General body repairs, exterior

Chapter overview

• Body front
  1
• 1 Body - front
  1
• 1.1 Body - front
  1
• 1.2 Body - front > 09.99
  1
• 1.3 Removing and installing lock carrier with attachments
  1
• 1.4 Removing and installing skirt
  3
• 1.5 Removing and installing front wing
  4
• 2 Body, front 10.99 >
  6
• 2.1 Body, front 10.99 >
  6
• 2.2 Tools
  6
• 2.3 Lock carrier with attachments - Assembly overview
  7
• 2.4 Removing and installing lock carrier with attachments
  8
• 2.5 Lock carrier - service position
  10
• 2.6 Front wing - Assembly overview
  11
• 2.7 Wing dimensions
  13
• 2.8 Noise insulation (petrol engine) - Assembly overview
  14
• 2.9 Noise insulation (Diesel engine) - Assembly overview
  15
• Bonnet, Flaps
  16
• 1 Bonnet
  16
• 1.1 Bonnet
  16
• 1.2 Assembly overview
  16
• 1.3 Removing and installing bonnet 10.99 >
  18
• 1.4 Removing gas strut
  19
• 1.5 Releasing gas from strut
  20
• 1.6 Adjusting bonnet
  20
• 1.7 Removing and installing bonnet lock cable
  21
• 1.8 Removing and installing bonnet lock
  23
• 2 Rear boot lid/tailgate
  23
• 2.1 Rear boot lid/tailgate
  23
• 2.2 Tools
  23
• 2.3 Removing gas strut
  24
• 2.4 Releasing gas from strut
  25
• 2.5 Adjusting boot lid/tailgate
  25
• 2.6 Removing and installing tailgate/boot lid lock
  27
• 2.7 Removing and installing lock cylinder
  29
• 2.8 Maintaining common key locking
  32
• 3 Tank flap unit
  32
• 3.1 Tank flap unit
  32
• 3.2 Tools
  32
• 3.3 Assembly overview
  33
• 3.4 Removing and installing tank flap unit
  34
• 3.5 Dismantling and assembling tank flap unit
  36
• Front doors/Door components/Central locking system
  38
• 1 Doors front
  38
• 1.1 Doors front
  38
• 1.2 Tools
  38
• 1.3 Assembly overview
  39
• 1.4 Removing and installing door
  42
• 1.5 Adjusting door
  42
• 1.6 Front door 09.96 >
  43
• 1.7 Removing and installing front door 09.96 >
  46
• 1.8 Adjusting front door 09.96 >
  46
• 1.9 Driver's door of postal vehicles
  47
• 1.10 Door lock - Assembly overview
  49
• 1.11 Removing and installing door lock
  50
• 1.12 Removing inner release handle
  52
• 1.13 Door handle - Assembly overview
  52
• 1.14 Removing and installing door handle
  54
• 1.15 Maintaining common key locking
  56
• 1.16 Door handle with inner profile key - Assembly overview
  57
• 1.17 Removing and installing lock cylinder with inner profile key
  59
• 1.18 Door seals
  63
• 1.19 Removing and installing door inner seal
  64
• 2 Central locking
  65
• 2.1 Central locking
  65
• 2.2 Assembly overview
  65
• 2.3 New coupling and junction piece for pipe connector
  68
• 2.4 Removing and installing bi-pressure pump
  68
• 2.5 Removing and installing tank flap positioning element
  69
• 2.6 Removing and installing front door positioning element
  69
• 2.7 Removing and installing rear door lock positioning element
  71
• 2.8 Removing and installing boot lid/tailgate positioning element
  72
• 2.9 Activating individual door opening of central locking system
  72
• 2.10 Functional check of central locking
  73
• 2.11 Functional check of central locking with radio remote control
  73
• 2.12 Matching ignition keys to radio wave remote control
  74
• Rear doors/Door components
  75
• 1 Rear door
  75
• 1.1 Rear door
  75
• 1.2 Tools
  75
• 1.3 Assembly overview
  76
• 1.4 Removing and installing door
  79
• 1.5 Rear door 09.96 >
  80
• 1.6 Removing and installing rear door 09.96 >
  83
• 1.7 Adjusting door
  84
• 1.8 Door lock - Assembly overview
  85
• 1.9 Removing and installing door lock
  86
• 1.10 Removing inner release handle
  88
• 1.11 Door handle - Assembly overview
  89
• 1.12 Removing and installing door handle
  90
• 1.13 Door seals
  91
• 1.14 Removing and installing door inner seal
  92
• Sliding/tilting roof
  93
• 1 Sliding/tilting roof with glass panel > 09.99
  93
• 1.1 Sliding/tilting roof with glass panel > 09.99
  93
• 1.2 Sliding/tilting roof with glass panel - Assembly overview
  93
• 1.3 Removing sliding/tilting roof glass panel
  97
• 1.4 Adjusting panel seal
  97
• 1.5 Installing sliding/tilting roof glass panel
  98
• 1.6 Removing sliding headlining
  98
• 1.7 Installing sliding headlining
  99
• 1.8 Checking parallel running
  99
• 1.9 Adjusting parallel running
  99
• 1.10 Adjusting height of sliding/tilting roof glass panel
  100
• 1.11 Removing and installing carrier unit
  101
• 1.12 Setting "Zero position" on sliding/tilting roof drive
  103
• 1.13 Cleaning water drain hoses
  104
• 1.14 Sliding/tilting sunroof with glass panel 10.99 >
  106
• 1.15 Function
  106
• 1.16 Sliding/tilting roof with glass panel - Assembly overview
  107
• 1.17 Removing sliding/tilting sunroof glass panel
  111
• 1.18 Installing sliding/tilting sunroof glass panel
  111
• 1.19 Sliding/tilting roof glass panel (height adjustment)
  112
• 1.20 Adjusting panel seal
  113
• 1.21 Renewing panel seal
  114
• 1.22 Removing wind deflector
  115
• 1.23 Removing and installing sliding headlining
  115
• 1.24 Removing sliding/tilting sunroof preselector switch
  116
• 1.25 Removing drive for sliding/tilting sunroof
  117
• 1.26 Adjusting drive for sliding/tilting sunroof ("0" position)
  117
• 1.27 Checking parallel running
  117
• 1.28 Adjusting parallel running
  118
• 1.29 Removing coulisse guide
  119
• 1.30 Removing and installing carrier unit
  120
• 1.31 Removing guide and cable
  122
• 1.32 Cleaning water drain hoses
  124
• 2 Fabric folding roof
  126
• 2.1 Fabric folding roof
  126
• 2.2 Fabric folding roof assembly overview
  126
• 2.3 Removing and installing fabric folding roof complete
  130
• 2.4 Removing and installing folding roof with cover and trim panel
  130
• 2.5 Renewing fabric folding roof cover or trim panel
  133
• 2.6 Tensioning fabric folding roof
  134
• 2.7 Checking parallel running
  135
• 2.8 Adjusting parallel running
  135
• 2.9 Renewing roof spoiler
  135
• Bumpers
  137
• 1 Front bumper >09.99
  137
• 1.1 Front bumper >09.99
  137
• 1.2 Assembly overview
  137
• 2 Front bumper 10.99 >
  140
• 2.1 Front bumper 10.99 >
  140
• 2.2 Bumper cover - Assembly overview
  140
• 2.3 Removing and installing bumper cover
  143
• 2.4 Bumper carrier - Assembly overview
  144
• 3 Rear bumper
  145
• 3.1 Rear bumper
  145
• 3.2 Rear bumper > 09.99
  145
• 3.3 Assembly overview
  145
• 4 Rear bumper 10.99 >
  147
• 4.1 Rear bumper 10.99 >
  147
• 4.2 Bumper cover - Assembly overview
  147
• 4.3 Removing and installing bumper cover
  149
• 4.4 Bumper carrier - Assembly overview
  150
• Glazing
  152
• 1 Flush bonded windows
  152
• 1.1 Flush bonded windows
  152
• 1.2 Tools
  152
• 1.3 Materials
  153
• 1.4 Windscreen - Assembly overview
  154
• 1.5 Removing and installing plenum chamber trim
  156
• 1.6 Removing windscreen
  158
• 1.7 Installing windscreen
  159
• 1.8 Side window - Assembly overview
  160
• 1.9 Removing undamaged side window
  160
• 1.10 Removing broken side window
  162
• 1.11 Installing side window
  162
• 1.12 Rear window - Assembly overview
  163
• 1.13 Removing undamaged rear window
  163
• 1.14 Removing broken rear window
  165
• 1.15 Installing rear window
  165
• 1.16 Preparing old undamaged window for glazing
  166
• 1.17 Preparing new window for glazing
  167
• 1.18 Preparing body flange for glazing
  168
• 1.19 Installation instructions
  169
• 1.20 Curing time
  169
• 1.21 Touching up paint damage
  170
• 1.22 Cleaning off surplus adhesive sealing material
  170
• 2 Door windows
  171
• 2.1 Door windows
  171
• 2.2 Front door window - Assembly overview
  171
• 2.3 Removing and installing window slot seal
  172
• 2.4 Removing door window
  173
• 2.5 Adjusting door window
  174
• 2.6 Removing and installing window lifter
  174
• 2.7 Servicing electric window lifters
  175
• 2.8 Rear door window - Assembly overview
  178
• 2.9 Removing and installing door window
  179
• 2.10 Fitting door window to window lifter
  181
• 2.11 Removing and installing window lifters
  181
• 2.12 Removing and installing triangular window
  183
• Exterior equipment
  184
• 1 Roof moulding >09.99
  184
• 1.1 Roof moulding >09.99
  184
• 1.2 Removing and installing moulding for roof
  184
• 1.3 Removing and installing roof moulding for door
  185
• 2 Trim >09.99
  186
• 2.1 Trim >09.99
  186
• 2.2 Removing and installing radiator grille with trim frame
  186
• 3 Protective strips
  188
• 3.1 Protective strips
  188
• 3.2 Renewing side protective strips
  188
• 4 Removing and installing wheel housing liner
  190
• 4.1 Removing and installing wheel housing liner
  190
• 5 Rear view mirror >09.99
  191
• 5.1 Rear view mirror >09.99
  191
• 5.2 Tools
  191
• 5.3 Assembly overview
  192
• 6 Rear view mirror 10.99 >
  194
• 6.1 Rear view mirror 10.99 >
  194
• 6.2 Removing mirror housing
  194
• 7 Spoiler >09.99
  195
• 7.1 Spoiler >09.99
  195
• 7.2 Removing and installing front spoiler
  195
• 8 Rear spoiler
  196
• 8.1 Rear spoiler
  196
• 8.2 Tools
  196
• 8.3 Rear spoiler
  197
• 8.4 Assembly overview
  197
• 8.5 Removing and installing rear spoiler 10.99 >
  198