General body repairs, exterior

Chapter overview

• Body - front
  1
• 1 Lock carrier to 2010
  1
• 1.1 Assembly overview – lock carrier
  1
• 1.3 Service position with front bumper cover installed
  4
• 1.5 Removing and installing lock carrier with attachments
  7
• 2 Lock carrier from 2010
  10
• 2.1 Assembly overview – lock carrier
  10
• 2.3 Service position with front bumper cover removed
  13
• 2.4 Removing and installing front end with add-on parts
  13
• 2.5 Removing and installing subframe
  15
• 3 Wings
  18
• 3.1 Assembly overview - wing
  18
• 3.2 Removing and installing wing
  18
• 4 Bulkhead
  21
• 4.1 Assembly overview - plenum chamber bulkhead
  21
• 4.2 Assembly overview - plenum chamber cover
  22
• 4.3 Assembly overview - plenum chamber bulkhead
  24
• 4.4 Assembly overview - battery housing cover
  25
• 4.5 Removing and installing plenum chamber cover
  26
• Bonnet, rear lid
  30
• 1 Bonnet
  30
• 1.1 Assembly overview - bonnet
  30
• 1.2 Assembly overview - bonnet lock and release components
  32
• 1.3 Assembly overview - bonnet stay
  33
• 1.4 Removing and installing bonnet
  33
• 1.5 Adjusting bonnet
  35
• 1.6 Removing and installing rear lid lock
  36
• 1.7 Removing and installing striker pin
  38
• 1.8 Removing and installing bonnet release lever
  38
• 1.9 Removing and installing hinges
  38
• 1.10 Removing and installing insulation
  40
• 1.11 Removing and installing gas strut
  41
• 1.12 Releasing gas from gas strut
  42
• 2 Rear lid
  43
• 2.1 Assembly overview - rear lid
  43
• 2.2 Assembly overview - guide wedge and centring lug
  45
• 2.3 Assembly overview - locking and release components, rear lid
  46
• 2.4 Assembly overview - interior operating mechanism
  50
• 2.5 Assembly overview - light strip
  51
• 2.6 Removing and installing rear lid
  51
• 2.7 Adjusting rear lid
  53
• 2.8 Removing and installing light strip
  57
• 2.9 Removing and installing hinges
  58
• 2.10 Removing and installing rear lid lock
  64
• 2.11 Removing and installing childproof lock operating mechanism
  65
• 2.12 Removing and installing lock carrier for rear lid
  65
• 2.13 Removing lock cylinder from and installing in lock carrier
  69
• 2.14 Removing and installing mechanical lock cylinder
  70
• 2.15 Exterior handle without lock cylinder 2010, as of 2010
  72
• 2.16 Removing and installing interior door handle
  77
• 2.17 Removing and installing rear lid seal
  78
• 2.18 Removing and installing gas strut
  78
• 3 Tank flap unit
  80
• 3.1 Assembly overview - fuel tank flap
  80
• 3.2 Removing and installing fuel tank flap
  81
• Front doors, door components, central locking
  84
• 1 Door
  84
• 1.1 Assembly overview - front door
  84
• 1.2 Assembly overview - additional seals for postal and courier vehicles
  86
• 1.3 Removing and installing inner door seals
  86
• 1.4 Removing and installing door seal
  87
• 1.5 Removing and installing door seal
  88
• 1.6 Removing and installing front door
  89
• 1.7 Renewing front door
  91
• 1.8 Removing and installing striker pin
  92
• 1.9 Greasing new door hinges
  93
• 1.10 Adjusting door
  93
• 1.11 Adjusting striker pin
  97
• 2 Door components
  98
• 2.1 Assembly overview – subframe
  98
• 2.2 Assembly overview - door handle and door lock
  99
• 2.3 Assembly overview - window channels and window slot (aperture) seals
  100
• 2.4 Removing and installing subframe
  101
• 2.5 Removing and installing lock cylinder
  104
• 2.6 Removing and installing door handle
  105
• 2.7 Removing and installing door lock
  108
• 2.8 Removing and installing mounting bracket
  110
• 2.9 Removing and installing window regulator motor
  111
• 3 Central locking
  114
• 3.1 Overview of fitting locations - central locking
  114
• 3.2 Assembly overview - key with illumination and battery
  117
• 3.3 Assembly overview - ignition key to 2010
  118
• 3.4 Assembly overview - ignition key from 2010
  119
• 3.5 Removing and installing battery for illuminated key
  119
• 3.6 Removing and installing ignition key battery to 2010
  121
• 3.7 Removing and installing ignition key battery from 2010
  122
• Rear doors, door components
  123
• 1 Sliding door
  123
• 1.1 Assembly overview - sliding door roller guides
  123
• 1.2 Assembly overview - sliding door locking and release components
  125
• 1.3 Assembly overview - sliding door remote release mechanism
  127
• 1.4 Assembly overview - interior operating mechanism
  128
• 1.5 Assembly overview - middle guide rail
  129
• 1.6 Removing and installing inner door seals
  130
• 1.7 Removing and installing seal
  131
• 1.8 Removing and installing sliding door
  132
• 1.9 Adjusting sliding door
  133
• 1.10 Removing and installing striker pin
  138
• 1.11 Removing and installing striker pin and power latching motor
  139
• 1.12 Removing and installing lower roller guide
  141
• 1.13 Removing and installing door arrester
  142
• 1.14 Removing and installing hinge
  143
• 1.15 Removing and installing door lock
  144
• 1.16 Removing and installing sliding door remote release mechanism
  145
• 1.17 Removing and installing contact module and contact strip
  147
• 1.18 Removing and installing lock cylinder housing and exterior door handle
  149
• 1.19 Removing and installing mounting bracket
  149
• 1.20 Removing and installing interior door handle
  150
• 1.21 Removing and installing upper guide rail
  152
• 1.22 Removing and installing middle guide rail
  153
• 2 Electrically operated sliding door
  157
• 2.1 Assembly overview - electrical components of electrically operated sliding door
  157
• 2.2 Assembly overview - guide rail with roller bearing
  159
• 2.3 Assembly overview - upper roller guide with transponder
  160
• 2.4 Assembly overview - lower roller guide
  160
• 2.5 Assembly overview - wiring for electric sliding door operation
  162
• 2.7 Removing and installing sliding door with electrical controls
  164
• 2.8 Removing and installing striker pin with power latching motor
  165
• 2.9 Removing and installing door arrester
  167
• 2.10 Removing and installing motor to open right sliding door V323
  168
• 2.11 Removing and installing guide rail with roller bearing
  169
• 2.12 Removing and installing upper guide rail with reader coil
  172
• 2.13 Removing and installing upper roller guide with transponder
  174
• 2.14 Removing and installing lower roller guide
  175
• 2.15 Removing and installing right electric sliding door sender unit G481
  176
• 3 Sliding door - high
  178
• 3.1 Assembly overview - locking and release components for high sliding door
  178
• 3.2 Assembly overview - emergency release
  180
• 3.3 Removing and installing inner door seals
  180
• 3.4 Renewing pre-seal
  181
• 3.5 Removing and installing additional lock
  181
• 3.6 Removing and installing manual release mechanism
  182
• 3.7 Removing and installing centre stop
  183
• 3.8 Removing and installing guide wedge - wedge guide
  184
• 4 Cab door - double cab
  186
• 4.1 Assembly overview - cab door
  186
• 4.2 Assembly overview - door handle and door lock
  187
• 4.3 Removing and installing inner door seals
  188
• 4.4 Removing and installing cab door
  189
• 4.5 Adjusting cab door
  191
• 4.6 Removing and installing striker pin
  192
• 4.7 Removing and installing door hinge
  193
• 4.8 Removing and installing door arrester
  194
• 4.9 Removing and installing impact bar
  194
• 4.10 Removing and installing lock cylinder housing
  195
• 4.11 Removing and installing door handle
  196
• 4.12 Removing and installing mounting bracket
  199
• 4.13 Removing and installing door lock
  199
• 5 Wing doors
  203
• 5.1 Assembly overview - wing door
  203
• 5.2 Assembly overview - wing door hinges
  205
• 5.3 Assembly overview - door arrester with opening angle of 250°
  206
• 5.5 Assembly overview - locking and release components, wing doors, high roof
  208
• 5.6 Assembly overview – subframe
  209
• 5.7 Removing and installing wing door seal
  209
• 5.8 Removing and installing inner seal of wing door
  211
• 5.9 Removing and installing wing door
  211
• 5.10 Adjusting wing door
  213
• 5.11 Removing and installing upper striker pin
  219
• 5.12 Removing and installing lower striker pin
  220
• 5.13 Replacing wing door
  221
• 5.14 Removing and installing wing door hinges
  221
• 5.15 Removing and installing door arrester
  223
• 5.16 Installing stop in wing door for door arrester with opening angle of 250°
  224
• 5.17 Removing and installing upper right wing door lock
  226
• 5.18 Removing and installing release lever
  227
• 5.19 Removing and installing lower right wing door lock
  229
• 5.20 Removing and installing lower left wing door lock
  229
• 5.21 Removing and installing childproof lock
  230
• 5.22 Removing and installing latch carrier
  230
• 5.23 Removing and installing interior door handle
  232
• 5.24 Removing and installing exterior door handle
  232
• 5.25 Removing and installing subframe
  233
• 5.26 Removing and installing light strip
  235
• 5.27 Removing and installing upper left wing door lock
  235
• 5.28 Removing and installing lock cylinder
  236
• Sunroof
  238
• 1 Sliding/tilting sunroof with glass panel (Webasto)
  238
• 1.1 Assembly overview - sliding sunroof
  238
• 1.2 Function
  240
• 1.3 Removing and installing sliding/tilting sunroof glass panel
  241
• 1.4 Adjusting height of sliding/tilting sunroof glass panel
  242
• 1.5 Checking parallel running of glass panel
  243
• 1.6 Adjusting parallel running of glass panel
  244
• 1.7 Renewing panel seal
  244
• 1.8 Removing wind deflector
  244
• 1.9 Removing and installing sliding headliner
  245
• 1.10 Removing and installing sliding/tilting sunroof drive
  245
• 1.11 Adjusting drive for sliding/tilting sunroof (zero position)
  246
• 1.12 Removing pre-selector control for sliding/tilting sunroof
  248
• 1.13 Removing and installing carrier unit
  249
• 1.14 Operating without current
  250
• 1.15 Cleaning water drain hoses
  250
• Convertible roof, hardtop, canopy
  253
• 1 Convertible roof frame and soft top canopy
  253
• 1.1 Assembly overview - canopy frame with canopy
  253
• 1.2 Contact corrosion
  255
• Bumpers
  257
• 1 Front bumper cover to 2010
  257
• 1.1 Assembly overview - front bumper cover
  257
• 1.2 Assembly overview - front bumper cover, add-on parts
  259
• 1.3 Assembly overview - front bumper cover, add-on parts, commercial vehicles
  260
• 1.4 Assembly overview - bumper carrier
  261
• 1.5 Removing and installing front bumper cover
  261
• 1.6 Removing and installing bumper carrier
  264
• 1.7 Repairing front bumper cover
  265
• 2 Front bumper cover from 2010
  267
• 2.1 Assembly overview - front bumper cover
  267
• 2.2 Assembly overview - front bumper cover, add-on parts
  269
• 2.3 Assembly overview - parking aid and brackets in front bumper cover
  270
• 2.4 Assembly overview - bumper carrier
  271
• 2.5 Removing and installing front bumper cover
  271
• 2.6 Removing and installing front bumper carrier
  273
• 2.7 Repairing front bumper cover
  276
• 2.8 Installing brackets for parking aid system
  276
• 3 Rear bumper cover to 2010
  281
• 3.1 Assembly overview - rear bumper cover
  281
• 3.2 Assembly overview - rear bumper cover, add-on parts
  282
• 3.3 Assembly overview - parking aid and brackets in rear bumper cover
  283
• 3.4 Assembly overview - rear bumper cover, substructure parts
  283
• 3.5 Assembly overview - rear bumper carrier
  285
• 3.6 Removing and installing rear bumper cover
  285
• 3.7 Repairing rear bumper cover
  287
• 3.8 Installing brackets for parking aid system
  287
• 4 Rear bumper cover from 2010
  292
• 4.1 Assembly overview - rear bumper cover
  292
• 4.2 Removing and installing rear bumper cover
  293
• Glazing
  296
• 1 Repair instructions
  296
• 1.1 Minimum curing periods for bonded windows
  296
• 1.2 Window repair
  297
• 1.3 Fitting instructions
  298
• 1.4 Preparing old undamaged window for glazing
  299
• 1.5 Preparing new window for glazing
  300
• 1.6 Preparing body flange for glazing
  300
• 1.7 Touching up paint damage
  301
• 1.8 Cleaning off excess adhesive
  301
• 2 Windscreen
  302
• 2.1 Assembly overview - windscreen
  302
• 2.2 Windscreen spacings
  302
• 2.3 Removing and installing windscreen
  305
• 3 Side window
  310
• 3.1 Assembly overview - side windows
  310
• 3.2 Removing and installing rear side window
  313
• 4 Sliding window
  319
• 4.1 Assembly overview - sliding window
  319
• 4.2 Removing sliding window for sliding door
  319
• 4.3 Removing and installing sliding window in side panel
  321
• 5 Rear windscreen
  328
• 5.1 Assembly overview - rear window
  328
• 5.2 Assembly overview - rear window, double cab and dropside
  330
• 5.3 Assembly overview - rear window, wing door
  331
• 5.4 Assembly overview - sliding window and rear window for partition
  332
• 5.5 Removing undamaged double cab and dropside rear window
  332
• 5.6 Removing broken double cab and dropside rear window
  332
• 5.7 Installing rear window for double cab and dropside
  332
• 5.8 Removing undamaged rear window
  333
• 5.9 Removing broken rear window
  334
• 5.10 Installing rear window
  334
• 5.11 Removing undamaged wing door window
  334
• 5.12 Removing damaged wing door window
  335
• 5.13 Installing rear wing door window
  335
• 5.14 Removing and installing sliding window and rear window for partition
  335
• 6 Front door windows
  338
• 6.1 Removing and installing door window
  338
• 6.2 Adjusting door window
  338
• Exterior equipment
  340
• 1 Radiator grille to 2010
  340
• 1.1 Assembly overview - radiator grille
  340
• 1.2 Removing and installing radiator grille
  340
• 1.3 Removing and installing radiator grille trim and strip
  342
• 2 Radiator grille from 2010
  344
• 2.1 Assembly overview - radiator grille and emblem
  344
• 2.2 Removing and installing radiator grille and emblem
  345
• 3 Mouldings, trims, extensions
  346
• 3.1 Assembly overview - B-pillar trim
  346
• 3.2 Assembly overview - guide rail
  347
• 3.3 Removing and installing trim strip
  347
• 3.4 Removing and installing roller guide trim
  354
• 3.5 Removing and installing wing cover
  356
• 3.6 Removing and installing guide rail
  356
• 3.7 Renewing roof strip
  359
• 3.8 Renewing protective films
  359
• 4 Noise insulation
  361
• 4.1 Assembly overview - noise insulation
  361
• 4.2 Removing and installing noise insulation
  361
• 5 Underbody cladding
  364
• 5.1 Assembly overviews
  364
• 6 Trim film and protective film
  379
• 6.1 Removing and installing trim film for fog light trim
  379
• 6.2 Fitting instructions
  382
• 7 Exterior mirror to 2010
  383
• 7.1 Assembly overview – exterior mirror, up to 2010
  383
• 7.2 Removing and installing mirror housing
  383
• 7.3 Removing and installing mirror glass
  386
• 7.4 Removing and installing exterior mirror
  386
• 8 Exterior mirrors from 2010
  388
• 8.1 Assembly overview - exterior mirror
  388
• 8.2 Removing and installing mirror glass
  389
• 8.3 Removing and installing housing frame
  391
• 8.4 Removing and installing mirror housing
  393
• 8.5 Removing and installing exterior mirror
  394
• 9 Exterior mirror, double cab and dropside
  396
• 9.1 Assembly overview - exterior mirror, double cab and dropside
  396
• 9.2 Removing and installing double cab and dropside exterior mirror
  397
• 10 Wheel housing liner
  398
• 10.1 Assembly overview - front wheel housing liner
  398
• 10.2 Assembly overview - rear wheel housing liner
  399
• 10.3 Removing and installing front wheel housing liner
  399
• 10.4 Removing and installing rear wheel housing liner
  401
• 11 Lettering and emblem
  403
• 11.1 Assembly overview - lettering on rear lid
  403
• 11.2 Assembly overview - lettering on rear wing doors
  404
• 11.3 Assembly overview - lettering on rear lid, dropside
  405
• 11.4 Dimensions - lettering and emblems on rear lid
  407
• 11.5 Dimensions – lettering on rear, wing doors
  408
• 11.6 Dimensions – lettering on rear, dropside
  410
• 11.7 Removing and installing rear emblem
  411
• 11.8 Removing and installing “BLUEMOTION” lettering on radiator grille
  413
• 11.9 Removing and installing lettering or emblem
  414
• 12 Load floor body
  415
• 12.1 Contact corrosion
  415
• 12.2 Assembly overview - dropside body
  415
• 12.3 Load floor and tailboard
  416
• 12.4 Assembly overview – tailboard, add-on parts
  419
• 12.5 Assembly overview - skid plate for short wheelbase
  420
• 12.6 Assembly overview - skid plate for long wheelbase
  421
• 12.7 Assembly overview - rear wheel housing
  422
• 12.8 Assembly overview - tank trim
  423
• 13 Towing bracket
  424
• 13.1 Assembly overview - rigid towing bracket
  424
• 13.2 Assembly overview - towing bracket, double cab and dropside
  426
• 13.3 Assembly overview - towing eye
  427
• 13.4 Removing and installing rigid towing bracket
  427
• 13.5 Removing and installing towing bracket, double cab and dropside
  429
• 13.6 Removing and installing towing eye
  431
• 14 Spare wheel bracket
  433
• 14.1 Assembly overview - closed bodies
  433
• 14.2 Assembly overview - open bodies
  433
• 15 Mudflap
  435
• 15.1 Assembly overview - front mud flaps
  435
• 15.2 Assembly overview - rear mud flaps
  436
• 15.3 Assembly overview - rear mud flaps, double cab and dropside
  437