General body repairs, exterior

Chapter overview

• Body - front
  1
• 1 Lock carrier
  1
• 1.1 Assembly overview - lock carrier with attachments
  1
• 1.2 Removing and installing lock carrier with attachments
  2
• 2 Wing
  4
• 2.1 Assembly overview - front wing
  4
• 2.2 Removing and installing wing
  5
• 3 Maintenance flap
  7
• 3.1 Removing maintenance flap cover
  7
• Bonnet, rear lid
  8
• 1 Bonnet
  8
• 1.1 Assembly overview - bonnet with old type hinges
  8
• 1.2 Removing bonnet (with old type hinges)
  9
• 1.3 Installing and adjusting bonnet (with old type hinges)
  9
• 1.4 Retrofitting new type hinges
  10
• 1.5 Assembly overview - bonnet with new type hinges
  12
• 1.6 Removing bonnet (with new type hinges)
  13
• 1.7 Installing and adjusting bonnet (with new type hinges)
  14
• 1.8 Removing and installing air intake grille and radiator grille
  15
• 1.9 Assembly overview - bonnet lock release cable
  16
• 1.10 Removing and installing bonnet lock cable
  17
• Front doors, door components, central locking
  18
• 1 Front door
  18
• 1.1 Assembly overview - front door
  18
• 1.2 Removing front door
  19
• 1.3 Installing and adjusting front door
  20
• 1.4 Door arrester ▸ 03.98 and 03.98 ▸
  21
• 1.5 Removing and installing door arrester
  21
• 1.6 Retrofitting new type door arrester
  22
• 1.7 Removing and installing window regulator
  24
• 1.8 Removing and installing step insert
  24
• 1.9 Removing and installing door lock
  25
• 1.10 Assembly overview - door handle
  25
• 1.11 Removing and installing door handle
  26
• 1.12 Removing lock cylinder
  27
• 2 Central locking
  28
• 2.1 Assembly overview - central locking
  28
• 2.2 Function
  28
• 2.3 Removing and installing door lock and servomotor of front door
  29
• 2.4 Removing and installing central lock and remote control of sliding door
  30
• 2.5 Removing and installing door lock and servomotor of rear, right-hand hinged door
  33
• 2.6 Removing and installing central locking control unit
  34
• 3 Radio remote control for central locking
  36
• 3.1 Removing and installing pocket sender battery for radio remote control
  36
• 3.2 Adapting pocket sender
  37
• Rear doors, door components
  41
• 1 Sliding door
  41
• 1.1 Assembly overview - sliding door
  41
• 1.2 Removing sliding door
  42
• 1.3 Adjusting sliding door
  43
• 1.4 Removing central lock and remote control
  46
• 1.5 Removing door handle
  48
• 1.6 Removing lock cylinder
  50
• 1.7 Removing and installing step insert
  50
• 1.8 Assembly overview - guide rail
  51
• 1.9 Removing and installing guide rail
  52
• 2 Rear left-hand hinged door (high roof)
  53
• 2.1 Tools
  53
• 2.2 Assembly overview - rear left-hand hinged door (high roof)
  53
• 2.3 Removing and installing rear wing door
  55
• 2.4 Adjusting rear hinged doors
  55
• 2.5 Removing and installing door lock
  57
• 2.6 Removing lock rod
  58
• 2.7 Removing and installing magnetic door arrester
  59
• 2.8 Removing and installing magnetic door arrester 2000 >
  60
• 3 Rear right-hand hinged door (high roof)
  62
• 3.1 Tools
  62
• 3.2 Assembly overview - rear right-hand hinged door (high roof)
  62
• 3.3 Removing and installing inner door handle
  64
• 3.4 Removing door lock
  65
• 3.5 Removing door handle
  66
• 3.6 Removing lock cylinder
  66
• 4 Side hinged door
  67
• 4.1 Assembly overview - side hinged door
  67
• 4.2 Removing and installing side wing door
  68
• 4.3 Installing and adjusting side hinged door
  68
• 4.4 Removing and installing step insert
  70
• 4.5 Removing and installing inner door handle
  71
• 4.6 Removing and installing door lock
  71
• 4.7 Removing and installing door arrester
  72
• 4.8 Removing door handle
  73
• 4.9 Removing lock cylinder
  73
• Sunroof
  74
• 1 Sunroof with glass panel
  74
• Convertible roof, hardtop, canopy
  75
• 1 Three-way tipper
  75
• 1.1 Safety precautions when working on three-way tipper
  75
• 1.2 Assembly overview - three-way tipper
  76
• 1.3 Assembly overview - electrohydraulic power unit
  78
• 1.4 Function
  78
• 1.5 Hydraulic flow diagram
  79
• 1.6 Rules for cleanliness
  80
• 1.7 Removing and installing high pressure hose
  80
• 1.8 Identification of high pressure hose
  80
• 1.9 Removing and installing electrohydraulic power unit
  81
• 1.10 Removing and installing multi-piston hydraulic cylinder
  81
• 1.11 Shutoff cable of tipping mechanism limit switch F 239
  83
• 1.12 Fault finding
  84
• Bumpers
  87
• 1 Front bumper
  87
• 1.1 Assembly overview - front bumper
  87
• 1.2 Assembly overview - securing elements
  88
• 2 Rear bumper
  89
• 2.1 Assembly overview - rear bumper
  89
• 2.2 Removing and installing rear bumper
  90
• Glazing
  91
• 1 Flush bonded windows
  91
• 1.1 Tools
  91
• 1.2 Materials
  93
• 1.3 Assembly overview - windscreen
  93
• 1.4 Removing windscreen
  94
• 1.5 Installing windscreen
  95
• 1.6 Assembly overview - rear window
  95
• 1.7 Removing rear window
  96
• 1.8 Removing damaged rear window
  97
• 1.9 Installing rear window
  97
• 1.10 Preparing old undamaged window for glazing
  97
• 1.11 Preparing new window for glazing
  97
• 1.12 Preparing body flange for glazing
  98
• 1.13 Installation instructions
  99
• 1.14 Curing time
  100
• 1.15 Touching up paint damage
  100
• 1.16 Cleaning off excess adhesive sealing material
  100
• 2 Door windows
  101
• 2.1 Removing door windows
  101
• Exterior equipment
  102
• 1 Exterior mirror
  102
• 1.1 Assembly overview - exterior mirror
  102
• 1.2 Removing and installing mirror glass
  103
• 1.3 Removing and installing mirror housing (electric adjustment)
  103
• 1.4 Removing mirror triangle cover cap
  104
• 1.5 Panorama mirror
  105
• 2 Decorative trim
  107
• 2.1 Tools
  107
• 2.2 Attachment notes for lettering
  107
• 2.3 Fitting side lettering
  107
• 3 Spare wheel carrier
  110
• 3.1 Tools
  110
• 3.2 Spare wheel carrier
  110