General body repairs, exterior

Chapter overview

• Body - front
  1
• 1 Lock carrier
  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 components
  3
• 2 Front wing
  6
• 2.1 Assembly overview - front wing 01.96 ▸
  6
• 3 Noise insulation
  7
• 3.1 Assembly overview - noise insulation
  7
• 3.2 Renewing damping material
  8
• Bonnet, rear lid
  9
• 1 Bonnet
  9
• 1.1 Removing bonnet ▸ 12.95
  9
• 1.2 Installing and adjusting bonnet ▸ 12.95
  10
• 1.3 Assembly overview - bonnet 01.96 ▸
  11
• 1.4 Removing bonnet 01.96 ▸
  13
• 1.5 Installing and adjusting bonnet 01.96 ▸
  14
• 1.6 Removing and installing bonnet lock cable ▸ 12.95
  16
• 1.7 Removing and installing bonnet lock cable 01.96 ▸
  16
• 2 Rear lid
  18
• 2.1 Assembly overview - rear lid
  18
• 2.2 Removing and installing rear lid
  19
• 2.3 Adjusting rear lid
  20
• 2.4 Removing rear lid lock mechanism
  22
• 2.5 Removing lock cylinder
  23
• 2.6 Removing gas strut
  23
• 2.7 Releasing gas from gas strut
  24
• Front doors, door components, central locking
  25
• 1 Front door
  25
• 1.1 Assembly overview - front door
  25
• 1.2 Removing door ▸ 12.95
  26
• 1.3 Installing and adjusting door ▸ 12.95
  27
• 1.4 Removing door 01.96 ▸
  28
• 1.5 Installing and adjusting door 01.96 ▸
  28
• 1.6 Removing window lifters
  30
• 1.7 Repairing electric window lifters
  31
• 1.9 Over coming resistance with excess force limitation
  33
• 1.10 Initialising and releasing automatic closing function
  33
• 1.11 Removing and installing door window
  34
• 1.12 Removing door outer handle
  35
• 1.13 Removing door lock
  35
• 1.14 Removing lock cylinder (front door / side wing door)
  35
• 2 Central locking
  36
• 2.1 Assembly overview - central locking
  36
• 2.2 Removing and installing front door positioning element
  37
• 2.3 Removing and installing sliding door lock actuating element
  37
• 2.4 Removing and installing rear lid actuating element
  38
• 2.5 Removing and installing wing door lock actuating element
  38
• 2.6 Functional check of central locking with radio remote control
  38
• 2.7 Synchronising keys with radio remote control ▸ 04.00
  39
• 2.8 Removing and installing batteries for key with remote control ▸ 04.00
  40
• 2.9 Adapting ignition keys to remote control 05.00 ▸
  42
• 2.10 Adapting a new additional key 05.00 ▸
  43
• 2.11 Adapting ignition keys to remote control 05.00 ▸
  43
• 2.12 Assembly overview - battery for remote control with folding key 05.00 ▸
  43
• Rear doors, door components
  46
• 1 Sliding door
  46
• 1.1 Assembly overview - sliding door ▸ 12.95
  46
• 1.2 Assembly overview - sliding door 01.96 ▸ 03.01
  47
• 1.3 Assembly overview - sliding door 04.01 ▸
  49
• 1.4 Removing sliding door ▸ 03.01
  50
• 1.5 Removing sliding door 04.01 ▸
  51
• 1.6 Removing door arrester
  52
• 1.7 Removing step insert
  53
• 1.8 Adjusting sliding door ▸ 12.95
  53
• 1.9 Adjusting sliding door 01.96 ▸ 03.01
  56
• 1.10 Removing sliding door 04.01 ▸
  58
• 1.11 Removing central lock
  61
• 1.12 Removing door outer handle
  62
• 1.13 Removing lock cylinder (sliding door)
  63
• 1.14 Assembly overview - guide rail
  63
• 2 Side wing door
  65
• 2.1 Assembly overview - side wing door
  65
• 2.2 Removing, installing and adjusting side wing door
  66
• 2.3 Installing and adjusting wing door
  67
• 2.4 Removing door lock
  68
• 3 Rear wing door
  69
• 3.1 Assembly overview - left wing door
  69
• 3.2 Assembly overview - right wing door
  69
• 3.3 Removing wing door
  71
• 3.4 Adjusting wing doors
  71
• 3.5 Removing door locks
  73
• 3.6 Removing lock operating mechanism
  75
• 3.7 Adjusting lock operating mechanism
  75
• 3.8 Removing door inner opener
  76
• 3.9 Removing lock cylinder
  76
• Sunroof
  77
• 1 Sunroof with glass panel
  77
• 1.1 Assembly overview - sliding/tilting sunroof
  77
• 1.2 Removing sunroof glass panel
  78
• 1.3 Installing sliding/tilting sunroof glass panel
  78
• 1.4 Adjusting sunroof glass panel height
  79
• 1.5 Adjusting panel seal
  80
• 1.6 Removing and installing electric drive
  80
• 1.7 Checking electric drive (0 position)
  81
• 1.8 Checking and adjusting parallel running
  82
• 1.9 Removing sliding headlining
  84
• 1.10 Installing sliding headlining
  85
• 1.11 Removing and installing carrier unit
  86
• 1.12 Routing and cleaning water drain hoses
  89
• 2 Repairing glass/tilting sunroof
  91
• 2.1 Assembly overview - glass/tilting sunroof
  91
• 2.2 Removing glass panel
  91
• 2.3 Installing glass panel
  92
• 2.4 Routing and cleaning water drain hoses
  93
• 3 Sliding/tilting sunroof with glass panel
  97
• 3.1 Assembly overview - sliding/tilting sunroof
  97
• 3.2 Removing and installing sliding/tilting sunroof
  98
• 3.3 Removing and installing water collector plate (with sun roller blind)
  99
• 3.4 Removing and installing glass panel for sliding/tilting sunroof
  100
• 3.5 Removing and installing electric drive
  101
• 3.6 Checking parallel running
  101
• 3.7 Adjusting parallel running
  101
• Convertible soft top, hardtop, canopy
  103
• 1 Fitting the canopy frame and the canopy
  103
• 1.1 Canopy frame for dropside and double cab
  103
• 1.2 Assembly overview - canopy frame for dropside and double cab
  103
• 1.3 Assembly overview - canopy frame (cab height) for double cab
  104
• 1.4 Installing canopy frame and canopy
  106
• Bumpers
  108
• 1 Front bumper
  108
• 1.1 Assembly overview - front bumper ▸ 12.95
  108
• 1.2 Assembly overview - front bumper 01.96 ▸, long front end
  108
• 1.3 Assembly overview - 01.96 ▸, short front end
  109
• 2 Rear bumper
  111
• 2.1 Assembly overview - rear bumper ▸ 12.95
  111
• 2.2 Assembly overview - rear bumper 01.96 ▸
  112
• Glazing
  113
• 1 Flush bonded windows
  113
• 1.1 Tools
  113
• 1.2 Materials
  114
• 1.3 Assembly overview - flush bonded windows
  115
• 1.4 Assembly overview - windscreen
  116
• 1.5 Assembly overview - side and rear window
  117
• 1.6 Removing windscreen and undamaged side or rear window
  117
• 1.7 Removing damaged side and rear windows
  119
• 1.8 Installing windscreen, side and rear windows
  120
• 1.9 Preparing old undamaged window for glazing
  120
• 1.10 Preparing new window for glazing
  120
• 1.11 Preparing body flange or door window flange for glazing
  121
• 1.12 Installation instructions
  121
• 1.13 Curing time
  124
• 1.14 Touching up paint damage
  125
• 1.15 Cleaning off excess adhesive sealing material
  125
• 1.16 Installing frame (repair profile) (side and rear windows)
  125
• 1.17 Touching up window sealant
  126
• 2 Windows having threaded connections
  128
• 2.1 Assembly overview - side window with air intake vent
  128
• 2.2 Removing and installing side window with air intake vent
  128
• 3 Sliding window
  131
• 3.1 Assembly overview - sliding window (sliding door) ▸ 05.94
  131
• 3.2 Assembly overview - sliding window (sliding door) 06.94 ▸
  133
• 3.3 Assembly overview - sliding window with insect screen (sliding door) ▸ 05.94
  134
• 3.4 Assembly overview - sliding window with insect screen (sliding door) 06.94 ▸
  135
• 3.5 Replacing detent rail
  137
• 3.6 Renewing sealing frame
  138
• 3.7 Removing and installing web
  138
• 3.8 Removing and installing sliding window
  139
• 3.9 Retrofitting sliding window
  140
• Exterior equipment
  146
• 1 Trim
  146
• 1.1 Tools
  146
• 1.2 Assembly overview - radiator grille ▸ 12.95
  146
• 1.3 Removing and installing radiator grille ▸ 08.94
  148
• 1.4 Assembly overview - radiator grille with trim frame
  149
• 1.5 Removing and installing radiator grille with trim frame 09.94 ▸
  149
• 1.6 Assembly overview - radiator grille 01.96 ▸
  151
• 1.7 Removing and installing radiator grille 01.96 ▸
  152
• 2 Exterior mirror
  153
• 2.1 Tools
  153
• 2.2 Removing and installing exterior mirror
  153
• 3 Removing trim strip for number plate lighting/rear wing door
  154
• 4 Removing trim strip for number plate lighting/rear lid
  155