General body repairs, exterior

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety measures when working on vehicles with start/stop system
  1
• 1.3 Safety precautions when working on cooling system
  1
• 2 Repair notes
  2
• 2.1 Routing and attachment of lines
  2
• 2.2 Contact corrosion
  2
• 2.3 Bonding surfaces for self-adhesive components
  2
• 2.4 Secured threaded connections
  2
• Body - front
  3
• 1 Lock carrier
  3
• 1.1 Assembly overview – lock carrier
  3
• 1.2 Removing and installing lock carrier
  4
• 1.3 Moving to and back from service position
  6
• 2 Wings
  11
• 2.1 Assembly overview - wing
  11
• 2.2 Removing and installing wing
  11
• 3 Plenum chamber bulkhead
  17
• 3.1 Assembly overview - plenum chamber bulkhead
  17
• 3.2 Assembly overview - plenum chamber cover
  17
• 3.3 Removing and installing bulkhead
  18
• 3.4 Removing and installing plenum chamber cover
  20
• Bonnet, rear lid
  27
• 1 Bonnet
  27
• 1.1 Assembly overview - bonnet
  27
• 1.2 Assembly overview - Bowden cable
  28
• 1.3 Removing and installing bonnet
  29
• 1.4 Adjusting bonnet
  31
• 1.5 Removing and installing rear lid lock
  38
• 1.6 Removing and installing bonnet release lever
  45
• 1.7 Removing and installing striker pin
  48
• 1.8 Removing and installing hinges
  50
• 1.9 Removing and installing insulation
  52
• 1.10 Removing and installing support rod
  54
• 1.11 Removing and installing Bowden cable
  56
• 2 Tailgate
  64
• 2.1 Assembly overview - rear lid
  64
• 2.2 Removing and installing rear lid
  67
• 2.3 Adjusting rear lid
  70
• 2.4 Removing and installing rear lid lock
  77
• 2.5 Removing and installing operating mechanism
  89
• 2.6 Removing and installing hinges
  94
• 2.7 Removing and installing striker pin
  96
• 2.8 Removing and installing rear lid seal
  98
• 2.9 Removing and installing gas strut
  99
• 2.10 Releasing gas from gas strut
  101
• 2.11 Removing and installing drive unit for rear lid VX69
  104
• 2.12 Removing and installing rear lid control unit J605
  106
• 3 Tank flap unit
  108
• 3.1 Assembly overview - tank flap unit
  108
• 3.2 Removing and installing tank flap unit
  108
• 3.3 Removing and installing fuel tank flap
  112
• Front doors, door components, central locking
  114
• 1 Door
  114
• 1.1 Assembly overview - door
  114
• 1.2 Removing and installing inner door seal
  117
• 1.3 Removing and installing outer door seal
  119
• 1.4 Removing and installing door
  120
• 1.5 Adjusting door
  123
• 1.6 Adjusting striker pin
  126
• 1.7 Removing and installing door arrester
  128
• 2 Door components
  131
• 2.1 Assembly overview - door components
  131
• 2.2 Assembly overview - window regulator
  133
• 2.3 Assembly overview - door handle and door lock
  133
• 2.4 Removing and installing window regulator motor
  135
• 2.5 Removing and installing window regulator
  137
• 2.6 Removing and installing inner door cover
  140
• 2.7 Removing and installing striker pin
  143
• 2.8 Removing and installing cap on door handle
  145
• 2.9 Removing and installing lock cylinder
  151
• 2.10 Removing and installing door handle
  154
• 2.11 Removing and installing mounting bracket
  158
• 2.12 Removing and installing door lock
  160
• 2.13 Removing and installing window channel
  165
• 2.14 Removing and installing window slot outer seal
  168
• 2.15 Removing and installing window slot inner seal
  170
• 3 Central locking
  171
• 3.1 Overview of fitting locations - central locking
  171
• 3.3 Removing and installing tank filler flap locking motor V155
  174
• 3.4 Removing and installing ignition key battery
  175
• 3.5 Removing and installing cap on ignition key
  177
• Rear doors, door components
  179
• 1 Door
  179
• 1.1 Assembly overview - door
  179
• 1.2 Removing and installing door
  182
• 1.3 Adjusting door
  184
• 1.4 Adjusting striker pin
  187
• 1.5 Removing and installing door arrester
  189
• 1.6 Removing and installing inner door seal
  191
• 1.7 Removing and installing outer door seal
  194
• 2 Door components
  196
• 2.1 Assembly overview - door components
  196
• 2.2 Assembly overview - window regulator
  197
• 2.3 Assembly overview - door handle and door lock
  198
• 2.4 Removing and installing window regulator motor
  199
• 2.5 Removing and installing window regulator
  202
• 2.6 Removing and installing inner door cover
  204
• 2.7 Removing and installing striker pin
  206
• 2.8 Removing and installing cap on door handle
  208
• 2.9 Removing and installing door handle
  212
• 2.10 Removing and installing mounting bracket
  214
• 2.11 Removing and installing door lock
  217
• 2.12 Removing and installing window channel
  221
• 2.13 Removing and installing window slot outer seal
  224
• 2.14 Removing and installing window slot inner seal
  226
• Sunroof
  227
• 1 Sliding sunroof
  227
• 1.1 Assembly overview - sliding sunroof
  227
• 1.2 Assembly overview - sliding sunroof seals
  229
• 1.3 Removing and installing sunroof panel
  229
• 1.4 Removing and installing rear sunroof panel
  233
• 1.5 Adjusting sunroof panel
  238
• 1.6 Removing and installing sliding sunroof seals
  242
• 1.7 Removing and installing wind deflector
  247
• 1.8 Removing and installing sunroof motor V1
  250
• 1.9 Removing and installing sunroof roller blind motor V260
  252
• 1.10 Removing and installing sunroof roller blind control unit J394
  254
• 1.11 Removing and installing sliding sunroof adjustment control unit J245
  255
• 1.12 Removing and installing sunroof roller blind
  256
• 1.13 Removing and installing sliding sunroof frame
  261
• 1.14 Operating without current
  265
• 2 Water drain hoses
  267
• 2.1 Assembly overview - water drain hoses
  267
• 2.2 Removing and installing water drain hoses
  267
• 2.3 Cleaning water drain hoses
  268
• Bumpers
  271
• 1 Bumper, front
  271
• 1.1 Assembly overview - bumper cover
  271
• 1.2 Assembly overview - impact bar
  277
• 1.3 Removing and installing bumper cover
  279
• 1.4 Removing and installing add-on parts
  282
• 1.5 Repairing bumper cover
  292
• 2 Bumper, rear
  301
• 2.1 Assembly overview - bumper cover
  301
• 2.2 Assembly overview - impact bar
  305
• 2.3 Removing and installing bumper cover
  306
• 2.4 Removing and installing impact bar
  309
• 2.5 Removing and installing add-on parts
  311
• 2.6 Repairing bumper cover
  316
• Glazing
  325
• 1 Repair notes
  325
• 1.1 Minimum curing periods for bonded windows
  325
• 1.2 Window repair
  325
• 1.3 Installation instructions for bonded windows
  326
• 1.4 Preparing old undamaged windows for fitting
  327
• 1.5 Preparing new windows for installing
  328
• 1.6 Preparing body flange for fitting
  330
• 1.7 Cleaning off excess adhesive
  331
• 2 Windscreen
  332
• 2.1 Assembly overview - windscreen
  332
• 2.2 Removing and installing windscreen
  333
• 3 Rear windscreen
  341
• 3.1 Assembly overview - rear window
  341
• 3.2 Removing and installing rear window
  342
• 4 Door windows
  346
• 4.1 Assembly overview - front door window
  346
• 4.2 Assembly overview - rear door window
  346
• 4.3 Removing and installing front door window
  347
• 4.4 Removing and installing rear door window
  351
• 4.5 Removing and installing fixed rear door window
  355
• Exterior equipment
  358
• 1 Radiator grille and front trim
  358
• 1.1 Assembly overview – radiator grille
  358
• 1.2 Removing and installing radiator grille
  358
• 2 Spoiler
  361
• 2.1 Assembly overview - spoiler
  361
• 2.2 Removing and installing spoiler
  361
• 3 Mouldings, trims, extensions
  364
• 3.1 Assembly overview - trim strips
  364
• 3.2 Assembly overview - wheel arch covers
  365
• 3.3 Assembly overview – wheel arch covers, R model
  365
• 3.4 Assembly overview - side member trim
  366
• 3.5 Removing and installing cover
  367
• 3.6 Removing and installing rear trim cover for door, R model
  376
• 3.7 Removing and installing B-pillar trim on door
  378
• 3.8 Removing and installing trim strip
  381
• 3.9 Removing and installing entry moulding
  388
• 3.10 Removing and installing wheel arch covers
  390
• 3.11 Removing and installing side member trim
  399
• 4 Noise insulation
  402
• 4.1 Assembly overview - noise insulation
  402
• 5 Underbody cladding
  406
• 5.1 Overview of fitting locations - underbody cladding
  406
• 5.2 Assembly overview - bracing on underbody
  407
• 5.3 Removing and installing underbody cladding
  407
• 5.4 Removing and installing tunnel cross-piece
  414
• 6 Roof moulding and roof railing
  416
• 6.1 Assembly overview - roof railing
  416
• 6.2 Removing and installing roof railing
  416
• 7 Trim film and protective film
  418
• 7.1 Renewing decorative film
  418
• 8 Exterior mirror
  422
• 8.1 Assembly overview - exterior mirror
  422
• 8.2 Removing and installing exterior mirror
  423
• 8.3 Removing and installing mirror glass
  426
• 8.4 Removing and installing mirror adjustment unit
  428
• 8.5 Removing and installing mirror cover
  430
• 8.6 Removing and installing mirror trim
  432
• 8.7 Removing and installing turn signal
  433
• 8.8 Removing and installing entry light in exterior mirror
  435
• 9 Wheel housing liner
  437
• 9.1 Assembly overview - front wheel housing liner
  437
• 9.2 Assembly overview – front wheel housing liner, R model
  438
• 9.3 Assembly overview - rear wheel housing liner
  438
• 9.4 Removing and installing front wheel housing liner
  439
• 9.5 Removing and installing front wheel housing liner, R model
  441
• 9.6 Removing and installing rear wheel housing liner
  443
• 10 Lettering and emblems
  445
• 10.1 Assembly notes – bonded lettering
  445
• 10.2 Dimensions - lettering and emblems on rear
  446
• 10.3 Dimensions - lettering and emblems on sides
  448
• 10.4 Removing and installing badges at front
  449
• 10.5 Renewing lettering and badges at rear
  452
• 11 Towing bracket
  454
• 11.1 Assembly overview - towing bracket
  454
• 11.2 Removing and installing towing bracket
  454
• 12 Heat shields
  457
• 12.1 Overview of fitting locations - heat shields
  457
• 12.2 Removing and installing underbody heat shield
  458