General body repairs, exterior

Chapter overview

• Body - front
  1
• 1 Lock carrier
  1
• 1.1 Tools
  1
• 1.2 Assembly overview - Lock carrier with add-on parts ▸ 09.00
  2
• 1.3 Removing and refitting lock carrier with add-on parts ▸ 09.00
  3
• 1.4 Lock carrier - Service position ▸ 09.00
  4
• 1.5 Unbolting hydraulic oil cooler
  6
• 1.6 Assembly overview - Lock carrier add-on parts 10.00 ▸
  6
• 1.7 Removing and refitting lock carrier with add-on parts 10.00 ▸
  7
• 1.8 Assembly overview - Lock carrier, service position 10.00 ▸
  8
• 1.9 Service position 10.00 ▸
  10
• 2 Wing
  12
• 2.1 Tools
  12
• 2.2 Assembly overview - Front wing ▸ 09.00
  12
• 2.3 Removing and refitting front wing ▸ 09.00
  14
• 2.4 Removing and refitting closing piece
  15
• 2.5 Assembly overview - Front wing 10.00 ▸
  15
• 2.6 Removing and refitting front wing 10.00 ▸
  17
• 3 Noise insulation
  19
• 3.1 Tools
  19
• 3.2 Assembly overview - Noise insulation
  19
• Bonnet, rear lid
  21
• 1 Bonnet lid
  21
• 1.1 Tools
  21
• 1.2 Assembly overview - Bonnet lid
  21
• 1.3 Removing and refitting bonnet lid
  23
• 1.4 Adjusting bonnet
  24
• 1.5 Removing gas strut
  26
• 1.6 Releasing gas from gas strut
  26
• 1.7 Assembly overview- Bowden cable for bonnet lock
  26
• 1.8 Disconnecting Bowden cable
  27
• 1.9 Assembly overview- Bonnet lock
  28
• 1.10 Removing and refitting bonnet lock
  29
• 1.11 Adjusting bonnet lock
  30
• 1.12 Assembly overview- Bonnet seal
  31
• 1.13 Removing and refitting insulation
  31
• 2 Rear lid, saloon
  34
• 2.1 Tools
  34
• 2.2 Assembly overview - Rear lid
  34
• 2.3 Removing gas strut
  35
• 2.4 Adjusting rear lid ▸ 09.00
  35
• 2.5 Adjusting rear lid 10.00 ▸
  37
• 2.6 Assembly overview- Rear lid lock ▸ 09.00
  37
• 2.7 Removing and refitting lock cylinder carrier
  39
• 2.8 Assembly overview - Rear lid lock and lock cylinder carrier 10.00 ▸
  40
• 2.10 Assembly overview- Lock cylinder housing 10.00 ▸
  42
• 3 Rear lid, Estate
  43
• 3.1 Tools
  43
• 3.2 Assembly overview - Rear lid
  43
• 3.3 Removing gas strut
  44
• 3.4 Assembly overview- Rear lid lock, Estate ▸ 09.00
  45
• 3.5 Removing and refitting lock cylinder carrier, Estate ▸ 09.00
  46
• 3.6 Removing and refitting lock cylinder, Estate ▸ 09.00
  47
• 3.7 Assembly overview - Rear lid lock and lock cylinder carrier 10.00 ▸
  48
• 3.8 Assembly overview- Lock cylinder housing 10.00 ▸
  49
• 4 Tank flap unit
  50
• 4.1 Tools
  50
• 4.2 Assembly overview - Tank flap unit
  50
• 4.3 Removing and refitting tank flap unit
  51
• Front doors, door components, central locking
  54
• 1 Front door
  54
• 1.1 Tools
  54
• 1.2 Assembly overview - Front door
  55
• 1.3 Removing and refitting front door
  57
• 1.4 Adjusting front door
  58
• 1.5 Assembly overview - Door handle and door lock
  59
• 1.6 Removing and refitting lock cylinder housing
  60
• 1.7 Removing and refitting door handle
  61
• 1.8 Removing and refitting door lock
  63
• 1.9 Vehicles with electric windows
  66
• 1.10 Removing inner release handle
  67
• 1.11 Door seals
  67
• 1.12 Removing and refitting door inner seal
  68
• 1.13 Removing and refitting locking knob for locking rod
  68
• 2 Central locking
  71
• 2.1 Location overview - Central locking components
  71
• 2.2 Removing and refitting batteries for key (non-folding type) with remote-control unit
  73
• 2.3 Removing and refitting batteries for key (folding type) with remote control ▸ 07.00
  75
• 2.7 Configuring keys with remote-control
  79
• Rear doors, door components
  80
• 1 Rear door
  80
• 1.1 Tools
  80
• 1.2 Assembly overview - Rear door
  81
• 1.3 Removing and refitting rear door
  82
• 1.4 Adjusting rear door
  82
• 1.5 Assembly overview - Door handle and door lock
  83
• 1.6 Removing and refitting door handle
  85
• 1.7 Removing and refitting door lock
  87
• 1.8 Fitting door window to window actuator
  92
• 1.9 Removing inner release handle
  92
• 1.10 Door seals
  92
• 1.11 Removing and refitting door inner seal
  93
• Sunroof
  94
• 1 Sliding/tilting sunroof with glass panel ▸ 07.98
  94
• 1.1 Tools
  94
• 1.2 Assembly overview- Sliding/tilting sunroof with glass panel
  94
• 1.3 Removing glass panel for sliding/tilting sunroof
  96
• 1.4 Refitting glass panel for sliding/tilting sunroof
  96
• 1.5 Adjusting sliding/tilting sunroof glass panel height
  97
• 1.6 Adjusting panel seal
  98
• 1.7 Replacing panel seal
  98
• 1.8 Removing wind deflector
  99
• 1.9 Removing sun shield
  99
• 1.10 Removing drive for sliding/tilting sunroof
  100
• 1.11 Adjusting drive for sliding/tilting sunroof (zeroising)
  100
• 1.12 Removing pre-selector rotary switch for sliding/tilting sunroof
  100
• 1.13 Checking parallel running
  101
• 1.14 Adjusting parallel running
  101
• 1.15 Removing and refitting sliding/tilting sunroof carrier unit
  102
• 1.16 Operating without current
  102
• 1.17 Removing guide rail
  103
• 1.18 Cleaning water drain hoses
  104
• 2 Sliding/tilting sunroof with glass panel 08.98 ▸
  107
• 2.1 Tools
  107
• 2.2 Function
  107
• 2.3 Assembly overview- Sliding/tilting sunroof with glass panel
  108
• 2.4 Removing and refitting bellows
  110
• 2.5 Removing glass panel for sliding/tilting sunroof
  111
• 2.6 Refitting glass panel for sliding/tilting sunroof
  112
• 2.7 Adjusting sliding/tilting sunroof glass panel height
  113
• 2.8 Adjusting panel height
  114
• 2.9 Replacing panel seal
  115
• 2.10 Removing and refitting wind deflector
  115
• 2.11 Removing sun shield
  116
• 2.12 Removing and refitting sliding/tilting sunroof drive
  117
• 2.13 Adjusting drive for sliding/tilting sunroof (zeroising)
  117
• 2.14 Removing pre-selector rotary switch for sliding/tilting sunroof
  118
• 2.15 Checking parallel running
  118
• 2.16 Adjusting parallel running
  119
• 2.17 Removing and refitting assembly unit
  119
• 2.18 Operating without current
  122
• 2.19 Removing guide rail
  122
• 2.20 Cleaning water drain hoses
  123
• 3 Sliding/tilting sunroof with solar panel
  127
• 3.1 Tools
  127
• 3.2 Function
  127
• 3.3 Assembly overview- Sliding/tilting sunroof with solar panel
  128
• 3.4 Removing sliding/tilting sunroof solar panel
  129
• 3.5 Refitting sliding/tilting sunroof solar panel
  129
• 3.6 Adjusting sliding/tilting roof solar panel height
  130
• 3.7 Checking parallel running of solar panel
  131
• 3.8 Adjusting parallel running of solar panel
  131
• 3.9 Replacing panel seal
  132
• 3.10 Removing wind deflector
  132
• 3.11 Removing solar panel trim
  132
• 3.12 Removing drive for sliding/tilting sunroof
  132
• 3.13 Adjusting drive for sliding/tilting sunroof (zeroising)
  133
• 3.14 Removing pre-selector rotary switch for sliding/tilting sunroof
  134
• 3.15 Removing DC converter
  134
• 3.16 Removing solar contact in solar panel
  135
• 3.17 Removing solar contact from roof carrier unit
  135
• 3.18 Removing and refitting assembly unit
  135
• 3.19 Operating without current
  138
• 3.20 Cleaning water drain hoses
  138
• Bumpers
  142
• 1 Front bumper
  142
• 1.1 Tools
  142
• 1.2 Assembly overview - Front bumper cover ▸ 09.00
  142
• 1.3 Removing and refitting front bumper cover ▸ 09.00
  144
• 1.4 Removing release lever
  145
• 1.5 Adjusting guide
  145
• 1.6 Assembly overview - Front bumper cover 10.00 ▸
  145
• 1.7 Removing and refitting front bumper cover 10.00 ▸
  147
• 1.8 Assembly overview - Front bumper cover add-on parts 10.00 ▸
  148
• 1.9 Removing and refitting bumper strip
  149
• 1.10 Refitting number plate panel (US vehicles only)
  149
• 1.11 Assembly overview - Front bumper cover, underbody parts 10.00 ▸
  149
• 2 Rear bumper
  152
• 2.1 Tools
  152
• 2.2 Assembly overview - Rear bumper cover ▸ 09.00
  152
• 2.3 Removing and refitting rear bumper cover ▸ 09.00
  154
• 2.4 Assembly overview - Rear bumper cover 10.00 ▸
  155
• 2.5 Removing and refitting rear bumper cover 10.00 ▸
  156
• 2.6 Assembly overview - Rear bumper cover, add-on parts 10.00 ▸
  157
• 2.7 Removing and refitting bumper strip
  157
• 2.8 Assembly overview - Rear bumper cover, underbody parts 10.00 ▸
  158
• 2.10 Assembly overview - Towing bracket
  160
• 2.11 Assembly overview - Towing bracket (4 Motion)
  161
• 3 Rear bumper Estate
  162
• 3.1 Tools
  162
• 3.2 Assembly overview - Rear bumper cover ▸ 09.00
  162
• 3.3 Removing and refitting rear bumper cover ▸ 09.00
  164
• 3.4 Assembly overview - Rear bumper cover 10.00 ▸
  165
• 3.5 Removing and refitting rear bumper cover 10.00 ▸
  166
• 3.6 Assembly overview - Rear bumper cover, add-on parts 10.00 ▸
  167
• 3.7 Removing and refitting bumper strip
  167
• 3.8 Attaching transparent film
  168
• 3.9 Assembly overview - Rear bumper cover, underbody parts 10.00 ▸
  168
• Glazing
  170
• 1 Flush bonded windows
  170
• 1.1 Tools
  170
• 1.2 Materials
  171
• 1.3 Assembly overview - Windscreen
  172
• 1.4 Removing and refitting plenum chamber cover
  173
• 1.5 Removing windscreen
  174
• 1.6 Refitting windscreen
  176
• 1.8 Assembly overview- Side window, Estate ▸ 09.00
  176
• 1.9 Assembly overview- Side window, Estate 10.00 ▸
  178
• 1.10 Removing undamaged side window
  178
• 1.11 Removing broken side window
  180
• 1.12 Assembly overview- Side window, Saloon ▸ 09.00
  180
• 1.13 Assembly overview- Side window, Saloon 10.00 ▸
  181
• 1.14 Removing undamaged side window
  181
• 1.15 Removing broken side window
  182
• 1.16 Refitting side window
  182
• 1.17 Assembly overview- Rear window, Estate
  183
• 1.18 Removing undamaged rear window (Estate)
  184
• 1.19 Assembly overview - Rear window
  185
• 1.20 Removing undamaged rear window
  186
• 1.21 Removing broken rear window
  187
• 1.22 Refitting rear window
  187
• 1.23 Preparing old undamaged window for glazing
  188
• 1.24 Preparing new window for glazing
  188
• 1.25 Preparing new window without precoating for glazing
  189
• 1.26 Preparing body flange for glazing
  190
• 1.27 Installation instructions
  191
• 1.28 Curing time
  192
• 1.29 Touching up paint damage
  192
• 1.30 Cleaning off excess adhesive sealing material
  192
• 2 Front door windows
  193
• 2.1 Assembly overview- Front door window
  193
• 2.2 Removing front door window
  194
• 2.3 Adjusting door window
  194
• 2.4 Removing and refitting assembly carrier
  195
• 3 Rear door windows
  197
• 3.1 Assembly overview- Rear door window
  197
• 3.2 Removing rear door window
  198
• 3.3 Fitting door window to window lifter
  199
• 3.4 Removing and refitting assembly carrier
  199
• 3.5 Removing and refitting window motor or assembly carrier with window actuator
  201
• Exterior equipment
  204
• 1 Wheelarch liner
  204
• 1.1 Tools
  204
• 1.2 Assembly overview - Front wheelarch liner
  204
• 1.3 Assembly overview - Rear wheelarch liner
  206
• 2 Rear-view mirror
  207
• 2.1 Tools
  207
• 2.2 Assembly overview - Rear-view mirror
  207
• 2.3 Removing mirror housing
  208
• 2.4 Removing and refitting mirror housing with indicator
  209
• 3 Roof railing
  211
• 3.1 Assembly overview - Roof railing
  211
• 4 Roof mouldings
  213
• 4.1 Assembly overview- Roof moulding
  213
• 4.2 Assembly overview- Outer roof moulding
  214
• 4.3 Assembly overview - Water deflector
  215
• 5 Radiator grille
  216
• 5.1 Assembly overview- Radiator grille ▸ 09.00
  216
• 5.2 Assembly overview- Radiator grille 10.00 ▸
  217
• 5.3 Removing release lever
  217
• 6 Protective strips
  218
• 6.1 Tools
  218
• 6.2 Assembly overview- Protective side strips
  218
• 6.3 Removing and refitting protective side strips
  219
• 6.4 Assembly overview- Door sill trim
  222
• 6.5 Assembly overview - Door strips
  223
• 6.6 Replacing stone-chip protective film
  224
• 6.7 Replacing kick plate protective film
  225