General body repairs, exterior

Chapter overview

• Technical data
  1
• 1 \--- Change history ---
  1
• Body - front
  2
• 1 Front end
  2
• 1.1 Front end with complementary parts - assembly overview
  2
• 1.2 Front end with complementary parts - remove and install
  4
• 1.3 Front end with complementary parts - service position
  6
• 2 Mudguard
  11
• 2.1 Front wing - assembly overview
  11
• 2.2 Front wing - remove and install
  12
• 3 Bulkhead
  17
• 3.1 Upper bulkhead panel - assembly overview
  17
• 3.2 Plenum chamber cover - remove and install
  17
• Bonnet, rear lid
  20
• 1 Bonnet
  20
• 1.1 Bonnet - assembly overview
  20
• 1.2 Operating cable - assembly overview
  22
• 1.3 Bonnet - remove and install
  22
• 1.4 Bonnet - adjust
  25
• 1.5 Bonnet latch - remove and install
  28
• 1.6 Bonnet lock - adjust
  30
• 1.7 Bonnet latch actuating lever - remove and install
  32
• 1.8 Bonnet striker - remove and install
  34
• 1.9 Bonnet striker - adjust
  35
• 1.10 Bonnet hinge - remove and install
  37
• 1.11 Bonnet trim - remove and install
  38
• 1.12 Bonnet stay - remove and install
  40
• 1.13 Bowden cable - remove and install
  41
• 2 Rear lid
  43
• 2.1 Rear lid - assembly overview
  43
• 2.2 Rear lid - remove and install
  45
• 2.3 Rear lid - adjust
  49
• 2.4 Adjustment striker - remove and install
  51
• 2.5 Adjustment striker - adjust
  52
• 2.6 Rear lid lock - remove and install
  54
• 2.7 Rear lid lock activation - remove and install
  56
• 2.8 Rear lid hinge - remove and install
  58
• 2.9 Rear lid stop - remove and install
  61
• 2.10 Rear lid striker - adjust
  62
• 2.11 Rear lid trim - remove and install
  64
• 2.12 Rear lid struts - remove and install
  65
• 2.13 Rear lid shock absorber - depressurize
  67
• 3 Fuel reservoir nozzle compartment and lid set
  69
• 3.1 Tank flap cup - assembly overview
  69
• 3.2 Fuel tank nozzle compartment and lid set - remove and install
  69
• 3.3 Fuel tank cap - remove and install
  73
• 3.4 Fuel tank cap locking motor V155 - remove and install
  73
• Front doors, door components, central locking
  75
• 1 Front door
  75
• 1.1 Front door - assembly overview
  75
• 1.2 Front door - remove and install
  78
• 1.3 Front door - adjusting
  82
• 1.4 Front door striker - adjust
  84
• 1.5 Door arrester - remove and install
  86
• 2 Assembly parts
  88
• 2.1 Assembly parts - assembly overview
  88
• 2.2 Front door external handle and lock - assembly overview
  90
• 2.3 Internal front door cover - remove and install
  92
• 2.4 Front door striker - remove and install
  94
• 2.5 Lock cylinder cap - remove and install
  96
• 2.6 Cap without lock cylinder - remove and install
  98
• 2.7 Lock cylinder - remove and install
  102
• 2.8 External door handle - remove and install
  105
• 2.9 External handle support - remove and install
  110
• 2.10 Front door lock - remove and install
  112
• 2.11 Internal front door trim - remove and install
  117
• 3 Central locking system
  120
• 3.1 Central locking - general assembly overview
  120
• 3.2 Ignition key battery - remove and install
  123
• 3.3 Ignition key cover - remove and install
  125
• Rear doors, door components
  127
• 1 Rear door
  127
• 1.1 Rear door - assembly overview
  127
• 1.2 Rear passenger door - remove and install
  130
• 1.3 Rear passenger door - adjust
  134
• 1.4 Rear door striker - adjust
  136
• 1.5 Door arrester - remove and install
  138
• 2 Assembly parts
  141
• 2.1 Assembly parts - assembly overview
  141
• 2.2 Rear door external handle and lock - assembly overview
  143
• 2.3 Rear door inner cover - remove and install
  145
• 2.4 Rear door striker - remove and install
  147
• 2.5 Cap without lock cylinder - remove and install
  149
• 2.6 External door handle - remove and install
  153
• 2.7 External handle support - remove and install
  155
• 2.8 Rear door lock - remove and install
  158
• 2.9 External rear door trim - remove and install
  162
• 2.10 Rear door internal trim - remove and install
  163
• Sunroof
  166
• 1 Sunroof
  166
• 1.1 Sunroof - assembly overview
  166
• 1.2 Sunroof seals - assembly overview
  168
• 1.3 Front glass panel - remove and install
  168
• 1.4 Rear glass panel - remove and install
  171
• 1.5 Sunroof panel - adjust
  176
• 1.6 Rear panel seal - remove and install
  179
• 1.7 Windbreak - remove and install
  184
• 1.8 Sliding sunroof activation motor V1 - remove and install
  188
• 1.9 Sun blind motor V260 - remove and install
  190
• 1.10 Sun blind movement control unit J394 - remove and install
  192
• 1.11 Sliding sunroof movement control unit J245 - remove and install
  193
• 1.12 Sun blind - remove and install
  194
• 1.13 Assembly frame - remove and install
  198
• 1.14 Manual activation
  202
• 2 Sunroof drain hoses
  204
• 2.1 Sunroof drain hoses - assembly overview
  204
• 2.2 Water drain hoses - clean
  204
• 2.3 Sunroof drainage hoses - remove and install
  206
• Bumpers
  209
• 1 Front bumper
  209
• 1.1 Front bumper cover - assembly overview
  209
• 1.2 Front protector support - assembly overview
  211
• 1.3 Front bumper protector - remove and install
  213
• 1.4 Front cover support - remove and install
  217
• 1.5 Support of the parking aid device sensor - install
  220
• 2 Rear bumper
  229
• 2.1 Rear bumper protector - assembly overview
  229
• 2.2 Rear protector support - assembly overview
  230
• 2.3 Rear bumper protector - remove and install
  231
• 2.4 Rear protector support - remove and install
  234
• 2.5 Support of the parking aid device sensor - install
  235
• Glazing
  245
• 1 Repair instructions
  245
• 1.1 Minimum adhesive curing time
  245
• 1.2 Damaged windows - repair
  245
• 1.3 Assembly instructions and material for bonded windows
  246
• 1.4 Stickers for engraving the VIS number on the windows (only for Brazil) - supply
  247
• 1.5 Undamaged windows - prepare for install
  248
• 1.6 New glass - prepare for install
  248
• 1.7 Body flange - prepare to install the window
  250
• 1.8 Adhesive residue cleaning
  251
• 2 Windscreen
  252
• 2.1 Windscreen - assembly overview
  252
• 2.2 Windscreen - remove and install
  253
• 3 Rear window
  258
• 3.1 Rear window - assembly overview
  258
• 3.2 Rear window - remove and install
  258
• 4 Door window glass
  263
• 4.1 Front door window glass - assembly overview
  263
• 4.2 Rear door window glass - assembly overview
  263
• 4.3 Rear door fixed window - assembly overview
  264
• 4.4 Front door window glass - remove and install
  265
• 4.5 Rear door window glass - remove and install
  269
• 4.6 Rear door fixed window - remove and install
  273
• 5 Window drive mechanism
  277
• 5.1 Front door latch operation mechanism - assembly overview
  277
• 5.2 Rear door latch operation mechanism - assembly overview
  277
• 5.3 Front door window mechanism motor - remove and install
  278
• 5.4 Front door window drive mechanism - remove and install
  281
• 5.5 Rear door window mechanism motor - remove and install
  284
• 5.6 Rear door window drive mechanism - remove and install
  286
• 6 Window channels and trim strips
  290
• 6.1 Front door window channel - remove and install
  290
• 6.2 Front door window external trim - remove and install
  292
• 6.3 Front door window internal trim - remove and install
  294
• 6.4 Rear door window channel - remove and install
  295
• 6.5 Rear door window exterior trim - remove and install
  298
• 6.6 Rear door window internal trim - remove and install
  299
• Exterior equipment
  301
• 1 Front grid
  301
• 1.1 Radiator grille - assembly overview
  301
• 1.2 Front bonnet - remove and install
  301
• 2 Roof spoiler
  304
• 2.1 Roof spoiler - assembly overview
  304
• 2.2 Roof spoiler - remove and install
  304
• 3 Trims and linings
  310
• 3.1 Windscreen lower trim - assembly overview
  310
• 3.2 Wheel housing trims - assembly overview
  311
• 3.3 Rear lid outer trim - assembly overview
  311
• 3.4 Side member trim - assembly overview
  312
• 3.5 Windscreen lower trim - remove and install
  313
• 3.6 Wheel housing trim - remove and install
  316
• 3.7 Rear lid outer trim - remove and install
  322
• 3.8 Side member trim - remove and install
  324
• 3.9 Rear door outer trim - remove and install
  326
• 3.10 A-pillar exterior trim - remove and install
  333
• 3.11 B-pillar exterior trim - remove and install
  334
• 3.12 Exterior side member trim - remove and install
  338
• 4 Underbody trim
  341
• 4.1 Floor lower lining - assembly overview
  341
• 4.2 Underbody cross piece - assembly overview
  341
• 4.3 Underbody trim - remove and install
  342
• 4.4 Underbody cross piece - remove and install
  343
• 5 Roof rack
  346
• 5.1 Roof rack - assembly overview
  346
• 5.2 Roof rack - remove and install
  346
• 6 External rear-view mirror
  348
• 6.1 External rear-view mirror - assembly overview
  348
• 6.2 Exterior rear-view mirror - remove and install
  350
• 6.3 Exterior mirror glass - remove and install
  352
• 6.4 Exterior mirror adjustment unit - remove and install
  354
• 6.5 Exterior mirror glass cover - remove and install
  356
• 6.6 Exterior mirror trim - remove and install
  358
• 6.7 Turn signal - remove and install
  360
• 7 Wheel housing liner
  362
• 7.1 Front wheel housing liner - assembly overview
  362
• 7.2 Rear wheel housing liner - assembly overview
  363
• 7.3 Front wheel housing liner - remove and install
  363
• 7.4 Rear wheel housing liner - remove and install
  365
• 8 Lettering and badges
  367
• 8.1 Adhesive lettering - remove and install
  367
• 8.2 Rear lid lettering
  368
• 8.3 Side letterings
  371
• 8.4 Front badge - remove and install
  373
• 8.5 Rear badge - replace
  375
• 9 Heat shield
  378
• 9.1 Heat shield - assembly overview
  378
• 9.2 Heat shield for the centre tunnel - remove and install
  379
• 9.3 Heat shield for the fuel tank region - remove and install
  380
• 9.4 Heat shield for the rear silencer - remove and install
  381