General body repairs, exterior

Chapter overview

• Body - front
  1
• 1 Lock carrier
  1
• 1.1 Assembly overview – lock carrier
  1
• 1.2 Removing and installing lock carrier
  2
• 1.3 Moving to and back from service position
  5
• 1.4 Repairing lock carrier
  9
• 2 Wings
  12
• 2.1 Assembly overview - wing
  12
• 2.2 Removing and installing wing
  14
• 2.3 Removing and installing wing panel brace
  17
• 3 Bulkhead
  20
• 3.1 Assembly overview - plenum chamber bulkhead
  20
• 3.2 Assembly overview - plenum chamber cover
  20
• 3.3 Removing and installing bulkhead
  21
• 3.4 Removing and installing plenum chamber cover
  22
• Bonnet, rear lid
  26
• 1 Bonnet
  26
• 1.1 Assembly overview - bonnet
  26
• 1.2 Assembly overview - Bowden cable
  27
• 1.3 Removing and installing bonnet
  28
• 1.4 Adjusting bonnet
  30
• 1.5 Removing and installing rear lid lock
  37
• 1.6 Removing and installing bonnet release lever
  39
• 1.7 Removing and installing striker pin
  40
• 1.8 Removing and installing hinges
  42
• 1.9 Removing and installing insulation
  44
• 1.10 Removing and installing gas strut
  46
• 1.11 Releasing gas from gas strut
  48
• 1.12 Removing and installing Bowden cable
  48
• 2 Rear lid
  52
• 2.1 Assembly overview - rear lid
  52
• 2.2 Removing and installing rear lid
  54
• 2.3 Adjusting rear lid
  59
• 2.4 Removing and installing rear lid lock
  65
• 2.5 Removing and installing operating mechanism
  67
• 2.6 Removing and installing hinges
  72
• 2.7 Removing and installing striker pin
  75
• 2.8 Removing and installing rear lid seal
  76
• 2.9 Removing and installing gas strut
  78
• 2.10 Releasing gas from gas strut
  79
• 3 Tank flap unit
  81
• 3.1 Assembly overview - tank flap unit
  81
• 3.2 Removing and installing tank flap unit
  81
• 3.3 Removing and installing fuel tank flap
  83
• Front doors, door components, central locking
  85
• 1 Door
  85
• 1.1 Assembly overview - door
  85
• 1.2 Removing and installing inner door seal
  88
• 1.3 Removing and installing outer door seal
  90
• 1.4 Removing and installing door
  92
• 1.5 Adjusting door
  96
• 1.6 Adjusting striker pin
  99
• 1.7 Removing and installing door arrester
  101
• 2 Door components
  104
• 2.1 Assembly overview - door components
  104
• 2.2 Assembly overview - window regulator
  106
• 2.3 Assembly overview - door handle and door lock
  107
• 2.4 Removing and installing window regulator motor
  107
• 2.5 Removing and installing window regulator
  110
• 2.6 Removing and installing inner door cover
  114
• 2.7 Removing and installing striker pin
  116
• 2.8 Removing and installing cap on door handle
  118
• 2.9 Removing and installing door handle
  124
• 2.10 Removing and installing mounting bracket
  126
• 2.11 Removing and installing door lock
  129
• 2.12 Removing and installing window channel
  133
• 2.13 Removing and installing window slot inner seal
  136
• 2.14 Removing and installing window slot outer seal
  137
• 2.15 Removing and installing lock cylinder
  138
• 2.16 Removing and installing outer padding
  141
• 3 Central locking
  144
• 3.1 Overview of fitting locations - central locking
  144
• 3.3 Removing and installing tank filler flap locking motor V155
  149
• 3.4 Removing and installing ignition key battery
  150
• 3.5 Removing and installing cap on ignition key
  152
• Rear doors, door components
  154
• 1 Door
  154
• 1.1 Assembly overview - door
  154
• 1.2 Removing and installing door
  157
• 1.3 Adjusting door
  160
• 1.4 Adjusting striker pin
  163
• 1.5 Removing and installing door arrester
  165
• 1.6 Removing and installing outer door seal
  167
• 1.7 Removing and installing inner door seal
  169
• 2 Door components
  172
• 2.1 Assembly overview - door components
  172
• 2.2 Assembly overview - window regulator
  174
• 2.3 Assembly overview - door handle and door lock
  175
• 2.4 Removing and installing window regulator motor
  175
• 2.5 Removing and installing window regulator
  178
• 2.6 Removing and installing window crank
  180
• 2.7 Removing and installing inner door cover
  184
• 2.8 Removing and installing striker pin
  186
• 2.9 Removing and installing door handle
  188
• 2.10 Removing and installing mounting bracket
  190
• 2.11 Removing and installing door lock
  193
• 2.12 Removing and installing window channel
  197
• 2.13 Removing and installing window slot outer seal
  200
• 2.14 Removing and installing window slot inner seal
  201
• 2.15 Removing and installing cap on door handle
  202
• 2.16 Removing and installing outer padding
  204
• Sunroof
  207
• 1 Sliding sunroof
  207
• 1.1 Distinguishing features - sliding sunroof, saloon
  207
• 1.2 Assembly overview - sliding sunroof
  209
• 1.3 Assembly overview - sunroof roller blind
  217
• 1.4 Removing and installing sunroof panel
  220
• 1.5 Removing and installing rear sunroof panel
  229
• 1.6 Removing and installing sliding sunroof frame
  238
• 1.7 Removing and installing rear part
  254
• 1.8 Removing and installing tilt mechanism for sliding sunroof
  259
• 1.9 Removing and installing sunroof roller blind cables
  261
• 1.10 Removing and installing wind deflector
  264
• 1.11 Removing and installing glass panel
  272
• 1.12 Adjusting sunroof panel
  284
• 1.13 Removing and installing slotted guide
  290
• 1.14 Removing and installing front trim for sliding sunroof
  299
• 1.15 Removing and installing sliding sunroof adjustment control unit J245
  308
• 1.16 Removing and installing sunroof roller blind control unit J394
  321
• 1.17 Adapting sliding sunroof adjustment control unit J245
  323
• 1.18 Adapting sunroof roller blind control unit J394
  325
• 1.19 Removing and installing sunroof motor V1
  325
• 1.20 Removing and installing sunroof roller blind motor V260
  329
• 1.21 Removing and installing sunroof roller blind
  331
• 1.22 Removing and installing sliding sunroof seals
  353
• 1.23 Operating without current
  362
• 2 Water drain hoses
  367
• 2.1 Assembly overview - water drain hoses
  367
• 2.2 Cleaning water drain hoses
  368
• 2.3 Removing and installing water drain hoses
  371
• Bumpers
  374
• 1 Bumper, front
  374
• 1.1 Assembly overview - bumper cover
  374
• 1.2 Assembly overview - add-on parts
  375
• 1.3 Assembly overview - impact bar
  383
• 1.4 Assembly overview – guides
  383
• 1.5 Removing and installing bumper cover
  384
• 1.6 Repairing bumper cover
  387
• 1.7 Installing holder for parking aid sender
  387
• 1.8 Installing retainer for parking aid sender
  392
• 2 Bumper, rear
  397
• 2.1 Assembly overview - bumper cover
  397
• 2.2 Assembly overview - add-on parts
  399
• 2.3 Assembly overview - impact bar
  404
• 2.4 Assembly overview – guides
  405
• 2.5 Removing and installing bumper cover
  407
• 2.6 Repairing bumper cover
  414
• 2.7 Removing and installing impact bar
  414
• 2.8 Installing holder for parking aid sender
  415
• 2.9 Installing retainer for parking aid sender
  420
• Glazing
  425
• 1 Repair notes
  425
• 1.1 Minimum curing periods for bonded windows
  425
• 1.2 Window repair
  425
• 1.3 Installation instructions for bonded windows
  426
• 1.4 Preparing old undamaged windows for fitting
  427
• 1.5 Preparing new windows for installing
  428
• 1.6 Preparing body flange for fitting
  430
• 1.7 Cleaning off excess adhesive
  431
• 2 Windscreen
  433
• 2.1 Assembly overview - windscreen
  433
• 2.2 Removing and installing windscreen
  434
• 3 Rear windscreen
  441
• 3.1 Assembly overview - rear window
  441
• 3.2 Removing and installing rear window
  442
• 4 Side window
  447
• 4.1 Assembly overview - front side window
  447
• 4.2 Assembly overview - rear side windows
  447
• 4.3 Removing and installing front side window
  449
• 4.4 Removing and installing rear side window
  451
• 5 Door windows
  454
• 5.1 Assembly overview - front door window
  454
• 5.2 Assembly overview - rear door window
  455
• 5.3 Removing and installing front door window
  456
• 5.4 Removing and installing rear door window
  460
• 5.5 Removing and installing fixed rear door window
  463
• Exterior equipment
  466
• 1 Radiator grille and front trim
  466
• 1.1 Assembly overview – radiator grille
  466
• 1.2 Removing and installing radiator grille
  468
• 2 Spoiler
  473
• 2.1 Assembly overview - spoiler
  473
• 2.2 Removing and installing spoiler
  474
• 2.3 Removing and installing side spoiler
  476
• 3 Mouldings, trims, extensions
  481
• 3.1 Assembly overview - side member trim
  481
• 3.2 Assembly overview - water deflector
  483
• 3.3 Assembly overview - heat shield
  484
• 3.4 Removing and installing side member trim
  485
• 3.5 Removing and installing wheel arch covers
  498
• 3.6 Removing and installing cover
  505
• 3.7 Removing and installing water deflector
  507
• 3.8 Removing and installing B-pillar trim on door
  509
• 3.9 Removing and installing C-pillar trim on door
  511
• 3.10 Removing and installing underbody heat shield
  512
• 3.11 Removing and installing heat shield for centre exhaust system
  514
• 3.12 Removing and installing heat shield for rear silencer
  514
• 4 Noise insulation
  517
• 4.1 Assembly overview - noise insulation
  517
• 5 Underbody cladding
  520
• 5.1 Assembly overview - underbody cladding
  520
• 5.2 Removing and installing underbody cladding
  521
• 5.3 Removing and installing centre underbody panels
  523
• 5.4 Removing and installing rear underbody cladding
  525
• 5.5 Removing and installing tunnel cross-piece
  527
• 6 Trim film and protective film
  531
• 6.1 Renewing protective films
  531
• 7 Roof moulding and roof railing
  535
• 7.1 Assembly overview - roof railing
  535
• 7.2 Removing and installing roof railing
  535
• 8 Exterior mirror
  537
• 8.1 Assembly overview - exterior mirror
  537
• 8.2 Removing and installing exterior mirror
  538
• 8.3 Removing and installing mirror glass
  540
• 8.4 Removing and installing mirror adjustment unit
  542
• 8.5 Removing and installing mirror cover
  545
• 8.6 Removing and installing mirror trim
  546
• 9 Wheel housing liner
  549
• 9.1 Assembly overview - front wheel housing liner
  549
• 9.2 Assembly overview - rear wheel housing liner
  550
• 9.3 Removing and installing front wheel housing liner
  552
• 9.4 Removing and installing rear wheel housing liner
  554
• 10 Lettering and emblems
  557
• 10.1 Dimensions - lettering and emblems on rear
  557
• 10.2 Dimensions - lettering and emblems on sides
  559
• 10.3 Removing and installing badges at front
  560
• 10.4 Renewing lettering and badges at rear
  565
• 11 Special add-on parts
  567
• 11.1 Assembly overview - special add-on parts, Cross Golf
  567
• 12 Towing bracket
  568
• 12.1 Assembly overview - towing bracket
  568
• 12.2 Assembly overview - Bowden cable
  569
• 12.3 Removing and installing towing bracket
  571
• 12.4 Removing and installing Bowden cable
  576