General body repairs, exterior

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety measures when working on vehicles with a start/stop system
  1
• 1.3 Safety precautions when working on the cooling system
  1
• 2 Repair instructions
  2
• 2.1 Pipe/wire routing and attachment
  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
  7
• 2 Wings
  11
• 2.1 Assembly overview – wing
  11
• 2.2 Removing and installing wing
  12
• 3 Bulkhead
  16
• 3.1 Assembly overview – bulkhead
  16
• 3.2 Assembly overview – plenum chamber cover
  16
• 3.3 Removing and installing bulkhead
  17
• 3.4 Removing and installing plenum chamber cover
  19
• Bonnet, rear lid
  25
• 1 Bonnet
  25
• 1.1 Assembly overview – bonnet
  25
• 1.2 Assembly overview – Bowden cable
  26
• 1.3 Removing and installing bonnet
  27
• 1.4 Adjusting bonnet
  30
• 1.5 Removing and installing bonnet lock
  34
• 1.6 Removing and installing bonnet lock operating lever
  38
• 1.7 Removing and installing striker pin
  40
• 1.8 Removing and installing hinges
  42
• 1.9 Removing and installing insulation
  43
• 1.10 Removing and installing gas strut
  45
• 1.11 Releasing gas from gas strut
  47
• 1.12 Removing and installing Bowden cable
  47
• 2 Rear lid
  51
• 2.1 Assembly overview – rear lid
  51
• 2.2 Removing and installing rear lid
  53
• 2.3 Adjusting rear lid
  56
• 2.4 Removing and installing bonnet lock
  62
• 2.5 Removing and installing operating mechanism
  73
• 2.6 Removing and installing hinges
  74
• 2.7 Removing and installing striker pin
  76
• 2.8 Removing and installing rear lid seal
  77
• 2.9 Removing and installing gas strut
  79
• 2.10 Releasing gas from gas strut
  80
• 2.11 Removing and installing rear lid drive unit VX69
  83
• 3 Tank flap unit
  86
• 3.1 Assembly overview – tank flap unit
  86
• 3.2 Removing and installing tank flap unit
  86
• 3.3 Removing and installing fuel tank flap
  89
• Front doors, door components, central locking
  92
• 1 Door
  92
• 1.1 Assembly overview – door
  92
• 1.2 Removing and installing inner door seal
  95
• 1.3 Removing and installing outer door seal
  97
• 1.4 Removing and installing side member seal
  99
• 1.5 Removing and installing door
  100
• 1.6 Adjusting door
  103
• 1.7 Adjusting striker pin
  106
• 1.8 Removing and installing door arrester
  108
• 2 Door components
  110
• 2.1 Assembly overview – door components
  110
• 2.2 Assembly overview – window regulator
  111
• 2.3 Assembly overview – door handle and door lock
  112
• 2.4 Removing and installing window regulator motor
  114
• 2.5 Removing and installing window regulator
  116
• 2.6 Removing and installing inner door cover
  118
• 2.7 Removing and installing striker pin
  120
• 2.8 Removing and installing cap on door handle
  122
• 2.9 Removing and installing lock cylinder
  129
• 2.10 Removing and installing door handle
  131
• 2.11 Removing and installing mounting bracket
  135
• 2.12 Removing and installing door lock
  137
• 2.13 Removing and installing window channel
  141
• 2.14 Removing and installing window slot outer seal
  144
• 2.15 Removing and installing window slot inner seal
  146
• 3 Central locking
  147
• 3.1 Overview of fitting locations – central locking system
  147
• 3.3 Removing and installing tank filler flap locking motor V155
  150
• 3.4 Removing and installing ignition key battery
  152
• 3.5 Removing and installing cap on ignition key
  154
• Rear doors, door components
  155
• 1 Door
  155
• 1.1 Assembly overview – door
  155
• 1.2 Removing and installing door
  158
• 1.3 Adjusting door
  160
• 1.4 Adjusting striker pin
  163
• 1.5 Removing and installing door arrester
  165
• 1.6 Removing and installing inner door seal
  166
• 1.7 Removing and installing outer 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
  174
• 2.4 Removing and installing window regulator motor
  176
• 2.5 Removing and installing window regulator
  178
• 2.6 Removing and installing inner door cover
  180
• 2.7 Removing and installing striker pin
  182
• 2.8 Removing and installing cap on door handle
  184
• 2.9 Removing and installing door handle
  188
• 2.10 Removing and installing mounting bracket
  192
• 2.11 Removing and installing door lock
  194
• 2.12 Removing and installing window channel
  198
• 2.13 Removing and installing window slot outer seal
  201
• 2.14 Removing and installing window slot inner seal
  203
• Sunroof
  204
• 1 Sliding sunroof
  204
• 1.1 Assembly overview – sliding sunroof
  204
• 1.2 Assembly overview – wind deflector
  206
• 1.3 Removing and installing sunroof panel
  207
• 1.4 Removing and installing rear sunroof panel
  211
• 1.5 Adjusting sunroof panel
  215
• 1.6 Removing and installing sliding sunroof seals
  219
• 1.7 Removing and installing wind deflector
  223
• 1.8 Removing and installing sunroof motor V1
  224
• 1.9 Removing and installing sunroof roller blind motor V260
  227
• 1.10 Removing and installing sunroof roller blind control unit J394
  228
• 1.11 Removing and installing sliding sunroof adjustment control unit J245
  229
• 1.12 Removing and installing sunroof roller blind
  230
• 1.13 Removing and installing sliding sunroof frame
  236
• 1.14 Removing and installing rear part
  238
• 1.15 Removing and installing tilt mechanism for sliding sunroof
  243
• 1.16 Removing and installing sunroof roller blind cables
  245
• 1.17 Manual operation
  248
• 2 Water drain hoses
  250
• 2.1 Assembly overview - water drain hoses
  250
• 2.2 Removing and installing water drain hoses
  250
• 2.3 Cleaning water drain hoses
  253
• Bumpers
  255
• 1 Bumper, front
  255
• 1.1 Assembly overview – bumper cover
  255
• 1.2 Assembly overview - attachments
  257
• 1.3 Assembly overview – bumper carrier
  261
• 1.4 Removing and installing bumper cover
  263
• 1.5 Repairing bumper cover
  266
• 2 Bumper, rear
  271
• 2.1 Assembly overview – bumper cover
  271
• 2.2 Assembly overview - guides for bumper cover
  272
• 2.3 Assembly overview - attachments
  272
• 2.4 Assembly overview – bumper carrier
  274
• 2.5 Removing and installing bumper cover
  274
• 2.6 Removing and installing bumper carrier
  277
• 2.7 Repairing bumper cover
  280
• Glazing
  289
• 1 Repair instructions
  289
• 1.1 Minimum drying times for bonded windows
  289
• 1.2 Window repair
  289
• 1.3 Installation instructions for bonded windows
  290
• 1.4 Preparing old undamaged windows for installing
  291
• 1.5 Preparing new windows for installing
  292
• 1.6 Preparing body flange for installing
  294
• 1.7 Cleaning off excess adhesive
  295
• 2 Windscreen
  296
• 2.1 Assembly overview – windscreen
  296
• 2.2 Removing and installing windscreen
  297
• 3 Rear windscreen
  305
• 3.1 Assembly overview – rear window
  305
• 3.2 Removing and installing rear window
  306
• 4 Side windows
  310
• 4.1 Assembly overview - rear side windows
  310
• 4.2 Removing and installing rear side window
  311
• 5 Door windows
  316
• 5.1 Assembly overview - front door window
  316
• 5.2 Assembly overview - rear door window
  316
• 5.3 Removing and installing front door window
  317
• 5.4 Removing and installing rear door window
  321
• 5.5 Removing and installing fixed front door window
  325
• 5.6 Removing and installing fixed rear door window
  326
• Exterior equipment
  329
• 1 Radiator grille and front trim
  329
• 1.1 Assembly overview – radiator grille
  329
• 1.2 Removing and installing radiator grille
  329
• 2 Spoiler
  332
• 2.1 Assembly overview – spoiler
  332
• 2.2 Removing and installing spoiler
  333
• 3 Mouldings, trims, extensions
  338
• 3.1 Assembly overview – water deflector
  338
• 3.2 Assembly overview - wheel arch covers
  339
• 3.3 Assembly overview - heat shield
  340
• 3.4 Removing and installing water deflector
  341
• 3.5 Removing and installing cover
  342
• 3.6 Removing and installing B-pillar trim on door
  348
• 3.7 Removing and installing trim strip
  350
• 3.8 Removing and installing step moulding
  355
• 3.9 Removing and installing wheel arch covers
  357
• 3.10 Removing and installing underbody heat shield
  363
• 4 Noise insulation
  367
• 4.1 Assembly overview - noise insulation
  367
• 5 Underbody cladding
  371
• 5.1 Assembly overview – underbody cladding
  371
• 5.2 Removing and installing underbody cladding
  373
• 5.3 Removing and installing tunnel cross-piece
  378
• 6 Roof moulding and roof railing
  380
• 6.1 Assembly overview - roof railing
  380
• 6.2 Removing and installing roof railing
  380
• 7 Exterior mirror
  382
• 7.1 Assembly overview – exterior mirror
  382
• 7.2 Removing and installing exterior mirror
  384
• 7.3 Removing and installing mirror glass
  386
• 7.4 Removing and installing mirror adjustment unit
  388
• 7.5 Removing and installing mirror cover
  389
• 7.6 Removing and installing mirror frame
  390
• 8 Wheel housing liner
  392
• 8.1 Assembly overview – front wheel housing liner
  392
• 8.2 Assembly overview – rear wheel housing liner
  393
• 8.3 Removing and installing front wheel housing liner
  395
• 8.4 Removing and installing rear wheel housing liner
  396
• 9 Lettering and badges
  398
• 9.1 Dimensions - lettering and badges on rear
  398
• 9.2 Dimensions – lettering and badges on sides
  401
• 9.3 Removing and installing badges at front
  403
• 9.4 Renewing lettering and badges at rear
  404
• 9.5 Renewing lettering and badges on sides
  406
• 9.6 Removing and installing lettering and badges for radiator grille
  408
• 10 Special add-on parts
  409
• 10.1 Assembly overview – special add-on parts
  409
• 11 Towing bracket
  410
• 11.1 Assembly overview – towing bracket
  410
• 11.2 Removing and installing towing bracket
  410