General body repairs, exterior

Chapter overview

• Body - front
  1
• 1 Lock carrier
  1
• 1.1 Assembly overview – lock carrier
  1
• 1.2 Removing and installing lock carrier
  4
• 2 Wings
  9
• 2.1 Assembly overview – wing
  9
• 2.2 Removing and installing wing
  10
• 3 Plenum chamber bulkhead
  15
• 3.1 Assembly overview – plenum chamber cover
  15
• 3.2 Removing and installing plenum chamber cover
  15
• Body - centre
  18
• 1 Removing and installing ladder frame
  18
• 1.1 General notes; Body repairs, General body repairs
  18
• 1.2 Assembly overview - ladder frame
  18
• 1.3 Installing holder for ABS hydraulic unit N55 with ABS control unit J104
  20
• 1.4 Removing and installing rear cross member
  22
• 1.5 Installing spare wheel bracket
  23
• 1.6 Installing brake lines
  24
• 1.7 Installing fuel lines
  25
• Bonnet, rear lid
  28
• 1 Bonnet
  28
• 1.1 Assembly overview – bonnet
  28
• 1.2 Assembly overview – Bowden cable
  29
• 1.3 Removing and installing bonnet
  30
• 1.4 Adjusting bonnet
  32
• 1.5 Removing and installing rear lid lock
  36
• 1.6 Removing and installing bonnet release lever
  39
• 1.7 Removing and installing striker pin
  39
• 1.8 Removing and installing hinges
  40
• 1.9 Removing and installing insulation
  42
• 1.10 Removing and installing Bowden cable
  43
• 1.11 Removing and installing bonnet stay
  44
• 2 Rear lid
  46
• 2.1 Assembly overview - add-on parts on tailgate
  46
• 2.2 Assembly overview - tailgate with torsion bar
  47
• 2.3 Assembly overview - hinge
  48
• 2.4 Assembly overview - tailgate lock
  49
• 2.5 Assembly overview - tailgate handle
  50
• 2.6 Assembly overview - arrester cable, tailgate
  53
• 2.7 Assembly overview - tailgate spacer
  54
• 2.8 Assembly overview - tailgate seals
  55
• 2.9 Removing and installing charging flap
  55
• 2.10 Adjusting tailgate
  57
• 2.11 Removing and installing hinge
  58
• 2.12 Removing and installing tailgate lock
  59
• 2.13 Removing and installing tailgate handle
  61
• 2.14 Removing and installing striker plate
  66
• 2.15 Removing and installing torsion bar
  68
• 3 Load bed
  70
• 3.1 Assembly overview - load bed
  70
• 3.2 Assembly overview - load bed add-on parts
  70
• 3.3 Assembly overview - fastening rings
  71
• 3.4 Removing and installing load bed
  73
• 3.5 Removing and installing cross member buffer
  75
• 4 Cab
  76
• 4.1 Assembly overview - cab
  76
• 4.2 Assembly overview - front mountings, cab
  77
• 4.3 Assembly overview - centre mountings, cab
  78
• 4.4 Assembly overview - rear mountings, cab
  79
• 4.5 Assembly overview - retaining strap, cab
  81
• 4.6 Removing and installing cab
  82
• 4.7 Removing and installing tether cab
  84
• 5 Tank flap unit
  90
• 5.1 Assembly overview - tank flap unit
  90
• 5.2 Removing and installing fuel tank flap
  90
• 5.3 Removing and installing tank flap unit
  91
• 5.4 Removing and installing actuator
  93
• Front doors, door components, central locking
  95
• 1 Door
  95
• 1.1 Assembly overview – door
  95
• 1.2 Removing and installing inner door seal
  97
• 1.3 Removing and installing door
  99
• 1.4 Adjusting striker pin
  102
• 1.5 Removing and installing door hinge
  103
• 1.6 Removing and installing door arrester
  106
• 2 Door components
  109
• 2.1 Assembly overview – door components
  109
• 2.2 Assembly overview – window regulator
  111
• 2.3 Assembly overview – Bowden cable
  111
• 2.4 Assembly overview - door lock cover
  112
• 2.5 Assembly overview - cap
  113
• 2.6 Assembly overview - window regulator motor
  114
• 2.7 Removing and installing window regulator motor
  115
• 2.8 Removing and installing window regulator
  117
• 2.9 Removing and installing door handle
  119
• 2.10 Removing and installing door lock
  120
• 2.11 Removing and installing window channel
  122
• 2.12 Removing and installing lock cylinder
  124
• 2.13 Removing and installing housing (without lock cylinder)
  126
• 2.14 Removing and installing interior door handle
  128
• 2.15 Removing and installing mounting bracket
  130
• 2.16 Removing and installing striker pin
  132
• 2.17 Removing and installing window slot outer seal
  132
• 2.18 Removing and installing window slot inner seal
  134
• 2.19 Removing and installing outer door seal
  136
• 2.20 Assembly overview - impact rail of front door
  139
• 3 Central locking
  140
• 3.1 Assembly overview - ignition key
  140
• 3.2 Removing and installing ignition key battery
  140
• Rear doors, door components
  143
• 1 Door
  143
• 1.1 Assembly overview – door
  143
• 1.2 Removing and installing door
  145
• 1.3 Adjusting striker pin
  147
• 1.4 Removing and installing door hinge
  148
• 1.5 Removing and installing door arrester
  150
• 1.6 Removing and installing inner door seal
  152
• 1.7 Removing and installing outer door seal
  153
• 2 Door components
  155
• 2.1 Assembly overview – door components
  155
• 2.2 Assembly overview – window regulator
  156
• 2.3 Assembly overview – Bowden cable
  157
• 2.4 Assembly overview - door lock cover
  158
• 2.5 Assembly overview - cap
  159
• 2.6 Assembly overview - window regulator motor
  160
• 2.7 Removing and installing window regulator motor
  161
• 2.8 Removing and installing window regulator
  163
• 2.9 Removing and installing door handle
  164
• 2.10 Removing and installing door lock
  165
• 2.11 Removing and installing housing (without lock cylinder)
  166
• 2.12 Removing and installing interior door handle
  168
• 2.13 Removing and installing mounting bracket
  170
• 2.14 Removing and installing striker pin
  171
• 2.15 Removing and installing window channel
  171
• 2.16 Removing and installing window slot inner seal
  173
• Sunroof
  175
• 1 Sliding/tilting sunroof
  175
• Convertible roof, hardtop, canopy
  176
• 1 Hardtop
  176
• 1.1 Assembly overview - aluminium rail
  176
• 1.2 Assembly overview - seals
  177
• 1.3 Assembly overview - protective films
  178
• 1.4 Removing and installing hardtop
  179
• 1.5 Preassembly of aluminium rail
  187
• 2 Lid for hardtop
  190
• 2.1 Assembly overview - hardtop lid
  190
• 2.2 Assembly overview - hinge
  191
• 2.3 Assembly overview - rotary latch lock
  192
• 2.4 Assembly overview - handle with lock cylinder
  193
• 2.5 Assembly overview - gas strut bracket
  194
• 2.6 Assembly overview - striker for lid
  195
• 2.7 Removing and installing hardtop lid
  196
• 2.8 Removing and installing hardtop lid hinge
  198
• 2.9 Removing and installing rotary latch lock
  199
• 2.10 Removing and installing handle with lock cylinder
  201
• 2.11 Removing and installing gas strut bracket
  203
• 2.12 Removing and installing hardtop lid striker
  204
• 2.13 Removing gas strut
  206
• 2.14 Releasing gas from gas strut
  207
• 2.15 Removing and installing lock cover
  207
• 2.16 Removing and installing high-level brake light
  208
• 2.17 Removing and installing hardtop lid seal
  210
• 3 Charging flap
  212
• 3.1 Assembly overview - retainer
  212
• 3.2 Assembly overview - tailgate seals
  212
• 3.3 Removing and installing anchor
  213
• 4 Glazing
  215
• 4.1 Assembly overview - glazing
  215
• 4.2 Assembly overview – rear window
  215
• 4.3 Removing and installing rear window
  216
• 4.4 Removing and installing sliding window
  222
• 4.5 Removing and installing front sliding window
  223
• 5 Trims, foam components
  226
• 5.1 Removing and installing top panel
  226
• 5.2 Removing and installing right D-pillar trim
  228
• 5.3 Removing and installing left D-pillar trim
  230
• 5.4 Removing and installing hardtop middle trim
  233
• 5.5 Removing and installing front trim
  238
• 5.6 Removing and installing edge protector
  240
• 5.7 Removing and installing rear seal
  240
• Bumpers
  242
• 1 Bumper, front
  242
• 1.1 Assembly overview – bumper cover
  242
• 1.2 Assembly overview – bumper carrier
  244
• 1.3 Assembly overview - add-on parts
  245
• 1.4 Removing and installing bumper cover
  250
• 1.5 Removing and installing bumper carrier
  255
• 1.6 Removing and installing add-on parts
  257
• 1.7 Repairing bumper cover
  262
• 2 Bumper, rear
  267
• 2.1 Assembly overview – bumper cover
  267
• 2.2 Removing and installing bumper carrier
  269
• 2.3 Removing and installing bumper cover
  270
• 2.4 Removing and installing closure plate
  272
• 2.5 Removing and installing lower step
  272
• 2.6 Removing and installing upper step
  273
• 2.7 Repairing bumper cover
  275
• Glazing
  276
• 1 Repair instructions
  276
• 1.1 Minimum drying times for bonded windows
  276
• 1.2 Window repair
  276
• 1.3 Installation instructions for bonded windows
  277
• 1.4 Preparing old undamaged windows for installing
  279
• 1.5 Preparing new windows for installing
  279
• 1.6 Preparing body flange for installing
  280
• 1.7 Cleaning off excess adhesive
  282
• 2 Windscreen
  283
• 2.1 Assembly overview – windscreen
  283
• 2.2 Removing and installing windscreen
  283
• 3 Rear windscreen
  289
• 3.1 Assembly overview – rear window
  289
• 3.2 Removing and installing rear window
  289
• 4 Door windows
  296
• 4.1 Assembly overview - front door window
  296
• 4.2 Assembly overview - rear door window
  296
• 4.3 Removing and installing front door window
  297
• 4.4 Removing and installing guide rail
  299
• 4.5 Removing and installing rear door window
  300
• 4.6 Removing and installing fixed door-window
  302
• Exterior equipment
  307
• 1 Radiator grille and front trim
  307
• 1.1 Assembly overview – radiator grille
  307
• 1.2 Removing and installing radiator grille
  308
• 2 Mouldings, trims, extensions
  311
• 2.1 Assembly overview - heat shield
  311
• 2.2 Removing and installing underbody heat shield
  312
• 3 Noise insulation
  317
• 3.1 Assembly overview - engine/gearbox guard
  317
• 3.2 Removing and installing engine/gearbox guard
  318
• 4 Trim film and protective film
  322
• 4.1 Renewing protective films
  322
• 5 Roof moulding and roof railing
  334
• 5.1 Renewing roof strip
  334
• 6 Exterior mirror
  336
• 6.1 Assembly overview – exterior mirror
  336
• 6.2 Removing and installing mirror glass
  337
• 6.3 Removing and installing mirror frame
  339
• 6.4 Removing and installing mirror cover
  340
• 6.5 Removing and installing exterior mirror
  342
• 7 Wheel housing liner
  345
• 7.1 Assembly overview – front wheel housing liner
  345
• 7.2 Assembly overview – rear wheel housing liner
  346
• 7.3 Removing and installing front wheel housing liner
  347
• 7.4 Removing and installing rear wheel housing liner
  349
• 8 Lettering and emblems
  352
• 8.1 Assembly overview – lettering and badges
  352
• 8.2 Removing and installing lettering
  352
• 8.3 Dimensions – lettering and badges at rear
  354
• 8.4 Dimensions - lettering and emblems on sides
  358
• 8.5 Removing and installing lettering and emblems for radiator grille
  359
• 8.6 Renewing lettering and badges at rear
  361
• 9 Special add-on parts
  363
• 9.1 Assembly overview – special add-on parts
  363
• 9.2 Assembly overview - side bar
  367
• 9.3 Assembly overview - design double roll bar
  368
• 9.4 Assembly overview - carrier for additional driving lights
  370
• 9.5 Assembly overview - rear step
  371
• 9.6 Removing and installing carrier for additional main beam headlights
  372
• 9.7 Roller cover for luggage compartment
  374
• 9.8 Removing and installing sports bar
  399
• 9.9 Removing and installing design double roll bar for luggage compartment cover
  405
• 10 Wheel arch cover
  409
• 10.1 Repair instructions
  409
• 10.2 Removing and installing wheel arch cover – wing
  413
• 10.3 Removing and installing wheel arch cover – left load bed
  421
• 10.4 Removing and installing wheel arch cover – right load bed
  429
• 11 Buffer - cross panel
  436
• 11.1 Assembly overview - buffer - rear cross panel
  436
• 12 Towing bracket
  437
• 12.1 Assembly overview – towing bracket
  437
• 12.2 Removing and installing towing bracket
  438
• 13 Spare wheel bracket
  440
• 13.1 Removing and installing spare wheel tether
  440
• 13.2 Assembly overview - spare wheel bracket
  442
• 14 Mudflap
  445
• 14.1 Assembly overview - mudflap
  445
• 14.2 Removing and installing mudflaps
  450