137
• 2.2 Assembly overview - rear door
  137
• 2.3 Removing and installing cover
  139
• 2.4 Removing and installing door retaining strap
  141
• 2.5 Removing and installing striker pin
  142
• 2.6 Assembly overview - door handle and door lock
  143
• 2.7 Removing and installing cap
  144
• 2.8 Removing and installing door handle
  147
• 2.9 Removing and installing door lock
  149
• 2.10 Removing and installing mounting bracket
  152
• 2.11 Removing and installing inner window slot seal
  154
• 2.12 Removing and installing outer window slot seal
  156
• 2.13 Removing and installing inner door seal
  159
• 2.14 Removing and installing outer door seal
  162
• 2.15 Assembly overview - insulation
  164
• Sunroof
  166
• 1 Sunroof with glass panel
  166
• 1.1 Tools
  166
• 1.2 Functional check
  166
• 1.3 Assembly overview
  167
• 1.4 Removing and installing sliding/tilting sunroof glass panel
  169
• 1.5 Height-adjustment of glass panel
  170
• 1.6 Checking parallel running of glass panel
  172
• 1.7 Adjusting parallel running of glass panel
  173
• 1.8 Renewing panel seal
  173
• 1.9 Removing and installing wind deflector
  174
• 1.10 Removing and installing sliding headliner
  175
• 1.11 Removing and installing sliding/tilting sunroof drive
  176
• 1.12 Setting drive for sliding/tilting sunroof to zero position
  177
• 1.13 Performing programming run for drive for sliding/tilting sunroof
  177
• 1.14 Removing pre-selector control for sliding/tilting sunroof
  178
• 1.15 Removing and installing carrier unit
  178
• 1.16 Cleaning water drain hoses
  181
• Bumpers
  183
• 1 Front bumper cover
  183
• 1.1 Tools
  183
• 1.2 Repairing front bumper cover
  183
• 1.3 Installing brackets for parking aid system
  183
• 1.4 Assembly overview - front bumper cover
  188
• 1.5 Removing and installing front bumper cover
  189
• 1.6 Front bumper cover add-on parts
  191
• 1.7 Installing front number plate carrier
  192
• 1.8 Assembly overview - guides for front bumper cover
  193
• 1.9 Assembly overview - front bumper carrier
  194
• 2 Rear bumper cover
  196
• 2.1 Tools
  196
• 2.2 Repairing rear bumper cover
  196
• 2.3 Installing brackets for parking aid system
  196
• 2.4 Assembly overview - rear bumper cover
  201
• 2.5 Removing and installing rear bumper cover
  202
• 2.6 Assembly overview - guides for rear bumper cover
  204
• 2.7 Assembly overview - rear bumper carrier
  204
• 2.8 Assembly overview - towing bracket
  205
• Glazing
  207
• 1 Flush bonded windows
  207
• 1.1 Tools
  207
• 1.2 Materials
  208
• 1.3 Repairing windscreen
  209
• 1.4 Assembly overview - windscreen
  209
• 1.5 Remove windscreen
  210
• 1.6 Install windscreen
  212
• 1.7 Assembly overview - rear window
  212
• 1.8 Removing undamaged rear window
  213
• 1.9 Removing broken rear window
  215
• 1.10 Installing rear window
  215
• 1.11 Preparing old undamaged window for glazing
  216
• 1.12 Preparing new window without precoating for glazing
  217
• 1.13 Preparing body flange for glazing
  217
• 1.14 Fitting instructions
  218
• 1.15 Minimum curing period
  219
• 1.16 Touching up paint damage
  220
• 1.17 Removing soiling caused by adhesive sealant
  220
• 2 Front door window
  221
• 2.1 Tools
  221
• 2.2 Assembly overview - front door window
  221
• 2.3 Removing and installing door window
  222
• 2.4 Removing and installing window regulator motor
  228
• 2.5 Removing and installing window regulator
  234
• 2.6 Removing and installing window channel
  236
• 3 Rear door window
  239
• 3.1 Tools
  239
• 3.2 Assembly overview - rear door windows
  239
• 3.3 Removing and installing door window
  240
• 3.4 Removing and installing window regulator motor
  244
• 3.5 Removing and installing window regulator
  249
• 3.6 Removing and installing window channel
  251
• 3.7 Removing and installing fixed door-window
  253
• Exterior equipment
  257
• 1 Wheel housing liner
  257
• 1.1 Tools
  257
• 1.2 Assembly overview - front wheel housing liner
  257
• 1.3 Removing and installing front wheel housing liner
  258
• 1.4 Assembly overview - rear wheel housing liner
  260
• 1.5 Removing and installing rear wheel housing liner
  261
• 2 Exterior mirror
  265
• 2.1 Tools
  265
• 2.2 Assembly overview - exterior mirror (manual operation)
  265
• 2.4 Assembly overview - exterior mirror, electrically operated, with turn signal repeater
  267
• 2.5 Removing and installing mirror glass
  269
• 2.6 Removing and installing exterior mirror trim, without turn signal repeater
  270
• 2.7 Removing and installing exterior mirror trim, with turn signal repeater
  272
• 2.8 Removing and installing exterior mirror housing, without turn signal repeater
  274
• 2.9 Removing and installing exterior mirror housing, with turn signal repeater
  275
• 2.10 Removing and installing adjustment unit with motor for exterior mirror
  277
• 2.11 Removing and installing assembly bracket
  280
• 2.12 Removing and installing exterior mirror (manual operation)
  281
• 2.13 Removing and installing exterior mirror (electrical operation)
  285
• 3 Radiator grille
  290
• 3.1 Tools
  290
• 3.2 Removing and installing radiator grille
  290
• 3.3 Removing and installing emblem
  292
• 4 Rear spoiler
  297
• 4.1 Removing and installing rear spoiler
  297
• 5 Mouldings and trims
  304
• 5.1 Water deflector
  304
• 5.2 Assembly overview - side member cover
  308
• 5.3 Assembly overview - B-pillar trim
  309
• 5.4 Removing and installing B-pillar trim
  310
• 5.5 Side member extension
  312
• 6 Lettering
  317
• 6.1 Tools
  317
• 6.2 Installation instructions for lettering and emblems
  317
• 6.3 Dimensions - lettering on rear lid
  318
• 6.4 Dimensions - lettering on wing
  320
• 7 Noise insulation
  322
• 7.1 Assembly overview - noise insulation
  322
• 7.2 Removing and installing noise insulation
  324