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
• 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
  5
• 1.3 Moving to and back from service position
  8
• 1.4 Repairing lock carrier
  12
• 2 Wings
  15
• 2.1 Assembly overview – wing
  15
• 2.2 Assembly overview - deformable element
  17
• 2.3 Removing and installing wing
  17
• 2.4 Removing and installing wing bracket
  23
• 3 Bulkhead
  26
• 3.1 Assembly overview – bulkhead
  26
• 3.2 Assembly overview – plenum chamber cover
  26
• 3.3 Removing and installing bulkhead
  27
• 3.4 Removing and installing plenum chamber cover
  28
• Bonnet, rear lid
  32
• 1 Bonnet
  32
• 1.1 Assembly overview – bonnet
  32
• 1.2 Assembly overview – Bowden cable
  33
• 1.3 Removing and installing bonnet
  34
• 1.4 Adjusting bonnet
  36
• 1.5 Removing and installing rear lid lock
  43
• 1.6 Removing and installing bonnet lock operating lever
  48
• 1.7 Removing and installing striker pin
  50
• 1.8 Removing and installing hinges
  52
• 1.9 Removing and installing insulation
  54
• 1.10 Removing and installing gas strut
  56
• 1.11 Releasing gas from gas strut
  58
• 1.12 Removing and installing Bowden cable
  58
• 2 Rear lid
  62
• 2.1 Assembly overview – rear lid
  62
• 2.2 Removing and installing rear lid
  64
• 2.3 Adjusting rear lid
  66
• 2.4 Removing and installing rear lid lock
  72
• 2.5 Removing and installing operating mechanism
  74
• 2.6 Removing and installing hinges
  79
• 2.7 Removing and installing striker pin
  82
• 2.8 Removing and installing rear lid seal
  83
• 2.9 Removing and installing gas strut
  85
• 2.10 Releasing gas from gas strut
  86
• 3 Tank flap unit
  88
• 3.1 Assembly overview – tank flap unit
  88
• 3.2 Removing and installing tank flap unit
  88
• 3.3 Removing and installing fuel tank flap
  90
• 3.4 Removing and installing actuator
  91
• Front doors, door components, central locking
  93
• 1 Door
  93
• 1.1 Assembly overview – door
  93
• 1.2 Removing and installing inner door seal
  96
• 1.3 Removing and installing outer door seal
  98
• 1.4 Removing and installing door
  99
• 1.5 Adjusting door
  103
• 1.6 Adjusting striker pin
  105
• 1.7 Removing and installing door arrester
  107
• 2 Door components
  110
• 2.1 Assembly overview – door components
  110
• 2.2 Assembly overview – window regulator
  112
• 2.3 Assembly overview – door handle and door lock
  112
• 2.4 Removing and installing window regulator motor V14/V15
  113
• 2.5 Removing and installing window regulator
  116
• 2.6 Removing and installing inner door cover
  119
• 2.7 Removing and installing striker pin
  122
• 2.8 Removing and installing cover cap, for lock cylinder
  123
• 2.9 Removing and installing cover cap, without lock cylinder
  125
• 2.10 Removing and installing lock cylinder
  129
• 2.11 Removing and installing door handle
  132
• 2.12 Removing and installing mounting bracket
  134
• 2.13 Removing and installing door lock
  137
• 2.14 Removing and installing window channel
  141
• 2.15 Removing and installing window slot outer seal
  144
• 2.16 Removing and installing window slot inner seal
  146
• 3 Central locking
  147
• 3.1 Overview of fitting locations – central locking system
  147
• 3.2 Removing and installing door control unit J386/J387
  149
• 3.3 Removing and installing ignition key battery
  150
• Rear doors, door components
  153
• 1 Door
  153
• 1.1 Assembly overview – door
  153
• 1.2 Removing and installing door
  156
• 1.3 Adjusting door
  159
• 1.4 Adjusting striker pin
  161
• 1.5 Removing and installing door arrester
  163
• 1.6 Removing and installing inner door seal
  165
• 1.7 Removing and installing outer door seal
  168
• 2 Door components
  170
• 2.1 Assembly overview – door components
  170
• 2.2 Assembly overview – window regulator
  172
• 2.3 Assembly overview – door handle and door lock
  172
• 2.4 Removing and installing window regulator motor
  173
• 2.5 Removing and installing window regulator
  176
• 2.6 Removing and installing window crank
  179
• 2.7 Removing and installing inner door cover
  183
• 2.8 Removing and installing striker pin
  185
• 2.9 Removing and installing cap
  187
• 2.10 Removing and installing door handle
  190
• 2.11 Removing and installing mounting bracket
  191
• 2.12 Removing and installing door lock
  194
• 2.13 Removing and installing window channel
  199
• 2.14 Removing and installing window slot outer seal
  202
• 2.15 Removing and installing window slot inner seal
  203
• Sunroof
  205
• 1 Sliding sunroof
  205
• 1.1 Assembly overview – sliding sunroof
  205
• 1.2 Assembly overview – sunroof roller blind
  207
• 1.3 Assembly overview – wind deflector
  207
• 1.4 Removing and installing sunroof panel
  208
• 1.5 Removing and installing rear sunroof panel
  212
• 1.6 Adjusting sunroof panel
  216
• 1.7 Removing and installing sliding sunroof frame
  221
• 1.8 Removing and installing rear part
  224
• 1.9 Removing and installing tilt mechanism for sliding sunroof
  229
• 1.10 Removing and installing sunroof roller blind cables
  231
• 1.11 Removing and installing wind deflector
  234
• 1.12 Removing and installing J245sliding sunroof adjustment control unit
  237
• 1.13 Removing and installing roller blind adjustment control unit J394
  239
• 1.14 Closing sunroof by hand
  241
• 1.15 Removing and installing sliding sunroof seals
  242
• 1.16 Removing and installing sunroof roller blind
  247
• 1.17 Programming sliding sunroof adjustment control unit J245
  252
• 1.18 Programming sunroof roller blind adjustment control unit J394
  254
• 2 Water drain hoses
  255
• 2.1 Assembly overview - water drain hoses
  255
• 2.2 Cleaning water drain hoses
  255
• 2.3 Removing and installing water drain hoses
  257
• Bumpers
  259
• 1 Bumper, front
  259
• 1.1 Assembly overview – bumper cover
  259
• 1.2 Assembly overview - add-on parts
  260
• 1.3 Assembly overview – bumper carrier
  275
• 1.4 Removing and installing bumper cover
  276
• 1.5 Repairing bumper cover
  279
• 1.6 Installing brackets for parking aid system
  279
• 1.7 Installing brackets for park assist steering
  285
• 2 Bumper, rear
  290
• 2.1 Assembly overview – bumper cover
  290
• 2.2 Assembly overview - guides for bumper cover
  291
• 2.3 Assembly overview - add-on parts
  292
• 2.4 Assembly overview – bumper carrier
  298
• 2.5 Removing and installing bumper cover
  299
• 2.6 Removing and installing bumper carrier
  302
• 2.7 Repairing bumper cover
  303
• 2.8 Installing brackets for parking aid system
  304
• 2.9 Installing brackets for park assist steering
  309
• Glazing
  314
• 1 Repair instructions
  314
• 1.1 Minimum drying times for bonded windows
  314
• 1.2 Window repair
  315
• 1.3 Installation instructions for bonded windows
  315
• 1.4 Preparing old undamaged windows for installing
  317
• 1.5 Preparing new windows for installing
  318
• 1.6 Preparing body flange for installing
  320
• 1.7 Cleaning off excess adhesive
  321
• 2 Windscreen
  322
• 2.1 Assembly overview – windscreen
  322
• 2.2 Removing and installing windscreen
  323
• 3 Rear windscreen
  330
• 3.1 Assembly overview – rear window
  330
• 3.2 Removing and installing rear window
  330
• 4 Side windows
  335
• 4.1 Assembly overview - front side window
  335
• 4.2 Assembly overview - rear side windows
  335
• 4.3 Removing and installing front side window
  336
• 4.4 Removing and installing rear side window
  338
• 5 Door windows
  341
• 5.1 Assembly overview - front door window
  341
• 5.2 Assembly overview - rear door window
  341
• 5.3 Assembly overview - fixed rear door window
  342
• 5.4 Removing and installing front door window
  343
• 5.5 Removing and installing rear door window
  347
• 5.6 Removing and installing fixed rear door window
  351
• Exterior equipment
  353
• 1 Radiator grille and front trim
  353
• 1.1 Assembly overview – radiator grille
  353
• 1.2 Removing and installing radiator grille
  355
• 2 Mouldings, trims, extensions
  360
• 2.1 Assembly overview – water deflector
  360
• 2.2 Assembly overview - heat shield
  361
• 2.3 Assembly overview – side member trim
  362
• 2.4 Removing and installing water deflector
  365
• 2.5 Removing and installing wheel arch trim
  367
• 2.6 Removing and installing door cover
  374
• 2.7 Removing and installing B-pillar trim on door
  377
• 2.8 Removing and installing C-pillar trim on door
  379
• 2.9 Removing and installing trim strip
  380
• 2.10 Removing and installing side spoiler
  382
• 2.11 Removing and installing underbody heat shield
  385
• 2.12 Removing and installing heat shield for centre exhaust system
  387
• 2.13 Removing and installing heat shield for rear silencer
  387
• 2.14 Removing and installing side member trim
  389
• 3 Noise insulation
  405
• 3.1 Assembly overview - noise insulation
  405
• 4 Underbody cladding
  408
• 4.1 Assembly overview – underbody cladding
  408
• 4.2 Removing and installing underbody cladding
  409
• 4.3 Removing and installing centre underbody panels
  411
• 4.4 Removing and installing rear underbody cladding
  412
• 4.5 Removing and installing front tunnel cross-piece
  413
• 4.6 Removing and installing rear tunnel cross-piece
  415
• 5 Roof moulding and roof railing
  417
• 5.1 Assembly overview - roof railing
  417
• 5.2 Removing and installing roof railing
  417
• 6 Exterior mirror
  419
• 6.1 Assembly overview – exterior mirror
  419
• 6.2 Removing and installing exterior mirror
  420
• 6.3 Removing and installing mirror glass
  423
• 6.4 Removing and installing mirror adjustment unit
  426
• 6.5 Removing and installing mirror cover
  428
• 6.6 Removing and installing mirror frame
  429
• 7 Wheel housing liner
  431
• 7.1 Assembly overview – front wheel housing liner
  431
• 7.2 Assembly overview – rear wheel housing liner
  432
• 7.3 Removing and installing front wheel housing liner
  433
• 7.4 Removing and installing rear wheel housing liner
  435
• 8 Lettering and badges
  438
• 8.1 Dimensions - lettering and emblems on rear lid
  438
• 8.2 Dimensions - lettering and emblems on wing
  442
• 8.3 Removing and installing badges at front
  444
• 8.4 Removing and installing lettering
  451
• 9 Special add-on parts
  453
• 9.1 Assembly overview – special add-on parts
  453
• 10 Towing bracket
  456
• 10.1 Assembly overview – towing bracket
  456
• 10.2 Assembly overview – Bowden cable
  457
• 10.3 Removing and installing towing bracket
  458
• 10.4 Removing and installing Bowden cable
  462