General body repairs, exterior

Chapter overview

• Technical data
  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
  31
• 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 stay - remove and install
  38
• 1.12 Bowden cable - remove and install
  39
• 2 Rear lid
  42
• 2.1 Rear lid - assembly overview
  42
• 2.2 Rear lid - remove and install
  44
• 2.3 Rear lid - adjust
  48
• 2.4 Adjustment striker - adjust
  51
• 2.5 Rear lid lock - remove and install
  53
• 2.6 Rear lid lock activation - remove and install
  55
• 2.7 Rear lid hinge - remove and install
  57
• 2.8 Rear lid stop - remove and install
  60
• 2.9 Rear lid striker - adjust
  61
• 2.10 Rear lid trim - remove and install
  62
• 2.11 Rear lid struts - remove and install
  64
• 2.12 Rear lid shock absorber - depressurize
  66
• 3 Fuel reservoir nozzle compartment and lid set
  68
• 3.1 Tank flap cup - assembly overview
  68
• 3.2 Fuel tank nozzle compartment and lid set - remove and install
  68
• 3.3 Fuel tank cap - remove and install
  72
• 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
• 2.12 Front door outer trim - remove and install
  119
• 3 Central locking system
  121
• 3.1 Central locking - general assembly overview
  121
• 3.2 Ignition key battery - remove and install
  124
• 3.3 Ignition key cover - remove and install
  126
• Rear doors, door components
  128
• 1 Rear door
  128
• 1.1 Rear door - assembly overview
  128
• 1.2 Rear passenger door - remove and install
  131
• 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
  144
• 2.4 Rear door striker - remove and install
  146
• 2.5 Cap without lock cylinder - remove and install
  148
• 2.6 External door handle - remove and install
  152
• 2.7 External handle support - remove and install
  154
• 2.8 Rear door lock - remove and install
  157
• 2.9 External rear door trim - remove and install
  161
• 2.10 Rear door internal trim - remove and install
  162
• Bumpers
  165
• 1 Front bumper
  165
• 1.1 Front bumper cover - assembly overview
  165
• 1.2 Front protector support - assembly overview
  167
• 1.3 Front bumper protector - remove and install
  169
• 1.4 Front cover support - remove and install
  172
• 1.5 Support of the parking aid device sensor - install
  174
• 2 Rear bumper
  184
• 2.1 Rear bumper protector - assembly overview
  184
• 2.2 Rear protector support - assembly overview
  185
• 2.3 Rear bumper protector - remove and install
  186
• 2.4 Rear protector support - remove and install
  189
• 2.5 Support of the parking aid device sensor - install
  190
• Glazing
  200
• 1 Repair instructions
  200
• 1.1 Minimum adhesive curing time
  200
• 1.2 Damaged windows - repair
  200
• 1.3 Assembly instructions and material for bonded windows
  201
• 1.4 Stickers for engraving the VIS number on the windows (only for Brazil) - supply
  202
• 1.5 Undamaged windows - prepare for install
  203
• 1.6 New glass - prepare for install
  203
• 1.7 Body flange - prepare to install the window
  205
• 1.8 Adhesive residue cleaning
  206
• 2 Windscreen
  207
• 2.1 Windscreen - assembly overview
  207
• 2.2 Windscreen - remove and install
  208
• 3 Rear window
  213
• 3.1 Rear window - assembly overview
  213
• 3.2 Rear window - remove and install
  213
• 4 Door window glass
  218
• 4.1 Front door window glass - assembly overview
  218
• 4.2 Rear door window glass - assembly overview
  219
• 4.3 Front door window glass - remove and install
  219
• 4.4 Rear door window glass - remove and install
  223
• 5 Window drive mechanism
  228
• 5.1 Front door latch operation mechanism - assembly overview
  228
• 5.2 Rear door latch operation mechanism - assembly overview
  228
• 5.3 Front door window mechanism motor - remove and install
  229
• 5.4 Front door window drive mechanism - remove and install
  232
• 5.5 Rear door window mechanism motor - remove and install
  235
• 5.6 Rear door window drive mechanism - remove and install
  237
• 6 Window channels and trim strips
  241
• 6.1 Front door window channel - remove and install
  241
• 6.2 Front door window external trim - remove and install
  243
• 6.3 Front door window internal trim - remove and install
  245
• 6.4 Rear door window channel - remove and install
  246
• 6.5 Rear door window exterior trim - remove and install
  249
• 6.6 Rear door window internal trim - remove and install
  250
• Exterior equipment
  252
• 1 Front grid
  252
• 1.1 Radiator grille - assembly overview
  252
• 1.2 Front bonnet - remove and install
  252
• 2 Roof spoiler
  255
• 2.1 Roof spoiler - assembly overview
  255
• 2.2 Roof spoiler - remove and install
  255
• 3 Trims and linings
  262
• 3.1 Windscreen lower trim - assembly overview
  262
• 3.2 Wheel housing trims - assembly overview
  263
• 3.3 Rear lid outer trim - assembly overview
  263
• 3.4 Side member trim - assembly overview
  264
• 3.5 Windscreen lower trim - remove and install
  265
• 3.6 Wheel housing trim - remove and install
  268
• 3.7 Rear lid outer trim - remove and install
  274
• 3.8 Side member trim - remove and install
  276
• 3.9 Rear door outer trim - remove and install
  279
• 3.10 A-pillar exterior trim - remove and install
  285
• 3.11 B-pillar exterior trim - remove and install
  287
• 4 Underbody trim
  292
• 4.1 Floor lower lining - assembly overview
  292
• 4.2 Underbody cross piece - assembly overview
  292
• 4.3 Underbody trim - remove and install
  293
• 4.4 Underbody cross piece - remove and install
  294
• 5 Roof rack
  297
• 5.1 Roof rack - assembly overview
  297
• 5.2 Roof rack - remove and install
  297
• 6 External rear-view mirror
  299
• 6.1 External rear-view mirror - assembly overview
  299
• 6.2 Exterior rear-view mirror - remove and install
  301
• 6.3 Exterior mirror glass - remove and install
  303
• 6.4 Exterior mirror adjustment unit - remove and install
  305
• 6.5 Exterior mirror glass cover - remove and install
  307
• 6.6 Exterior mirror trim - remove and install
  309
• 6.7 Turn signal - remove and install
  311
• 7 Wheel housing liner
  313
• 7.1 Front wheel housing liner - assembly overview
  313
• 7.2 Rear wheel housing liner - assembly overview
  314
• 7.3 Front wheel housing liner - remove and install
  314
• 7.4 Rear wheel housing liner - remove and install
  316
• 8 Lettering and badges
  318
• 8.1 Adhesive lettering - remove and install
  318
• 8.2 Rear lid lettering
  319
• 8.3 Side letterings
  321
• 8.4 Front badge - remove and install
  323
• 8.5 Rear badge - replace
  325
• 9 Heat shield
  328
• 9.1 Heat shield - assembly overview
  328
• 9.2 Heat shield for the centre tunnel - remove and install
  329
• 9.3 Heat shield for the fuel tank region - remove and install
  330
• 9.4 Heat shield for the rear silencer - remove and install
  331