General body repairs, exterior

Chapter overview

• Body - front
  1
• 1 Body - front section
  1
• 1.1 Front end with complementary parts - remove and install
  1
• 1.2 Front end - service position
  2
• 1.3 Front wing - assembly overview
  4
• 1.4 Noise insulation (petrol engine) - assembly overview
  6
• 1.5 Noise insulation (diesel engine) - assembly overview
  7
• 2 Bulkhead
  9
• 2.1 Tools
  9
• 2.2 Auxiliary materials for Brazilian market
  9
• 2.3 Auxiliary materials for export market
  10
• 2.4 Matching table
  10
• 2.5 Engine compartment partition panel - assembly overview
  11
• 2.6 Minimum adhesive drying time
  11
• 3 Engine compartment upper partition panel
  12
• 3.1 Engine compartment upper partition panel - assembly overview
  12
• Bonnet, rear lid
  13
• 1 Bonnet
  13
• 1.1 Bonnet - assembly overview
  13
• 1.2 Bonnet - adjust
  13
• 1.3 Latch operation cable - assembly overview
  14
• 1.4 Latch operating cable - remove and install
  15
• 1.5 Bonnet hinge - remove and install
  17
• 1.6 Front bonnet latch - assembly overview
  18
• 1.7 Bonnet latch - remove and install
  19
• 2 Rear lid (Fox)
  21
• 2.1 Assembly overview
  21
• 2.2 Rear door shock absorber - remove and install
  23
• 2.3 Rear door shock absorber - replace
  23
• 2.4 Rear lid trim - remove and install
  23
• 2.5 Rear lid - remove and install
  25
• 2.6 Rear lid hinge - remove and install
  26
• 2.7 Rear lid - adjust
  27
• 2.8 Rear lid lock (► 12.04) - remove and install
  29
• 2.9 Rear lid lock (01.05 ►) - remove and install
  32
• 2.10 Rear lid lock cylinder handle (Push Button - 01.05 ►) - remove and install
  32
• 2.11 Rear lid release motor V139 (Push Button - 01.05 ►) - remove and install
  33
• 2.12 Lock cylinder (Push Button - 01.05 ►) - assembly overview
  34
• 2.13 Lock cylinder (Push Button - 01.05 ►) - remove and install
  36
• 3 Rear lid (Spacefox)
  37
• 3.1 Rear lid - assembly overview
  37
• 3.2 Rear door shock absorber - remove and install
  38
• 3.3 Rear door shock absorber - replace
  39
• 3.4 Rear lid trim - remove and install
  39
• 3.5 Rear lid - remove and install
  40
• 3.6 Rear lid hinge - remove and install
  41
• 3.7 Rear lid - adjust
  42
• 3.8 Rear lid lock - remove and install
  42
• 3.9 Rear lid lock cylinder handle - remove and install
  43
• 3.10 Rear lid release motor V139 - remove and install
  43
• 3.11 Lock cylinder - assembly overview
  43
• 3.12 Latch cylinder - remove and install
  44
• 4 Fuel reservoir nozzle compartment and lid set
  45
• 4.1 Fuel tank nozzle compartment and lid set - remove and install
  45
• Front doors, door components, central locking
  46
• 1 Front door
  46
• 1.1 Front door - assembly overview
  46
• 1.2 Front door - remove and install
  48
• 1.3 Front door - adjust
  49
• 1.4 Front door - disassemble and assemble
  51
• 1.5 Front door - replace
  51
• 1.6 Door arrester - adjust
  52
• 1.7 Door limiter - remove and install
  52
• 1.8 Internal handle - replace
  53
• 1.9 Front door external handle and lock - assembly overview
  53
• 1.10 Lock cylinder housing - remove and install
  55
• 1.11 Central locking motor for driver / passenger door V56/V57 - replace
  56
• 1.12 Cylinder housing - disassemble and assemble
  57
• 1.13 Cylinders and keys (Specific information for Brazil) - request
  59
• 1.14 External door handle - remove and install
  59
• 1.15 External door handle - replace
  60
• 1.16 Door lock - remove and install
  60
• 1.17 Door lock - replace
  64
• 1.18 Lock Bowden cable - replace
  64
• 1.19 Door sealing membrane - remove and install
  66
• 1.20 Door sealing packings - assembly overview
  68
• 1.21 External door packing - remove and install
  69
• 1.22 Internal door trim - remove and install
  71
• 1.23 Cylinders and keys (Specific information for Brazil) - request
  72
• 2 Central locking
  73
• 2.1 Central locking installation location overview - 2-door
  73
• 2.2 Central locking installation location overview - 4-door
  75
• 2.3 Central locking installation locations overview
  77
• 2.4 Central control unit for convenience system J393 - remove
  79
• 2.5 Remote-command key - assembly overview
  79
• 2.6 Batteries for remote-command key - remove and install
  80
• 2.8 Key - synchronize
  83
• Rear doors, door components
  84
• 1 Rear passenger doors
  84
• 1.1 Rear passenger doors - assembly overview
  84
• 1.2 Rear passenger door - remove and install
  85
• 1.3 Rear passenger door - adjust
  87
• 1.4 Rear passenger door - disassemble and assemble
  89
• 1.5 Rear door - replace
  89
• 1.6 Door arrester - adjust
  90
• 1.7 Door limiter - remove and install
  90
• 1.8 Internal handle - replace
  91
• 1.9 Rear door external handle and lock - assembly overview
  92
• 1.10 Cylinder housing without lock cylinder - remove and install
  93
• 1.11 External door handle - remove and install
  94
• 1.12 External door handle - replace
  95
• 1.13 Rear door lock - remove and install
  95
• 1.14 Rear door lock - replace
  99
• 1.15 Inversion lever - replace
  99
• 1.16 Lock operating cable - remove and install
  100
• 1.17 Rear left/right power latching motor V307/V308 - replace
  101
• 1.18 Door sealing membrane - remove and install
  102
• 1.19 Door sealing packings - assembly overview
  104
• 1.20 External door packing - remove and install
  106
• 1.21 Internal door trim - remove and install
  107
• Sunroof
  109
• 1 Sliding / tilting sunroof (Fox)
  109
• 1.1 Operation
  109
• 1.2 Sliding/tilting sunroof with glass lid - Assembly overview
  109
• 1.3 Sliding/tilting sunroof glass lid - remove
  111
• 1.4 Glass lid for sliding/tilting sunroof - install
  111
• 1.5 Glass lid for sliding/tilting sunroof (height adjustment) - adjust
  112
• 1.6 Lid trim - replace
  113
• 1.7 Air deflector - remove
  114
• 1.8 Sunroof lining - remove and install
  114
• 1.9 Sliding sunroof movement control unit J245 - remove
  115
• 1.10 Sliding/tilting sunroof selector key - remove
  116
• 1.11 Sliding sunroof activation motor V1 - remove
  116
• 1.12 Sliding sunroof motor V1 (zero position) - adjust
  117
• 1.13 Parallelism - check
  117
• 1.14 Parallelism - adjust
  117
• 1.15 Sliding guide - remove
  118
• 1.16 Sunroof - remove and install
  118
• 1.17 Guide with steel cable - remove
  121
• 1.18 Drain hoses - clean
  122
• Bumpers
  125
• 1 Front bumper
  125
• 1.1 Front protector - assembly overview
  125
• 1.2 Front bumper protector - remove and install
  126
• 1.3 Front protector support - assembly overview
  131
• 2 Rear bumper (Fox)
  132
• 2.1 Rear protector - assembly overview
  132
• 2.2 Rear protector - remove and install
  132
• 2.3 Rear protector support - remove and install
  134
• 3 Rear bumper (Spacefox)
  137
• 3.1 Rear bumper - assembly overview
  137
• 3.2 Rear protector - remove and install
  138
• 3.3 Rear protector support - assembly overview
  139
• Glazing
  140
• 1 Glasses glued with adhesive
  140
• 1.1 Tools
  140
• 1.2 Auxiliary materials for Brazilian market
  142
• 1.3 Auxiliary materials for export market
  142
• 1.4 Matching table
  143
• 1.5 Stickers for engraving the VIS number on the windows (only for Brazil) - supply
  143
• 1.6 Windscreen - assembly overview
  143
• 1.7 Windscreen - remove
  144
• 1.8 Windscreen - install
  145
• 1.9 Side glasses (Fox - 2-door) - assembly overview
  145
• 1.10 Undamaged side glass (Fox - 2-door) - remove
  146
• 1.11 Damaged side glass (Fox - 2-door) - remove
  147
• 1.12 Side glass internal trim (Fox - 2-door) - install
  147
• 1.13 Side glass (Fox - 2-door) - install
  148
• 1.14 Side glass (Spacefox) - assembly overview
  148
• 1.15 Undamaged side glass (Spacefox) - remove
  149
• 1.16 Damaged side glass (Spacefox) - remove
  150
• 1.17 Side glass (Spacefox) - install
  150
• 1.18 Rear window (Fox) - assembly overview
  150
• 1.19 Undamaged rear window (Fox) - remove
  151
• 1.20 Damaged rear window (Fox) - remove
  152
• 1.21 Rear window - install
  153
• 1.22 Rear glass (Spacefox) - assembly overview
  153
• 1.23 Undamaged rear window (Spacefox) - remove
  153
• 1.24 Damaged rear window (Spacefox) - remove
  155
• 1.25 Undamaged glass - prepare for install
  156
• 1.26 New glass - prepare for install
  157
• 1.27 Body flange - prepare to install the window
  158
• 1.28 Assembly instructions
  159
• 1.29 Minimum adhesive drying time
  160
• 1.30 Paint damage - repair
  161
• 1.31 Cleaning in case of resulting adhesive residues
  162
• 2 Tilting window
  163
• 2.1 Tilting window (Fox - 2-door) - remove and install
  163
• 2.2 Glass internal packing - install
  164
• 2.3 Tilting window - adjust
  164
• 3 Door window glass
  165
• 3.1 Front door window glass - assembly overview
  165
• 3.2 Front door window glass - remove and install
  165
• 3.4 Window drive mechanism - remove and install
  169
• 3.5 Window drive motor - remove and install
  171
• 3.6 Front door window crank - remove and install
  171
• 3.7 Front door window channel - remove and install
  172
• 3.8 Front door window internal trim - remove and install
  172
• 3.9 Front door window external trim - replace
  172
• 3.10 Rear door window glass - assembly overview
  172
• 3.11 Rear door window glass - remove and install
  174
• 3.12 Rear door window power activation mechanism - remove and install
  175
• 3.13 Rear door window drive motor - remove and install
  176
• 3.14 Rear door window drive mechanism - remove and install
  177
• 3.15 Rear door glass rear guide rail - remove and install
  177
• 3.16 Rear door window channel - remove and install
  178
• 3.17 Rear door window internal trim - remove and install
  178
• 3.18 Rear door window external trim - replace
  178
• 3.19 Rear door fixed glass - replace
  178
• Exterior equipment
  180
• 1 Materials used and operational care required
  180
• 1.1 Auxiliary materials for Brazilian market
  180
• 1.2 Auxiliary materials for export market
  180
• 1.3 Matching table
  181
• 1.4 Paint damage - repair
  181
• 1.6 Minimum adhesive drying time
  182
• 2 Spoiler
  183
• 2.1 Roof spoiler (Fox) - assembly overview
  183
• 2.2 Spoiler (Spacefox) - remove and install
  190
• 2.3 Assembly overview
  190
• 2.5 Remove
  191
• 2.6 Install
  193
• 3 Roof Rack
  197
• 3.1 Roof rack (Crossfox) - remove and install
  197
• 3.2 Roof rack (Spacefox) - remove and install
  197
• 3.3 Roof rack fastening support (Spacefox) - replace
  202
• 4 Inscriptions
  205
• 4.1 (1.6) version lettering - replace
  205
• 4.2 Model lettering (Fox) - replace
  206
• 4.3 “Total Flex” badge - replace
  207
• 4.4 Plus version badge (side) - replace
  207
• 4.5 Version and “Total Flex” Badge (CrossFox) - replace
  208
• 4.6 Wing and front door decorative stripe (Fox Extreme) - replace
  209
• 4.7 Rear door decorative stripe (Fox Extreme) - replace
  209
• 4.8 “Fox extreme” (Fox Extreme) Inscription - replace
  210
• 4.9 “Fox-shape” badge on door (Fox Extreme) - replace
  211
• 4.10 Side badge - BlackFox version (Fox BlackFox) - replace
  212
• 4.11 “BlackFox” (Fox BlackFox) Badge on rear door - replace
  212
• 4.12 Rear side panel “Refresh” (Fox Refresh) Badge - replace
  213
• 4.13 “Fox Sunrise” (Fox Sunrise) badge on rear door - replace
  214
• 4.14 “Fox Sunrise” (Fox Sunrise) badge on rear side - replace
  215
• 4.15 “Fox Sunrise” (Fox Sunrise) Badge on external rear-view mirror case - replace
  216
• 4.16 “Spacefox” lettering on rear lid - replace
  217
• 4.17 “1.6” lettering on rear lid (Spacefox) - replace
  217
• 4.18 Decorative stripe on bumper rear protector - replace
  218
• 4.19 CrossFox (► 2007) side badge - replace
  219
• 4.20 CrossFox (2008 ►) side badge - replace
  220
• 5 Side footboard (CrossFox and Fox Sunrise)
  221
• 5.1 Rear bumper trim - replace
  221
• 5.2 Rear side panel trim - replace
  222
• 5.3 Front wing trim - replace
  223
• 5.4 Side footboard (CrossFox ► 02.06) - assembly overview
  224
• 5.5 Side footboard (CrossFox ; ► 02.06) - remove and install
  225
• 5.6 Side footboard rear lining (CrossFox ; ► 02.06) - general overview of assembly
  229
• 5.7 Side footboard rear lining (CrossFox; ► 02.06) - replace
  230
• 5.8 Side footboard (CrossFox ; 03.06 ►) - assembly overview
  232
• 5.9 Side footboard (CrossFox ; 03.06 ►) - assembly overview - continued
  234
• 5.10 Side footboard (CrossFox ; 03.06 ►) - remove and install
  235
• 5.11 Side footboard rear lining (CrossFox ; 03.06 ►) - assembly overview
  238
• 5.12 Side footboard rear lining (Crossfox ; 03.06 ►) - replace
  240
• 6 External rear-view mirror
  242
• 6.1 External rear-view mirror - assembly overview
  242
• 6.2 Exterior rear-view mirror - remove and install
  243
• 6.3 Mirror glass - remove and install
  244
• 6.4 Mirror frame - remove and install
  244
• 6.5 Mirror glass - remove and install
  245
• 7 Side trims
  247
• 7.1 Side trims (Fox - 2-door) - replace
  247
• 7.2 External longitudinal member lower lining (Fox 09.06 ►) - assembly overview
  249
• 7.3 External longitudinal member lower lining (Fox 09.06 ►) - remove and install
  249
• 8 Wheel arch protector
  253
• 8.1 Front wheel arch protector - remove and install
  253
• 8.2 Rear wheel arch protector - remove and install
  254
• 8.3 Rear wheel arch protector (Spacefox) - remove and install
  255
• 9 Central bumper protector - (CrossFox)
  256
• 9.1 Front bumper centre protector (Crossfox ; ► 2007) - assembly overview
  256
• 9.2 Front bumper centre protector (CrossFox ; ► 2007) - remove and install
  256
• 9.3 Front bumper centre protector (CrossFox ; 2008 ►) - remove and install
  258
• 9.4 Rear bumper central protector (CrossFox) - remove and install
  259
• 10 External linings
  260
• 10.1 Lower windscreen covering - assembly overview
  260
• 10.2 Lower windscreen covering - remove and install
  261
• 10.3 Floor lower lining - assembly overview
  263
• 10.4 Lower longitudinal member external lining - replace
  263
• 10.5 Pillar and door external lining - replace
  265
• 11 Rear and front spoiler (Fox)
  268
• 11.1 Front spoiler (Fox 09.06 ►) - remove and install
  268
• 11.2 Rear spoiler (Fox 09.06 ►) - remove and install
  269
• 12 Spare wheel support (CrossFox)
  270
• 12.1 Spare wheel support upper (fixed) hinge - remove and install
  270
• 12.2 Spare wheel support upper (fixed) hinge - position adjustment
  272
• 12.3 Spare wheel support lower (fixed) hinge - remove and install
  272
• 12.4 Spare wheel support lower (fixed) hinge - position adjustment
  275
• 12.6 Spare wheel support (► 2007) - remove and install
  278
• 12.7 Spare wheel support (2008 ►) - remove and install
  279
• 12.8 Spare wheel support external cover (2008 ►) - remove and install
  282
• 12.9 Spare wheel support internal cover (2008 ►) - remove and install
  283
• 12.10 Support unlocking lever cover (2008 ►) - remove and install
  284
• 12.11 Support lock activation cable (2008 ►) - remove and install
  284
• 12.12 Spare wheel latch buffer - remove and install
  286
• 13 Crossfox components
  288
• 13.1 Assembly overview
  288