General body repairs, exterior

Chapter overview

• Body - front
  1
• 1 Lock carrier
  1
• 1.1 Tools
  1
• 1.2 Electrical and electronic components and fitting locations
  2
• 1.3 Assembly overview - lock carrier, service position
  3
• 1.4 Assembly overview - lock carrier service position, W12 petrol engine
  4
• 1.5 Service position
  5
• 1.6 Assembly overview - lock carrier with add-on parts
  8
• 1.7 Removing and installing lock carrier with add-on parts
  9
• 2 Wing
  11
• 2.1 Tools
  11
• 2.2 Assembly overview - front wing
  11
• 2.3 Removing and installing front wing
  12
• 2.4 Front wing - bolting sequence
  14
• 3 Noise insulation
  16
• 3.1 Tools
  16
• 3.2 Assembly overview - noise insulation
  16
• 4 Underbody cladding
  18
• 4.1 Tools
  18
• 4.2 Assembly overview - underbody panel
  18
• 5 Plenum chamber bulkhead
  20
• 5.1 Tools
  20
• 5.2 Assembly overview - plenum chamber bulkhead
  20
• 6 Skid plate
  21
• 6.1 Tools
  21
• 6.2 Assembly overview - skid plate
  21
• 6.3 Assembly overview - engine skid plate
  23
• 6.4 Removing and installing engine skid plate
  24
• 6.5 Assembly overview - gearbox skid plate
  26
• 6.6 Removing and installing gearbox skid plate
  27
• 6.7 Assembly overview - rear differential skid plate
  29
• 6.8 Removing and installing rear differential skid plate
  30
• 6.9 Assembly overview - fuel tank underride guard
  32
• 6.10 Assembly overview - wishbone skid plate
  33
• 6.11 Assembly overview - sill guard
  34
• Bonnet, rear lid
  35
• 1 Contact corrosion!
  35
• 2 Bonnet
  36
• 2.1 Tools
  36
• 2.2 Assembly overview - bonnet
  36
• 2.3 Removing and installing bonnet
  38
• 2.4 Removing gas strut
  39
• 2.5 Releasing gas from gas strut
  39
• 2.6 Removing and installing insulation
  40
• 2.7 Assembly overview - locking and release components
  40
• 2.8 Removing and installing bonnet lock
  41
• 2.9 Adjusting bonnet
  43
• 2.10 Separating Bowden cable
  45
• 2.11 Removing and installing release lever
  45
• 3 Rear lid
  48
• 3.1 Tools
  48
• 3.2 Assembly overview - rear lid
  48
• 3.3 Removing and installing rear lid
  50
• 3.4 Adjusting rear lid
  51
• 3.5 Assembly overview - guide pins and guide wedges
  53
• 3.6 Adjusting guide wedge and guide pin
  55
• 3.7 Assembly overview - rear lid hinge
  56
• 3.8 Removing and installing rear lid hinges
  56
• 3.9 Removing and installing gas strut cover > 15.06
  58
• 3.10 Removing and installing gas strut cover 16.06 >
  58
• 3.11 Assembly overview - gas strut for rear lid opening window
  59
• 3.12 Removing and installing gas strut for rear lid opening window
  60
• 3.13 Assembly overview - rear lid gas strut
  62
• 3.14 Removing and installing rear lid gas strut
  63
• 3.15 Releasing gas from gas strut
  65
• 3.16 Assembly overview - hydraulic rear lid drive
  65
• 3.17 Removing and installing hydraulic pump for hydraulic rear lid drive
  67
• 3.18 Removing and installing hydraulic cylinder for hydraulic rear lid drive
  69
• 3.19 Filling with hydraulic fluid and checking fluid level
  73
• 3.20 Removing and installing control unit
  75
• 3.21 Removing and installing angle sensor
  76
• 3.22 Basic setting of rear lid electronics
  78
• 3.23 Assembly overview - locking and release components
  79
• 3.24 Removing and installing locking and release components
  80
• 3.25 Removing and installing rear lid lock
  81
• 3.26 Removing and installing striker pin with power latching system
  81
• 3.27 Removing and installing rear lid release motor
  82
• 3.28 Removing and installing rear lid opening window lock
  82
• 3.29 Removing and installing rear lid window release unit
  83
• 3.30 Assembly overview - handle for vehicles with spare wheel carrier on rear lid
  83
• 3.31 Removing and installing handle for vehicles with spare wheel carrier on rear lid
  85
• 3.32 Rear lid seal
  86
• 3.33 Removing and installing rear lid seal
  86
• 4 Rear spoiler
  89
• 4.1 Tools
  89
• 4.2 Assembly overview - rear spoiler
  89
• 4.3 Removing and installing rear spoiler
  90
• 5 Tank flap unit
  92
• 5.1 Tools
  92
• 5.2 Assembly overview - tank flap unit
  92
• 5.3 Removing and installing fuel tank filler cap locking and release components
  94
• Front doors, door components, central locking
  96
• 1 Front door
  96
• 1.1 Tools
  96
• 1.2 Assembly overview - front door
  97
• 1.3 Assembly overview - fittings carrier individual parts
  99
• 1.4 Assembly overview - door hinges
  100
• 1.5 Greasing new door hinges
  102
• 1.6 Removing and installing door
  103
• 1.7 Door adjustment
  103
• 1.8 Adjusting striker pin
  104
• 1.9 Assembly overview - door handle and door lock
  105
• 1.10 Removing and installing lock cylinder housing
  106
• 1.11 Removing and installing door handle
  107
• 1.12 Door handle with (Kessy) cable routing
  109
• 1.13 Removing and installing door lock
  109
• 1.14 Door seals
  114
• 1.15 Removing and installing inner door seal
  115
• 1.16 Removing and installing outer door seal
  115
• 1.17 Removing and installing door seal
  117
• 2 Central locking
  118
• 2.1 Assembly overview - central locking and convenience system
  118
• 2.2 Adapting keys with remote control
  120
• 2.3 Assembly overview - batteries for main key (foldable) with remote control
  121
• 2.4 Removing and installing batteries for folding main key with remote control system
  122
• Rear doors, door components
  123
• 1 Rear door
  123
• 1.1 Tools
  123
• 1.2 Assembly overview - rear door
  124
• 1.3 Assembly overview - fittings carrier individual parts
  126
• 1.4 Assembly overview - door hinges
  127
• 1.5 Greasing new door hinges
  129
• 1.6 Removing and installing door
  130
• 1.7 Adjusting door
  130
• 1.8 Adjusting striker pin
  131
• 1.9 Assembly overview - door handle and door lock
  132
• 1.10 Removing and installing lock cylinder housing
  133
• 1.11 Removing and installing door handle
  134
• 1.12 Door handle with (Kessy) cable routing
  136
• 1.13 Removing and installing door lock
  136
• 1.14 Door seals
  141
• 1.15 Removing and installing inner door seal
  141
• 1.16 Removing and installing outer door seal
  141
• 1.17 Removing and installing door seal
  143
• Sunroof
  144
• 1 Sunroof with glass panel
  144
• 1.1 Tools
  144
• 1.2 Function
  144
• 1.3 Assembly overview
  145
• 1.4 Removing sliding/tilting sunroof glass panel
  147
• 1.5 Installing sliding/tilting sunroof glass panel
  147
• 1.6 Adjusting height of sliding/tilting sunroof glass panel
  148
• 1.7 Checking parallel running of glass panel
  149
• 1.8 Adjusting parallel running of glass panel
  149
• 1.9 Adjusting panel seal
  150
• 1.10 Renewing panel seal
  150
• 1.11 Removing wind deflector
  151
• 1.12 Removing sliding headliner
  151
• 1.13 Removing drive for sliding/tilting sunroof
  152
• 1.14 Adjusting drive for sunroof (zero position)
  152
• 1.15 Removing pre-selector control for sliding/tilting sunroof
  153
• 1.16 Removing and installing carrier unit
  153
• 1.17 Removing coulisse guide
  155
• 1.18 Operating without current
  155
• 1.19 Cleaning water drain hoses
  156
• 2 Remove sliding/tilting sunroof with solar panel
  158
• 2.1 Tools
  158
• 2.2 Function
  158
• 2.3 Assembly overview
  159
• 2.4 Removing sliding/tilting sunroof solar panel
  160
• 2.5 Installing sliding/tilting sunroof solar panel
  161
• 2.6 Adjusting sliding/tilting sunroof solar panel height
  161
• 2.7 Checking parallel running of solar panel
  162
• 2.8 Adjusting parallel running of solar panel
  163
• 2.9 Renewing panel seal
  163
• 2.10 Removing wind deflector
  163
• 2.11 Removing solar panel trim
  164
• 2.12 Removing sliding/tilting sunroof drive
  164
• 2.13 Adjusting drive for sliding/tilting sunroof (zero position)
  165
• 2.14 Removing preselection control for sliding/tilting sunroof
  166
• 2.15 Removing and installing DC converter
  166
• 2.16 Removing and installing solar contact in solar panel
  166
• 2.17 Removing and installing solar contact in carrier unit
  167
• 2.18 Removing and installing carrier unit
  167
• 2.19 Operating without current
  169
• 2.20 Cleaning water drain hoses
  170
• Bumpers
  172
• 1 Front bumper > 10.2006
  172
• 1.1 Tools
  172
• 1.2 Repairing bumper cover
  172
• 1.3 Assembly overview - bumper cover
  172
• 1.4 Removing and installing bumper cover
  173
• 1.5 Front bumper add-on parts
  175
• 1.6 Front bumper cover - preparation for vehicles with skid plate
  176
• 1.7 Front bumper cover - preparation for vehicles with cable winch
  177
• 1.8 Front bumper substructure
  181
• 1.9 Assembly overview - bumper carrier
  182
• 1.10 Removing and installing bumper carrier
  182
• 1.11 Bumper carrier with cable winch mounting bracket
  183
• 2 Front bumper 11.2006 >
  187
• 2.1 Tools
  187
• 2.2 Repairing bumper cover
  187
• 2.3 Assembly overview - bumper cover
  187
• 2.4 Removing and installing bumper cover
  188
• 2.5 Front bumper add-on parts
  191
• 2.6 Front bumper substructure
  192
• 2.7 Assembly overview - bumper carrier
  193
• 2.8 Removing and installing bumper carrier
  193
• 3 Rear bumper
  195
• 3.1 Tools
  195
• 3.2 Repairing bumper cover
  195
• 3.3 Assembly overview - bumper cover
  195
• 3.4 Removing and installing bumper cover
  196
• 3.5 Rear bumper add-on parts
  199
• 3.6 Rear bumper substructure
  202
• 3.7 Assembly overview - bumper carrier
  203
• 3.8 Assembly overview - towing bracket
  204
• 3.9 Electrically retractable towing bracket
  205
• 3.11 Assembly overview - USA towing bracket
  210
• 3.12 USA towing bracket - bolting sequence
  211
• Glazing
  212
• 1 Flush bonded windows
  212
• 1.1 Tools
  212
• 1.2 Materials
  214
• 1.3 Repairing windscreen
  214
• 1.4 Assembly overview - windscreen
  214
• 1.5 Removing and installing plenum chamber cover
  216
• 1.6 Removing windscreen
  218
• 1.7 Installing windscreen
  220
• 1.9 Preparing a removed windscreen for glazing
  220
• 1.10 Preparing new window for glazing
  223
• 1.11 Preparing body flange for glazing
  227
• 1.12 Installation instructions
  228
• 1.13 Minimum curing time
  228
• 1.14 Touching up paint damage
  229
• 1.15 Cleaning off excess adhesive sealing material
  229
• 2 Windows having threaded connections
  230
• 2.1 Tools
  230
• 2.2 Assembly overview - side windows
  230
• 2.3 Removing and installing side window
  232
• 2.4 Assembly overview - rear lid opening window
  234
• 2.5 Removing and installing rear lid opening window
  234
• 2.6 Adjusting rear lid opening window
  235
• 2.7 Adjusting striker pin
  235
• 2.8 Assembly overview - rear lid opening window button and striker pin
  235
• 2.9 Window seal
  237
• 3 Front door windows
  238
• 3.1 Tools
  238
• 3.2 Assembly overview - front door
  238
• 3.3 Assembly overview - window frame parts
  240
• 3.4 Removing and installing door window
  241
• 3.5 Repairing window regulators
  244
• 3.6 Removing and installing window regulator motor
  245
• 4 Rear door windows
  246
• 4.1 Tools
  246
• 4.2 Assembly overview - rear door
  246
• 4.3 Assembly overview - window frame parts
  248
• 4.4 Removing and installing door window
  248
• 4.5 Repairing window regulators
  252
• 4.6 Removing and installing window regulator motor
  253
• Exterior equipment
  254
• 1 Wheel housing liners
  254
• 1.1 Tools
  254
• 1.2 Assembly overview - front wheel housing liner
  254
• 1.3 Assembly overview - rear wheel housing liner
  256
• 2 Exterior mirror
  257
• 2.1 Exterior mirror > 10.2006
  257
• 2.2 Exterior mirror 11.2006 >
  261
• 2.3 Assembly overview - exterior mirror
  268
• 2.4 Removing and installing exterior mirror
  268
• 3 Radiator grille
  270
• 3.1 Tools
  270
• 3.2 Assembly overview - radiator grille > 10.2006
  270
• 3.3 Removing and installing radiator grille > 10.2006
  271
• 3.4 Removing and installing chrome grille > 10.2006
  272
• 3.5 Assembly overview - radiator grille 11.2006 >
  272
• 3.6 Removing and installing radiator grille 11.2006 >
  274
• 3.7 Removing and installing emblem 11.2006 >
  276
• 3.8 Installing number plate carrier 11.2006 >
  278
• 3.9 Installing number plate carrier, USA 11.2006 >
  279
• 4 Mouldings and trims
  280
• 4.1 Tools
  280
• 4.2 Drip channel
  281
• 4.3 B-pillar trim
  284
• 4.4 Removing and installing side window trim
  286
• 4.5 Assembly overview - water deflector
  286
• 4.6 Front wing trim panel
  288
• 4.7 Front door trim panel
  290
• 4.8 Rear door trim panel
  292
• 4.9 Side member protective strips
  294
• 4.10 Renewing roof trim strips
  296
• 4.11 Door trim strips
  297
• 4.12 Protective film and trim film
  300
• 5 Wheel housing, wing and side member extensions
  301
• 5.1 Tools
  301
• 5.2 Materials
  301
• 5.3 Safety requirements
  302
• 5.4 Fitting notes for extensions
  302
• 5.5 Overview - components
  303
• 5.6 Front wheel housing extension
  304
• 5.7 Rear wheel housing extension
  306
• 5.8 Side member extension “R50”
  308
• 5.9 Side member extension “R Line”
  311
• 5.10 Preparing add-on parts for bonding
  313
• 5.11 Preparing new part for bonding
  313
• 5.12 Preparing body part for bonding
  313
• 5.13 Installation instructions
  313
• 5.14 Cleaning guidelines
  314
• 5.15 Minimum curing time
  314
• 5.16 Touching up paint damage
  314
• 5.17 Cleaning off excess adhesive sealing material
  314
• 6 Roof rack
  315
• 6.1 Tools
  315
• 6.2 Assembly overview - guide rail
  315
• 6.3 Removing and installing guide rail
  316
• 6.4 Guide rail - bolting sequence
  318
• 6.5 Assembly overview - roof rack
  319
• 6.6 Removing roof rack
  319
• 6.7 Assembly overview - roof rack repair kit
  322
• 6.8 Removing and installing roof rack repair kit
  322
• 6.9 Removing and installing roof rack lock cylinder
  324
• 6.10 Assembly overview - roof railing
  325
• 6.11 Removing and installing roof railing
  326
• 6.12 Assembly overview - roof-mounted luggage basket
  331
• 6.13 Removing and installing roof-mounted luggage basket
  332
• 7 Spare wheel carrier for rear lid
  334
• 7.1 Tools
  334
• 7.2 Assembly overview - spare wheel carrier for rear lid
  334
• 7.3 Removing and installing spare wheel
  336
• 7.4 Removing and installing spare wheel carrier
  336
• 7.5 Removing and installing lock carrier
  338
• 7.6 Removing and installing lock
  339
• 7.7 Removing and installing emergency release
  340
• 7.8 Adjusting guide for spare wheel carrier
  341
• 8 Lettering
  342
• 8.1 Tools
  342
• 8.2 Attachment notes for lettering
  342
• 8.3 Rear lettering dimensions
  342
• 8.4 Wing lettering dimensions - Individual
  344
• 8.5 Wing lettering dimensions – R-Line
  345