General body repairs, exterior

Chapter overview

• Body - front
  1
• 1 Body, front
  1
• 1.1 Tools
  1
• 1.2 Lock carrier - service position (vehicles with long front-end)
  1
• 1.3 Removing and installing lock carrier with add-on parts
  3
• 2 Front wing
  6
• 2.1 Tools
  6
• 2.2 Assembly overview 01.96 ▸
  6
• 3 Noise insulation
  9
• 3.1 Tools
  9
• 3.2 Assembly overview
  9
• 3.3 Renewing damping material
  10
• Bonnet, rear lid
  11
• 1 Bonnet
  11
• 1.1 Tools
  11
• 1.2 Removing bonnet ▸ 12.95
  11
• 1.3 Installing and adjusting bonnet ▸ 12.95
  12
• 1.4 Assembly overview 01.96 ▸
  13
• 1.5 Removing bonnet 01.96 ▸
  15
• 1.6 Installing and adjusting bonnet 01.96 ▸
  16
• 1.7 Removing and installing bonnet lock cable ▸ 12.95
  18
• 1.8 Removing and installing bonnet lock and bonnet lock cable 01.96 ▸
  18
• 2 Tailgate
  20
• 2.1 Tools
  20
• 2.2 Assembly overview
  20
• 2.3 Removing and installing bonnet
  21
• 2.4 Adjusting tailgate
  22
• 2.5 Removing and installing tailgate lock mechanism
  24
• 2.6 Removing and installing lock cylinder
  25
• 2.7 Removing gas strut
  25
• 2.8 Releasing gas from gas strut
  26
• Front doors, door components, central locking
  27
• 1 Front door
  27
• 1.1 Tools
  27
• 1.2 Assembly overview
  27
• 1.3 Removing and installing door ▸ 12.95
  29
• 1.4 Installing and adjusting door ▸ 12.95
  29
• 1.5 Removing and installing door 01.96 ▸
  30
• 1.6 Installing and adjusting door 01.96 ▸
  31
• 1.7 Removing and installing window regulator
  33
• 1.8 Repairing electric window regulators
  34
• 1.10 Overcoming resistance with excess force limitation
  36
• 1.11 Initialising and releasing automatic closing function
  36
• 1.12 Removing door window
  37
• 1.13 Installing door window
  37
• 1.14 Removing exterior door handle
  38
• 1.15 Removing door lock
  38
• 1.16 Removing lock cylinder (front door, side wing door)
  38
• 2 Central locking
  39
• 2.1 Tools
  39
• 2.2 Assembly overview - central locking
  39
• 2.3 Removing and installing front door positioning element
  40
• 2.4 Removing and installing sliding door lock actuating element
  41
• 2.5 Removing and installing tailgate door lock positioning element
  41
• 2.6 Removing and installing wing door lock actuating element
  42
• 2.7 Functional check of central locking with radio remote control
  42
• 2.8 Synchronising keys with radio remote control ▸ 04.00
  43
• 2.9 Removing and installing batteries for key with remote control ▸ 04.00
  44
• 2.10 Adapting ignition keys to remote control 05.00 ▸
  46
• 2.11 Adapting a new additional key 05.00 ▸
  49
• 2.12 Adapting ignition keys to remote control 05.00 ▸
  50
• Rear doors, door components
  53
• 1 Sliding door
  53
• 1.1 Tools
  53
• 1.2 Assembly overview ▸ 12.95
  53
• 1.3 Assembly overview 01.96 ▸ 03.01
  55
• 1.4 Assembly overview 04.01 ▸
  57
• 1.5 Removing and installing sliding door ▸ 03.01
  58
• 1.6 Removing and installing sliding door 04.01 ▸
  59
• 1.7 Removing and installing door arrester
  61
• 1.8 Adjusting sliding door ▸ 12.95
  61
• 1.9 Adjusting sliding door 01.96 ▸ 03.01
  64
• 1.10 Removing sliding door 04.01 ▸
  67
• 1.11 Removing and installing central lock
  70
• 1.12 Removing and installing exterior door handle
  71
• 1.13 Removing and installing lock cylinder (sliding door)
  72
• 1.14 Assembly overview - guide rail
  73
• 2 Rear wing door
  74
• 2.1 Tools
  74
• 2.2 Assembly overview - left wing door
  74
• 2.3 Assembly overview - right wing door
  75
• 2.4 Removing and installing wing door
  76
• 2.5 Adjusting wing doors
  77
• 2.6 Removing and installing door locks
  78
• 2.7 Removing and installing lock operating mechanism
  80
• 2.8 Adjusting lock operating mechanism
  80
• 2.9 Removing and installing inner door handle
  81
• 2.10 Removing and installing lock cylinder
  81
• 3 Side wing door
  82
• 3.1 Tools
  82
• 3.2 Assembly overview - side wing door
  82
• 3.3 Removing and installing wing door
  83
• 3.4 Removing and installing door lock
  85
• Sunroof
  86
• 1 Sunroof with glass panel
  86
• 1.1 Tools
  86
• 1.2 Assembly overview - sliding/tilting sunroof
  86
• 1.3 Removing sliding/tilting sunroof glass panel
  88
• 1.4 Installing sliding/tilting sunroof glass panel
  88
• 1.5 Adjusting height of sliding/tilting sunroof glass panel
  89
• 1.6 Adjusting panel seal
  90
• 1.7 Removing and installing electric drive
  90
• 1.8 Checking electric drive (0 position)
  91
• 1.9 Checking and adjusting parallel running
  93
• 1.10 Removing sliding headlining
  94
• 1.11 Installing sliding headlining
  96
• 1.12 Removing and installing carrier unit
  96
• 1.13 Routing and cleaning water drain hoses
  99
• 2 Servicing glass/tilting sun roof
  101
• 2.1 Assembly overview - glass/tilting roof
  101
• 2.2 Removing glass panel
  101
• 2.3 Installing glass panel
  102
• 2.4 Routing and cleaning water drain hoses
  103
• 3 Tilting/sliding roof with glass panel
  107
• 3.1 Tools
  107
• 3.2 Assembly overview - tilting/sliding roof
  107
• 3.3 Removing and installing tilting/sliding roof
  108
• 3.4 Removing and installing water collector plate (with sunblind)
  109
• 3.5 Removing and installing glass panel for tilting/sliding roof
  110
• 3.6 Removing and installing electric drive
  111
• 3.7 Checking parallel running
  111
• 3.8 Adjusting parallel running
  111
• Convertible roof, hardtop, canopy
  113
• 1 Fitting the canopy frame and the canopy
  113
• 1.1 Tools
  113
• 1.2 Canopy frame for dropside and double cab
  113
• 1.3 Assembly overview - canopy frame for dropside and double cab
  113
• 1.4 Assembly overview - canopy frame (cab height) for double cab
  114
• 1.5 Installing canopy frame and canopy
  116
• Bumpers
  118
• 1 Front bumper
  118
• 1.1 Tools
  118
• 1.2 Assembly overviews
  118
• 2 Rear bumper
  122
• 2.1 Tools
  122
• 2.2 Assembly overviews
  122
• 2.3 Towing bracket 08.90 ▸
  124
• Glazing
  126
• 1 Flush bonded windows
  126
• 1.1 Tools
  126
• 1.2 Materials
  127
• 1.3 Assembly overview - flush bonded windows
  128
• 1.4 Spacings for flush bonded windows
  129
• 1.5 Windscreen
  131
• 1.6 Assembly overview - side and rear window
  133
• 1.7 Removing windscreen and undamaged side, rear window
  133
• 1.8 Removing broken side and rear windows
  135
• 1.9 Installing windscreen, side and rear windows
  136
• 1.10 Preparing old undamaged window for glazing
  136
• 1.11 Preparing new window for glazing
  136
• 1.12 Preparing body flange or door window flange for glazing
  137
• 1.13 Installation instructions
  137
• 1.14 Minimum curing period
  138
• 1.15 Touching up paint damage
  138
• 1.16 Cleaning off excess adhesive sealing material
  138
• 1.17 Installing frame (repair profile) (side and rear windows)
  138
• 1.18 Touching up window sealant
  139
• 2 Windows having threaded connections
  141
• 2.1 Tools
  141
• 2.2 Assembly overview - side window with air intake vent
  141
• 2.3 Removing and installing side window with air intake vent
  142
• 3 Sliding window
  144
• 3.1 Tools
  144
• 3.2 Assembly overviews - sliding window (sliding door)
  144
• 3.3 Replacing detent rail
  149
• 3.4 Renewing sealing frame
  150
• 3.5 Renewing web
  151
• 3.6 Renewing sliding window
  151
• 3.7 Retrofitting sliding window
  152
• Exterior equipment
  159
• 1 Exterior mirror
  159
• 1.1 Tools
  159
• 1.2 Exterior mirror
  159
• 2 Trim
  162
• 2.1 Tools
  162
• 2.2 Assembly overview - radiator grille ▸ 12.95
  162
• 2.3 Removing radiator grille ▸ 08.94
  163
• 2.4 Radiator grille with trim frame 09.94 ▸
  164
• 2.5 Removing and installing radiator grille 01.96 ▸
  166
• 3 Cover strip for number plate lighting
  167
• 3.1 Tools
  167
• 3.2 Removing and installing for tailgate
  167
• 3.3 For removing and installing rear wing door
  167