General body repairs, exterior

Chapter overview

• Body - front
  1
• 1 Lock carrier
  1
• 1.1 Tools
  1
• 1.2 Assembly overview - lock carrier
  2
• 1.3 Service position
  3
• 1.4 Removing and installing lock carrier with attachments
  4
• 1.5 Assembly overview - retaining bracket for bumper bracket
  6
• 2 Wings
  8
• 2.1 Tools
  8
• 2.2 Assembly overview - front wing
  8
• 2.3 Removing and installing wing
  9
• 2.4 Removing and installing wing bracket
  11
• 2.5 Wing end plate
  12
• 3 Noise insulation
  13
• 3.1 Tools
  13
• 3.2 Assembly overview - noise insulation (long version)
  13
• 3.3 Assembly overview - noise insulation (short version)
  15
• 4 Skid plate
  16
• 5 Underbody cladding
  17
• 5.1 Tools
  17
• 5.2 Assembly overview - underbody cladding
  17
• 6 Bulkhead
  19
• 6.1 Tools
  19
• 6.2 Materials
  20
• 6.3 Assembly overview - bulkhead
  20
• 7 Cross piece
  21
• Bonnet, rear lid
  22
• 1 Bonnet (hood)
  22
• 1.1 Tools
  22
• 1.2 Assembly overview - bonnet
  22
• 1.3 Removing and installing bonnet
  24
• 1.4 Removing and installing bonnet hinge
  25
• 1.5 Removing and installing insulation
  26
• 1.6 Assembly overview - locking and release components for bonnet
  27
• 1.7 Removing and installing arrester
  27
• 1.8 Removing and installing bonnet lock
  28
• 1.9 Detaching Bowden cable
  31
• 1.10 Adjusting bonnet
  32
• 1.11 Assembly overview - release lever
  34
• 1.12 Removing and installing release lever
  35
• 2 Rear lid
  36
• 2.1 Tools
  36
• 2.2 Assembly overview - rear lid
  36
• 2.3 Removing and installing rear lid
  37
• 2.4 Removing and installing rear lid hinge
  39
• 2.5 Assembly overview - rear lid locking and unlocking parts
  41
• 2.6 Removing and installing lid lock
  42
• 2.7 Removing and installing striker pin
  44
• 2.8 Removing and installing handle trim with release button
  44
• 2.9 Adjusting rear lid
  47
• 2.10 Assembly overview - gas strut
  50
• 2.11 Removing and installing gas strut
  51
• 2.12 Releasing gas from gas strut
  51
• 2.13 Rear lid seal
  51
• 2.14 Removing and installing rear lid seal
  52
• 3 Tank flap unit
  54
• 3.1 Assembly overview - tank flap unit and actuator
  54
• 3.2 Removing and installing tank flap unit
  55
• 3.3 Removing and installing actuator
  57
• Front doors, door components, central locking
  58
• 1 Rear door
  58
• 1.1 Tools
  58
• 1.2 Assembly overview - front door
  59
• 1.3 Assembly overview - door hinges
  60
• 1.4 Greasing new door hinges
  62
• 1.5 Removing and installing door
  62
• 1.6 Adjusting door
  67
• 2 Door components
  69
• 2.1 Tools
  69
• 2.2 Assembly overview - assembly carrier
  70
• 2.3 Removing and installing subframe
  70
• 2.4 Assembly overview - door bag tether
  76
• 2.5 Assembly overview - door handle and door lock
  77
• 2.6 Removing and installing lock cylinder cover cap
  78
• 2.7 Removing and installing lock cylinder
  78
• 2.8 Removing and installing cover cap (without lock cylinder)
  79
• 2.9 Removing and installing door handle
  80
• 2.10 Removing and installing door lock
  81
• 2.11 Removing and installing door handle bracket
  86
• 2.12 Removing and installing retaining bracket
  89
• 2.13 Inner door seal
  90
• 2.14 Removing and installing inner door seal
  91
• 2.15 Removing and installing outer door seal
  92
• 2.16 Assembly overview - insulation
  96
• 3 Central locking
  97
• 3.1 Fitting location overview - central locking components
  97
• 3.2 Key with remote control
  99
• Rear doors, door components
  105
• 1 Rear door
  105
• 1.1 Tools
  105
• 1.2 Assembly overview - rear door
  106
• 1.3 Assembly overview - door hinges
  107
• 1.4 Greasing new door hinges
  109
• 1.5 Removing and installing door
  109
• 1.6 Adjusting door
  113
• 2 Door components
  115
• 2.1 Tools
  115
• 2.2 Assembly overview - assembly carrier
  116
• 2.3 Removing and installing subframe
  116
• 2.4 Assembly overview - door handle and door lock
  122
• 2.5 Removing and installing cap
  122
• 2.6 Removing and installing door handle
  124
• 2.7 Removing and installing door lock
  125
• 2.8 Removing and installing door handle bracket
  129
• 2.9 Removing and installing retaining bracket
  132
• 2.10 Door inner seals
  133
• 2.11 Removing and installing inner door seal
  134
• 2.12 Removing and installing outer door seal
  135
• 2.13 Assembly overview - insulation
  139
• Sunroof
  140
• 1 Panoramic sliding sunroof
  140
• 1.1 Tools
  140
• 1.2 Function
  140
• 1.3 Basic setting, panoramic sliding sunroof
  141
• 1.4 Assembly overview - panoramic sliding roof
  141
• 1.5 Removing and installing front glass panel
  143
• 1.6 Removing and installing rear glass panel
  145
• 1.7 Adjusting height of front and rear glass panel
  146
• 1.8 Renewing seals for rear glass panel
  147
• 1.9 Renewing outer seal
  149
• 1.10 Renewing inner seal
  150
• 1.11 Removing and installing wind deflector
  151
• 1.12 Removing and installing wind deflector bracket
  154
• 1.13 Removing and installing preselector for glass panel and sunroof sun blind
  155
• 1.14 Removing and installing sliding sunroof motor
  155
• 1.15 Removing and installing sun blind motor
  158
• 1.16 Removing and installing sun blind
  158
• 1.17 Assembly overview - assembly frame
  165
• 1.18 Installing and removing motor plate and sun blind cable
  166
• 1.19 Removing and installing assembly frame
  169
• 1.20 Removing and installing rear part
  171
• 1.21 Removing and installing front motor plate
  174
• 1.22 Removing and installing tilting mechanism and front glass panel cable
  176
• 1.23 Maintenance and care
  179
• 1.24 Operating without current
  180
• 1.25 Cleaning water drainage hoses
  182
• Bumpers
  185
• 1 Front bumper cover - difference between road version and off-road version
  185
• 1.1 General information
  185
• 2 Front bumper cover for road version up to 06.2011
  186
• 2.1 Tools
  186
• 2.2 Repairing front bumper cover
  186
• 2.3 Installing brackets for parking aid system
  186
• 2.4 Assembly overview - front bumper cover
  191
• 2.5 Removing and installing front bumper cover
  191
• 2.6 Front bumper cover add-on parts
  193
• 2.7 Front bumper cover substructure parts
  195
• 2.8 Assembly overview - front bumper carrier
  196
• 3 Front bumper cover for road version as of 07.2011
  197
• 3.1 Repairing front bumper cover
  197
• 3.2 Installing brackets for parking aid system
  197
• 3.3 Assembly overview - front bumper cover
  201
• 3.4 Removing and installing front bumper cover
  202
• 3.5 Front bumper cover add-on parts
  203
• 3.6 Front bumper cover substructure parts
  205
• 3.7 Assembly overview - front bumper carrier
  206
• 4.1 Tools
  207
• 4.2 Repairing front bumper cover
  207
• 4.3 Installing brackets for parking aid system
  207
• 4.4 Assembly overview - front bumper cover
  212
• 4.5 Removing and installing front bumper cover
  212
• 4.6 Front bumper cover add-on parts
  214
• 4.7 Front bumper cover substructure parts
  216
• 4.8 Assembly overview - front bumper carrier
  217
• 5.1 Tools
  218
• 5.2 Repairing front bumper cover
  218
• 5.3 Installing brackets for parking aid system
  218
• 5.4 Assembly overview - front bumper cover
  223
• 5.5 Removing and installing front bumper cover
  223
• 5.6 Front bumper cover add-on parts
  225
• 5.7 Front bumper cover substructure parts
  227
• 5.8 Assembly overview - front bumper carrier
  228
• 6 Rear bumper cover
  229
• 6.1 Tools
  229
• 6.2 Repairing rear bumper cover
  229
• 6.3 Assembly overview - rear bumper cover
  229
• 6.4 Removing and installing rear bumper cover
  230
• 6.5 Removing and installing bumper cover with towing bracket
  232
• 6.6 Rear bumper cover add-on parts
  233
• 6.7 Rear bumper cover substructure parts
  236
• 6.8 Rear bumper carrier
  237
• 7 Towing brackets
  239
• 7.1 Assembly overview - towing bracket
  239
• 7.2 Removing and installing towing bracket
  240
• 7.3 Assembly overview - towing bracket (USA)
  245
• 7.4 Removing and installing towing bracket (USA)
  246
• Glazing
  248
• 1 Flush bonded windows
  248
• 1.1 Tools
  248
• 1.2 Materials
  249
• 1.3 Repairing windscreen
  250
• 1.4 Assembly overview - windscreen
  250
• 1.5 Removing windscreen
  251
• 1.6 Installing windscreen
  252
• 1.7 Assembly overview - rear window
  253
• 1.8 Removing undamaged rear window
  254
• 1.9 Removing broken rear window
  255
• 1.10 Installing rear window
  255
• 1.11 Assembly overview - side window
  255
• 1.12 Removing undamaged side window
  256
• 1.13 Removing broken side window
  258
• 1.14 Installing side window
  258
• 1.15 Preparing old undamaged window for glazing
  258
• 1.16 Preparing new window without precoating for glazing
  258
• 1.17 Preparing body flange for glazing
  259
• 1.18 Fitting instructions
  260
• 1.19 Minimum curing period
  263
• 1.20 Touching up paint damage
  264
• 1.21 Cleaning in the event of dirt caused by adhesive sealing material
  264
• 2 Front door window
  265
• 2.1 Tools
  265
• 2.2 Assembly overview
  266
• 2.3 Removing and installing door window
  267
• 2.4 Removing and installing window regulator motor
  271
• 2.5 Installing
  272
• 2.6 Removing and installing window channel
  273
• 2.7 Removing and installing window channel trim strip
  276
• 3 Rear door window
  278
• 3.1 Tools
  278
• 3.2 Assembly overview
  279
• 3.3 Removing and installing door window
  280
• 3.4 Removing and installing window regulator motor
  285
• 3.5 Removing and installing window channel
  285
• 3.6 Removing and installing window channel trim strip
  287
• 3.7 Removing and installing fixed door window
  288
• Exterior equipment
  290
• 1 Wheel housing liner
  290
• 1.1 Tools
  290
• 1.2 Assembly overview - front wheel housing liner
  290
• 1.3 Removing and installing front wheel housing liner
  291
• 1.4 Assembly overview - rear wheel housing liner
  293
• 1.5 Removing and installing rear wheel housing liner
  293
• 1.6 Removing and installing side member cover
  296
• 2 Exterior mirror
  298
• 2.1 Tools
  298
• 2.2 Assembly overview - exterior mirror
  298
• 2.3 Removing and installing mirror glass
  299
• 2.4 Removing and installing housing frame
  300
• 2.5 Removing and installing mirror housing
  301
• 2.6 Removing and installing exterior mirror
  301
• 3 Radiator grille
  304
• 3.1 Tools
  304
• 3.2 Removing and installing radiator grille ► 06.2011
  304
• 3.3 Removing and installing radiator grille 07.2011 ►
  307
• 4 Roof railing
  309
• 4.1 Tools
  309
• 4.2 Assembly overview - roof railing
  309
• 4.3 Removing and installing roof railing
  310
• 4.4 Removing and installing roof railing retaining bracket
  312
• 5 Mouldings and trims
  315
• 5.1 Tools
  315
• 5.2 Plenum chamber cover
  316
• 5.3 Water deflector
  319
• 5.4 Protective side strips
  322
• 5.5 Front and rear door covers
  325
• 5.6 Removing and installing wheel arch trims
  328
• 6 Special add-on parts
  333
• 6.1 Safety requirements
  333
• 6.2 Tools
  333
• 6.3 Materials
  334
• 6.4 Component overview - special add-on parts
  335
• 6.5 Wheel arch trims
  336
• 6.6 Removing and installing front wheel arch trim
  338
• 6.7 Rear wheel arch trim
  342
• 6.8 Front and rear door covers
  345
• 6.9 Roof spoiler
  349
• 6.10 Fitting instructions
  352
• 6.11 Preparing add-on parts for bonding
  352
• 6.12 Preparing new add-on part for bonding
  353
• 6.13 Preparing body component for bonding
  353
• 6.14 Fitting instructions
  354
• 6.15 Minimum curing period
  354
• 6.16 Touching up paint damage
  354
• 6.17 Cleaning in the event of dirt caused by adhesive sealing material
  354
• 6.18 Cleaning guidelines
  355
• 7 Lettering
  356
• 7.1 Installation instructions for lettering and emblems
  356
• 7.2 Rear lettering - dimensions
  356
• 7.3 Lettering on side - dimensions
  357