General body repairs, exterior

Chapter overview

• Body - front
  1
• 1 Lock carrier
  1
• 1.1 Tools
  1
• 1.2 Assembly overview - lock carrier service position
  2
• 1.3 Service position
  3
• 1.4 Removing and installing lock carrier with attachments
  4
• 2 Wings
  7
• 2.1 Tools
  7
• 2.2 Assembly overview - front wing
  7
• 2.3 Removing and installing wing
  8
• 2.4 Removing and installing wing bracket
  10
• 3 Noise insulation
  12
• 3.1 Tools
  12
• 3.2 Assembly overview - noise insulation
  12
• 4 Underbody cladding
  14
• 4.1 Tools
  14
• 4.2 Assembly overview - underbody cladding
  14
• 5 Plenum chamber bulkhead
  16
• 5.1 Tools
  16
• 5.2 Assembly overview - plenum chamber bulkhead
  16
• Bonnet, rear lid
  17
• 1 Bonnet (hood)
  17
• 1.1 Tools
  17
• 1.2 Assembly overview - bonnet
  17
• 1.3 Removing and installing bonnet
  19
• 1.4 Assembly overview - bonnet stay
  20
• 1.5 Assembly overview - lid hinge
  21
• 1.6 Removing and installing bonnet hinge
  21
• 1.7 Assembly overview - connecting piece
  24
• 1.8 Removing and installing insulation
  25
• 1.9 Assembly overview - bonnet lock and release components
  27
• 1.10 Removing and installing bonnet lock
  28
• 1.11 Detaching Bowden cable
  29
• 1.12 Adjusting bonnet
  29
• 1.13 Removing and installing release lever
  31
• 2 Rear lid
  32
• 2.1 Tools
  32
• 2.2 Assembly overview - rear lid
  32
• 2.3 Removing and installing rear lid
  33
• 2.4 Removing gas strut
  35
• 2.5 Releasing gas from gas strut
  35
• 2.6 Assembly overview - rear lid hinge
  35
• 2.7 Removing and installing rear lid hinges
  36
• 2.8 Removing and installing striker pin
  39
• 2.9 Adjusting rear lid
  39
• 2.10 Assembly overview - handle trim
  41
• 2.11 Removing and installing handle trim
  42
• 2.12 Removing and installing bonnet lock
  44
• 2.13 Rear lid seal
  45
• 2.14 Removing and installing rear lid seal
  46
• 3 Tank flap unit
  48
• 3.1 Tools
  48
• 3.2 Assembly overview - tank flap unit
  48
• Front doors, door components, central locking
  53
• 1 Rear door
  53
• 1.1 Tools
  53
• 1.2 Materials
  55
• 1.3 Assembly overview - door assembly
  55
• 1.4 Assembly overview - door hinges
  57
• 1.5 Greasing new door hinges
  59
• 1.6 Removing and installing door
  60
• 1.7 Door alignment
  62
• 1.8 Removing and installing outer panel on door
  64
• 1.9 Installing new outer panel on door
  67
• 1.10 Removing and installing retaining rail on outer door panel
  72
• 1.11 Installation notes for bonding a new outer panel on door
  73
• 1.12 Minimum curing period
  74
• 1.13 Cleaning in the event of dirt caused by adhesive sealant
  74
• 1.14 Assembly overview - door inner part
  75
• 1.15 Assembly overview - door handle and door lock
  76
• 1.16 Removing and installing housing
  77
• 1.17 Removing and installing door handle
  78
• 1.18 Removing and installing door handle bracket
  80
• 1.19 Removing and installing door lock
  82
• 1.20 Assembly overview - side impact protection
  84
• 1.21 Inner door seal
  84
• 1.22 Removing and installing inner door seal
  85
• 1.23 Removing and installing outer door seal
  87
• 2 Central locking
  90
• 2.1 Fitting location overview - central locking components
  90
• 2.2 Adapting keys with remote control
  91
• 2.3 Assembly overview - battery for folding key with remote control
  92
• 2.4 Removing and installing battery for folding key with remote control
  93
• Rear doors, door components
  95
• 1 Rear door
  95
• 1.1 Tools
  95
• 1.2 Materials
  97
• 1.3 Assembly overview - door assembly
  97
• 1.4 Assembly overview - door hinges
  99
• 1.5 Greasing new door hinges
  101
• 1.6 Removing and installing door
  102
• 1.7 Door alignment
  104
• 1.8 Removing and installing outer panel on door
  106
• 1.9 Installing new outer panel on door
  109
• 1.10 Removing and installing retaining rail on outer door panel
  114
• 1.11 Installation notes for bonding a new outer panel on door
  115
• 1.12 Minimum curing period
  116
• 1.13 Cleaning in the event of dirt caused by adhesive sealant
  116
• 1.14 Assembly overview - door inner part
  117
• 1.15 Assembly overview - door handle and door lock
  118
• 1.16 Removing and installing housing
  119
• 1.17 Removing and installing door handle
  119
• 1.18 Removing mounting bracket
  121
• 1.19 Removing and installing door lock
  123
• 1.20 Assembly overview - side impact protection
  124
• 1.21 Door inner seals
  125
• 1.22 Removing and installing inner door seal
  126
• 1.23 Removing and installing outer door seal
  127
• Sunroof
  131
• 1 Sliding/tilting sunroof with glass panel (Meritor)
  131
• 1.1 Tools
  131
• 1.2 Function
  132
• 1.3 Assembly overview - sliding/tilting sunroof with glass panel
  132
• 1.4 Removing and installing bellows
  135
• 1.5 Removing sliding/tilting sunroof glass panel
  136
• 1.6 Installing sliding/tilting sunroof glass panel
  137
• 1.7 Adjusting height of sliding/tilting sunroof glass panel
  137
• 1.8 Adjusting panel seal
  138
• 1.9 Renewing panel seal
  139
• 1.10 Removing and installing wind deflector
  139
• 1.11 Removing and installing sliding headliner
  140
• 1.12 Removing and installing sliding/tilting sunroof glass panel drive
  141
• 1.13 Adjusting drive for sliding/tilting sunroof glass panel ("0" position)
  142
• 1.14 Removing and installing sliding/tilting sunroof glass panel automatic preselection switch
  143
• 1.15 Checking parallel running
  143
• 1.16 Adjusting parallel running
  143
• 1.17 Assembly overview - carrier unit
  144
• 1.18 Removing and installing carrier unit
  145
• 1.19 Operating without current
  147
• 1.20 Removing and installing guide plate
  147
• 1.21 Removing and installing guide plate
  148
• 1.22 Cleaning water drainage hoses
  149
• Bumpers
  152
• 1 Bumper, front
  152
• 1.1 Tools
  152
• 1.2 Repairing front bumper cover
  152
• 1.3 Assembly overview - front bumper cover (> 02.2009)
  152
• 1.4 Removing and installing front bumper cover (> 02.2009)
  153
• 1.5 Front bumper cover add-on parts (> 02.2009)
  155
• 1.6 Assembly overview - front bumper cover (03.2009 >)
  156
• 1.7 Removing and installing front bumper cover (03.2009 >)
  156
• 1.8 Front bumper cover add-on parts (03.2009 >)
  158
• 1.9 Removing and installing side guides (03.2009 >)
  159
• 1.10 Assembly overview - front bumper cover, Cross Golf (> 02.2009)
  159
• 1.11 Removing and installing front bumper cover, Cross Golf (> 02.2009)
  160
• 1.12 Front bumper cover add-on parts, Cross Golf (> 02.2009)
  162
• 1.13 Assembly overview - front bumper cover, Cross Golf (03.2010 >)
  163
• 1.14 Removing and installing front bumper cover, Cross Golf (03.2010 >)
  164
• 1.15 Front bumper cover add-on parts, Cross Golf (03.2010 >)
  166
• 1.16 Removing and installing side guides, Cross Golf (03.2010 >)
  168
• 1.17 Front bumper substructure
  169
• 1.18 Assembly overview - bumper carrier
  170
• 1.19 Installing brackets for parking aid system
  170
• 1.20 Installing brackets for park assist steering
  175
• 2 Bumper, rear
  180
• 2.1 Tools
  180
• 2.2 Repairing rear bumper cover
  180
• 2.3 Assembly overview - rear bumper cover (> 02.2009)
  180
• 2.4 Removing and installing bumper cover (> 02.2009)
  181
• 2.5 Rear bumper add-on parts (> 02.2009)
  183
• 2.6 Assembly overview - rear bumper cover (03.2009 >)
  184
• 2.7 Removing and installing rear bumper cover (03.2009 >)
  184
• 2.8 Rear bumper cover add-on parts (03.2009 >)
  186
• 2.9 Removing and installing side guides (03.2009 >)
  187
• 2.10 Assembly overview - rear bumper cover, Cross Golf (> 02.2009)
  187
• 2.11 Removing and installing rear bumper cover, Cross Golf (> 02.2009)
  188
• 2.12 Rear bumper cover add-on parts, Cross Golf (> 02.2009)
  190
• 2.13 Assembly overview - rear bumper cover, Cross Golf (03.2010 >)
  191
• 2.14 Removing and installing rear bumper cover, Cross Golf (03.2010 >)
  192
• 2.15 Rear bumper cover add-on parts, Cross Golf (03.2010 >)
  193
• 2.16 Removing and installing side guides (03.2010 >)
  194
• 2.17 Rear bumper substructure
  196
• 2.18 Assembly overview - bumper carrier
  197
• 2.19 Repairing bumper cover
  197
• 2.20 Installing brackets for parking aid system
  197
• 2.21 Assembly overview - towing bracket
  202
• Glazing
  204
• 1 Flush-bonded glazing
  204
• 1.1 Tools
  204
• 1.2 Materials
  205
• 1.3 Repairing windscreen
  206
• 1.4 Assembly overview - windscreen
  206
• 1.5 Assembly overview - plenum chamber cover
  208
• 1.6 Removing windscreen
  211
• 1.7 Installing windscreen
  211
• 1.8 Assembly overview - rear window
  212
• 1.9 Removing undamaged rear window
  212
• 1.10 Removing broken rear window
  213
• 1.11 Installing rear window
  214
• 1.12 Assembly overview - front side window
  214
• 1.13 Removing undamaged front side window
  216
• 1.14 Removing broken front side window
  217
• 1.15 Installing front side window
  217
• 1.16 Preparing old undamaged window for glazing
  218
• 1.17 Preparing new window without precoating for glazing
  218
• 1.18 Preparing new window with precoating for glazing
  219
• 1.19 Preparing body flange for glazing
  220
• 1.20 Fitting instructions
  222
• 1.21 Minimum curing period
  222
• 1.22 Touching up paint damage
  223
• 1.23 Cleaning in the event of dirt caused by adhesive sealant
  223
• 2 Front door window
  224
• 2.1 Tools
  224
• 2.2 Assembly overview - front door window
  224
• 2.3 Removing and installing door window
  225
• 2.4 Adjusting door window
  227
• 2.5 Assembly overview - window regulator motor
  229
• 2.6 Removing and installing window regulator motor
  230
• 2.7 Assembly overview - window channel
  232
• 2.8 Removing and installing window channel
  233
• 2.9 Assembly overview - window regulator
  234
• 2.10 Removing and installing window regulator
  235
• 3 Rear door windows
  237
• 3.1 Tools
  237
• 3.2 Assembly overview - rear door windows
  237
• 3.3 Removing and installing door window
  238
• 3.4 Assembly overview - fixed door window with window channel
  240
• 3.5 Removing and installing fixed door window with window channel
  241
• 3.6 Assembly overview - window regulator motor
  244
• 3.7 Removing and installing window regulator motor
  244
• 3.8 Assembly overview - window regulator
  247
• 3.9 Removing and installing window regulator
  247
• Exterior equipment
  249
• 1 Wheel housing liner
  249
• 1.1 Tools
  249
• 1.2 Assembly overview - front wheel housing liner
  249
• 1.3 Removing and installing front wheel housing liner
  250
• 1.4 Assembly overview - rear wheel housing liner
  252
• 1.5 Removing and installing rear wheel housing liner
  252
• 2 Exterior mirror
  254
• 2.1 Tools
  254
• 2.2 Assembly overview - exterior mirror
  254
• 2.3 Removing and installing mirror glass
  255
• 2.4 Removing and installing mirror housing
  256
• 2.5 Removing and installing trim
  257
• 2.6 Removing and installing turn signal repeater
  257
• 2.7 Removing and installing exterior mirror
  258
• 3 Radiator grille
  260
• 3.1 Assembly overview - radiator grille (> 02.2009)
  260
• 3.2 Removing and installing radiator grille (> 02.2009)
  261
• 3.3 Assembly overview - radiator grille (03.2009 >)
  263
• 3.4 Removing and installing radiator grille (03.2009 >)
  264
• 3.5 Removing and installing emblem
  266
• 4 Roof railing
  267
• 4.1 Assembly overview - roof railing (> 02.2009)
  267
• 4.2 Removing roof railing (> 02.2009)
  268
• 4.3 Installing railing (> 02.2009)
  269
• 4.4 Assembly overview - roof railing (03.2009 >)
  272
• 4.5 Removing roof railing (03.2009 >)
  273
• 4.6 Installing roof railing (03.2009 >)
  274
• 5 Mouldings and trims
  275
• 5.1 Tools
  275
• 5.2 Installation instructions for glued mouldings and trims
  275
• 5.3 Protective side strips
  276
• 5.4 Trim for bonnet
  278
• 5.5 Strip for rear lid
  281
• 5.6 Water deflector
  283
• 5.7 Removing and installing stone-chip protection trim
  286
• 5.8 Assembly overview - side member cover
  290
• 6 Special add-on parts
  291
• 6.1 Safety requirements
  291
• 6.2 Tools
  291
• 6.3 Materials
  292
• 6.4 Component overview - special add-on parts, Cross Golf (> 02.2009)
  292
• 6.5 Component overview - special add-on parts, Cross Golf (03.2010 >)
  293
• 6.6 Assembly overview - side member extension
  294
• 6.7 Removing and installing side member extension
  296
• 6.8 Removing and installing retaining strip for side member extension
  298
• 6.9 Removing and installing protective side mouldings
  301
• 6.10 Removing and installing front wheel arch trim
  304
• 6.11 Removing and installing rear wheel arch trim
  306
• 6.12 Fitting instructions
  308
• 6.13 Preparing body kit component for bonding
  308
• 6.14 Preparing body component for bonding
  309
• 6.15 Fitting instructions
  309
• 6.16 Minimum curing period
  310
• 6.17 Touching up paint damage
  310
• 6.18 Cleaning in the event of dirt caused by adhesive sealant
  310
• 6.19 Cleaning guidelines
  310
• 7 Lettering
  311
• 7.1 Tools
  311
• 7.2 Installation instructions for self-adhesive lettering and scuff protection films
  311
• 7.3 Rear lettering - dimensions
  311
• 7.4 Side lettering, Cross Golf
  312
• 7.5 Renewing scuff protection film, Cross Golf
  313
• 8 Vermin repellent system
  315
• 8.1 Assembly overview - vermin repellent system
  315