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
• Body - front
  2
• 1 Lock carrier
  2
• 1.1 Assembly overview – lock carrier
  2
• 1.2 Removing and installing lock carrier
  3
• 1.3 Moving to and back from service position
  7
• 2 Wings
  12
• 2.1 Assembly overview – wing
  12
• 2.2 Removing and installing wing
  12
• 3 Bulkhead
  18
• 3.1 Assembly overview – bulkhead
  18
• 3.2 Assembly overview – plenum chamber cover
  18
• 3.3 Removing and installing bulkhead
  19
• 3.4 Removing and installing plenum chamber cover
  21
• Bonnet, rear lid
  24
• 1 Bonnet
  24
• 1.1 Assembly overview – bonnet
  24
• 1.2 Assembly overview – Bowden cable
  26
• 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 lock operating lever
  40
• 1.7 Removing and installing striker pin
  46
• 1.8 Removing and installing hinges
  47
• 1.9 Removing and installing insulation
  48
• 1.10 Removing and installing bonnet stay
  50
• 1.11 Removing and installing Bowden cable
  52
• 2 Rear lid
  61
• 2.1 Assembly overview – rear lid
  61
• 2.2 Removing and installing rear lid
  63
• 2.3 Adjusting rear lid
  67
• 2.4 Removing and installing rear lid lock
  74
• 2.5 Removing and installing operating mechanism
  76
• 2.6 Removing and installing hinges
  78
• 2.7 Removing and installing striker pin
  81
• 2.8 Removing and installing rear lid seal
  82
• 2.9 Removing and installing gas strut
  84
• 2.10 Releasing gas from gas strut
  85
• 3 Tank flap unit
  87
• 3.1 Assembly overview – tank flap unit
  87
• 3.2 Removing and installing tank flap unit
  87
• 3.3 Removing and installing fuel tank flap
  91
• Front doors, door components, central locking
  94
• 1 Door
  94
• 1.1 Assembly overview – door
  94
• 1.2 Removing and installing inner door seal
  97
• 1.3 Removing and installing door
  99
• 1.4 Adjusting door
  102
• 1.5 Adjusting striker pin
  105
• 1.6 Removing and installing door arrester
  107
• 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
  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 cap on door handle
  124
• 2.9 Removing and installing lock cylinder
  130
• 2.10 Removing and installing door handle
  133
• 2.11 Removing and installing mounting bracket
  137
• 2.12 Removing and installing door lock
  139
• 2.13 Removing and installing window channel
  144
• 2.14 Removing and installing window slot outer seal
  147
• 2.15 Removing and installing window slot inner seal
  149
• 3 Central locking
  150
• 3.1 Overview of fitting locations – central locking system
  150
• 3.2 Removing and installing tank filler flap locking motor V155
  152
• 3.3 Removing and installing ignition key battery
  153
• 3.4 Removing and installing cap on ignition key
  155
• Rear doors, door components
  157
• 1 Door
  157
• 1.1 Assembly overview – door
  157
• 1.2 Removing and installing door
  160
• 1.3 Adjusting door
  162
• 1.4 Adjusting striker pin
  165
• 1.5 Removing and installing door arrester
  167
• 1.6 Removing and installing inner door seal
  169
• 1.7 Removing and installing outer door seal
  172
• 2 Door components
  174
• 2.1 Assembly overview – door components
  174
• 2.2 Assembly overview – window regulator
  176
• 2.3 Assembly overview – door handle and door lock
  176
• 2.4 Removing and installing window regulator motor
  177
• 2.5 Removing and installing window regulator
  180
• 2.6 Removing and installing inner door cover
  182
• 2.7 Removing and installing striker pin
  185
• 2.8 Removing and installing cap on door handle
  186
• 2.9 Removing and installing door handle
  190
• 2.10 Removing and installing mounting bracket
  192
• 2.11 Removing and installing door lock
  195
• 2.12 Removing and installing window channel
  199
• 2.13 Removing and installing window slot outer seal
  202
• 2.14 Removing and installing window slot inner seal
  204
• Bumpers
  205
• 1 Bumper, front
  205
• 1.1 Assembly overview – bumper cover
  205
• 1.2 Assembly overview – bumper carrier
  209
• 1.3 Removing and installing bumper cover
  211
• 1.4 Removing and installing add-on parts, R-Line
  216
• 1.5 Repairing bumper cover
  223
• 2 Bumper, rear
  233
• 2.1 Assembly overview – bumper cover
  233
• 2.2 Assembly overview – bumper carrier
  235
• 2.3 Removing and installing bumper cover
  236
• 2.4 Removing and installing bumper carrier
  239
• 2.5 Removing and installing add-on parts, R-Line
  241
• 2.6 Repairing bumper cover
  244
• Glazing
  255
• 1 Repair notes
  255
• 1.1 Minimum drying times for bonded windows
  255
• 1.2 Window repair
  256
• 1.3 Installation instructions for bonded windows
  256
• 1.4 Preparing old undamaged windows for installing
  258
• 1.5 Preparing new windows for installing
  259
• 1.6 Preparing body flange for installing
  260
• 1.7 Cleaning off excess adhesive
  262
• 2 Windscreen
  263
• 2.1 Assembly overview – windscreen
  263
• 2.2 Removing and installing windscreen
  264
• 3 Rear windscreen
  272
• 3.1 Assembly overview – rear window
  272
• 3.2 Removing and installing rear window
  273
• 4 Door windows
  277
• 4.1 Assembly overview - front door window
  277
• 4.2 Assembly overview - rear door window
  277
• 4.3 Removing and installing front door window
  279
• 4.4 Removing and installing rear door window
  283
• 4.5 Removing and installing fixed rear door window
  287
• Exterior equipment
  290
• 1 Radiator grille and front trim
  290
• 1.1 Assembly overview – radiator grille
  290
• 1.2 Removing and installing radiator grille
  291
• 2 Spoiler
  295
• 2.1 Assembly overview – spoiler
  295
• 2.2 Removing and installing spoiler
  295
• 3 Mouldings, trims, extensions
  301
• 3.1 Assembly overview – wheel arch covers
  301
• 3.2 Assembly overview – covers
  302
• 3.3 Assembly overview – side member trim
  303
• 3.4 Removing and installing cover
  304
• 3.5 Removing and installing A-pillar trim
  312
• 3.6 Removing and installing B-pillar trim on door
  313
• 3.7 Removing and installing step moulding
  316
• 3.8 Removing and installing wheel arch covers
  318
• 3.9 Removing and installing side member trim
  324
• 4 Noise insulation
  326
• 4.1 Assembly overview - noise insulation
  326
• 5 Underbody cladding
  329
• 5.1 Overview of fitting locations - underbody cladding
  329
• 5.2 Assembly overview - bracing on underbody
  330
• 5.3 Removing and installing underbody cladding
  330
• 5.4 Removing and installing tunnel cross-piece
  337
• 6 Roof moulding and roof railing
  339
• 6.1 Assembly overview - roof railing
  339
• 6.2 Removing and installing roof railing
  339
• 7 Exterior mirror
  341
• 7.1 Assembly overview – exterior mirror
  341
• 7.2 Removing and installing exterior mirror
  342
• 7.3 Removing and installing mirror glass
  345
• 7.4 Removing and installing mirror adjustment unit
  347
• 7.5 Removing and installing mirror cover
  349
• 7.6 Removing and installing mirror frame
  351
• 7.7 Removing and installing turn signal
  352
• 8 Wheel housing liner
  354
• 8.1 Assembly overview – front wheel housing liner
  354
• 8.2 Assembly overview – rear wheel housing liner
  355
• 8.3 Removing and installing front wheel housing liner
  355
• 8.4 Removing and installing rear wheel housing liner
  357
• 9 Lettering and badges
  360
• 9.1 Dimensions - lettering and badges on rear
  360
• 9.2 Removing and installing badges at front
  363
• 9.3 Renewing lettering and badges at rear
  365
• 10 Towing bracket
  367
• 10.1 Assembly overview – towing bracket
  367
• 10.2 Removing and installing towing bracket
  367
• 11 Heat shields
  370
• 11.1 Overview of fitting locations – heat shields
  370
• 11.2 Removing and installing underbody heat shield
  371