General body repairs, exterior

Chapter overview

• Body - front
  1
• 1 Lock carrier
  1
• 1.1 Tools
  1
• 1.2 Lock carrier - service position 06.00 >
  1
• 1.3 Removing and installing lock carrier with add-on components
  3
• 2 Wing
  5
• 2.1 Removing and installing front wing > 05.00
  5
• 2.2 Removing and installing front wing 06.00 >
  9
• 3 Noise insulation
  13
• 3.1 Assembly overview - noise insulation
  13
• Bonnet, rear lid
  14
• 1 Bonnet
  14
• 1.1 Tools
  14
• 1.2 Assembly overview - bonnet > 05.00
  14
• 1.3 Assembly overview - bonnet 06.00 >
  16
• 1.4 Assembly overview - bonnet 11.03 >
  17
• 1.5 Removing gas-filled strut 06.00 >
  18
• 1.6 Assembly overview - bonnet lock release cable
  18
• 1.7 Removing insulation
  19
• 2 Rear lid
  20
• 2.1 Tools
  20
• 2.2 Assembly overview - rear lid
  20
• 2.3 Removing gas-filled strut
  22
• 2.4 Releasing gas from gas-filled strut
  22
• 2.5 Adjusting rear lid
  23
• 2.6 Adjusting guide pins
  24
• 2.7 Adjusting striker plate
  24
• 2.8 Assembly overview - lid lock
  25
• 2.9 Assembly overview - lock cylinder
  26
• 3 Fuel tank flap
  28
• 3.1 Assembly overview - fuel tank flap
  28
• Front doors, door components, central locking
  29
• 1 Front door
  29
• 1.1 Tools
  29
• 1.2 Assembly overview - front door
  30
• 1.3 Removing and installing front door
  31
• 1.4 Renewing front door
  31
• 1.5 Assembly overview - door handle
  34
• 1.6 Removing and installing door handle
  36
• 1.7 Removing and installing lock cylinder
  37
• 1.8 Assembly overview - door lock
  41
• 1.9 Removing and installing door lock
  43
• 1.10 Removing inner release handle
  43
• 1.11 Removing and installing Bowden cable for door lock
  44
• 1.12 Removing and installing interior door seal
  46
• 2 Central locking
  47
• 2.1 Tools
  47
• 2.2 Location overview - central locking components
  47
• 2.3 Removing and installing actuator for front/rear door
  49
• 2.4 Removing and installing rear lid lock actuator
  50
• 2.5 Removing and installing actuator for fuel tank filler cap
  50
• 2.6 Removing and installing batteries for key with remote control > 04.01
  51
• 2.8 Adapting (synchronising) keys with remote control > 04.01
  55
• 2.9 Adapting keys 05.01 >
  56
• Rear doors, door components
  57
• 1 Rear door
  57
• 1.1 Tools
  57
• 1.2 Assembly overview - rear door
  57
• 1.3 Removing and installing rear door
  59
• 1.4 Renewing door
  59
• 1.5 Assembly overview - door handle
  59
• 1.6 Removing and installing door handle
  60
• 1.7 Assembly overview - door lock with operating components
  62
• 1.8 Removing and installing door lock
  63
• 1.9 Removing inner release handle
  63
• 1.10 Removing and installing Bowden cable for door lock
  64
• 1.11 Removing and installing interior door seal
  65
• Sunroof
  66
• 1 Sunroof with glass panel
  66
• 1.1 Assembly overview - sliding/tilting sunroof with glass panel
  66
• 1.2 Removing glass panel for sliding/tilting sunroof
  67
• 1.3 Adjusting panel seal
  68
• 1.4 Installing sunroof glass panel
  68
• 1.5 Removing and installing sun visor
  68
• 1.6 Checking parallel running
  69
• 1.7 Adjusting parallel running
  69
• 1.8 Adjusting height of sunroof glass panel
  70
• 1.9 Checking electric drive (zero position)
  70
• 1.10 Removing and installing sliding/tilting sunroof assembly unit
  72
• 1.11 Cleaning water drain hoses
  74
• Bumpers
  77
• 1 Front bumper > 05.00
  77
• 1.1 Repairing bumper cover
  77
• 1.2 Assembly overview - front bumper
  77
• 1.3 Replacing broken retainers in bumper cover with retaining clips
  78
• 2 Front bumper 06.00 >
  79
• 2.1 Assembly overview - front bumper
  79
• 2.2 Assembly overview - front bumper add-on components 11.03 >
  80
• 3 Rear bumper > 05.00
  81
• 3.1 Repairing bumper cover
  81
• 3.2 Assembly overview - rear bumper
  81
• 4 Rear bumper 06.00 >
  83
• 4.1 Assembly overview - rear bumper
  83
• 4.2 Assembly overview - towing bracket
  84
• Glazing
  85
• 1 Flush bonded windows
  85
• 1.1 Tools
  85
• 1.2 Materials
  86
• 1.3 Repairing windscreen
  87
• 1.4 Assembly overview - windscreen
  87
• 1.5 Removing windscreen
  88
• 1.6 Installing windscreen
  90
• 1.7 Assembly overview - rear window ▸ 05.00
  91
• 1.8 Removing undamaged rear window ▸ 05.00
  92
• 1.9 Assembly overview - rear window 06.00 ▸
  93
• 1.10 Removing undamaged rear window 06.00 ▸
  93
• 1.11 Removing broken rear window
  94
• 1.12 Installing rear window
  94
• 1.13 Preparing old undamaged window for glazing
  95
• 1.14 Preparing new window for glazing
  95
• 1.15 Preparing body flange for glazing
  97
• 1.16 Installation instructions
  97
• 1.17 Minimum curing period
  97
• 1.18 Touching up paint damage
  98
• 1.19 Cleaning off excess adhesive sealing material
  98
• 2 Windows having threaded connections
  99
• 2.1 Assembly overview - front side window
  99
• 2.2 Assembly overview - vent wing
  100
• 3 Door windows
  101
• 3.1 Assembly overview - front door window
  101
• 3.2 Removing and installing window crank handle
  102
• 3.3 Removing front door window
  102
• 3.4 Adjusting front door window
  103
• 3.5 Removing and installing front window regulator
  103
• 3.6 Assembly overview - rear door window
  103
• 3.7 Removing rear door window
  104
• 3.8 Adjusting rear door window
  105
• 3.9 Removing and installing rear window regulator
  105
• 3.10 Repairing electric window regulators
  106
• 3.12 Overcoming resistance with excess force limitation
  109
• 3.13 Initialising and releasing automatic closing function
  109
• Exterior equipment
  111
• 1 Wheel housing liner
  111
• 1.1 Assembly overview - front wheel housing liner
  111
• 1.2 Assembly overview - rear wheel housing liner
  112
• 2 Exterior mirror
  113
• 2.1 Tools
  113
• 2.2 Assembly overview - exterior mirror (old design)
  113
• 2.3 Assembly overview - exterior mirror (new design)
  115
• 2.4 Removing mirror housing
  116
• 2.5 Removing and installing mirror housing with turn signal 11.03 >
  116
• 3 Radiator grille
  119
• 3.1 Assembly overview - radiator grille > 05.00
  119
• 3.2 Removing and installing radiator grille with trim frame > 05.00
  119
• 3.3 Chrome strips for radiator grille 11.03 >
  121
• 4 Mouldings and trims
  122
• 4.1 Protective side mouldings
  122
• 4.2 Assembly overview - protective side mouldings
  122
• 4.3 Renewing scuff protection film
  123
• 4.4 Roof mouldings
  124
• 4.5 Side member extension
  125
• 4.6 Assembly overview - lettering > 05.00
  130
• 4.7 Assembly overview - lettering 06.00 >
  131
• 4.8 Removing side lettering
  132
• 5 Roof railing
  133
• 5.1 Assembly overview - roof railing
  133
• 6 Roof edge spoiler
  134
• 6.1 Tools
  134
• 6.2 Materials
  134
• 6.3 Assembly overview - roof edge spoiler
  135
• 6.4 Removing and installing roof edge spoiler
  136
• 6.5 Preparing body kit component for bonding
  139
• 6.6 Installation instructions
  139
• 6.7 Minimum curing period
  139
• 6.8 Touching up paint damage
  140
• 6.9 Cleaning off excess adhesive sealing material
  140