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
  7
• 1.3 Moving to and back from service position
  10
• 2 Wings
  15
• 2.1 Assembly overview - wing
  15
• 2.2 Removing and installing wing
  15
• 3 Plenum chamber bulkhead
  21
• 3.1 Assembly overview - plenum chamber bulkhead
  21
• 3.2 Assembly overview - plenum chamber cover
  21
• 3.3 Removing and installing bulkhead
  22
• 3.4 Removing and installing plenum chamber cover
  26
• Bonnet, rear lid
  31
• 1 Bonnet
  31
• 1.1 Assembly overview - bonnet
  31
• 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 striker pin
  48
• 1.7 Removing and installing hinges
  49
• 1.8 Removing and installing insulation
  54
• 1.9 Removing and installing gas strut
  56
• 1.10 Releasing gas from gas strut
  58
• 1.11 Removing and installing Bowden cable
  59
• 1.12 Removing and installing bonnet release lever
  66
• 2 Tailgate
  71
• 2.1 Assembly overview - rear lid
  71
• 2.2 Removing and installing rear lid
  73
• 2.3 Adjusting rear lid
  77
• 2.4 Removing and installing rear lid lock
  83
• 2.5 Removing and installing operating mechanism
  95
• 2.6 Removing and installing hinges
  97
• 2.7 Removing and installing striker pin
  100
• 2.8 Removing and installing rear lid seal
  101
• 2.9 Removing and installing gas strut
  103
• 2.10 Releasing gas from gas strut
  104
• 2.11 Removing and installing drive unit for rear lid VX69
  105
• 2.12 Removing and installing rear lid control unit J605
  108
• 3 Tank flap unit
  109
• 3.1 Assembly overview - tank flap unit
  109
• 3.2 Removing and installing tank flap unit
  109
• 3.3 Removing and installing fuel tank flap
  113
• 3.4 Assembly overview – charging flap unit
  115
• Front doors, door components, central locking
  117
• 1 Door
  117
• 1.1 Assembly overview - door
  117
• 1.2 Removing and installing inner door seal
  120
• 1.3 Removing and installing outer door seal
  122
• 1.4 Removing and installing door
  126
• 1.5 Adjusting door
  130
• 1.6 Adjusting striker pin
  132
• 1.7 Removing and installing door arrester
  134
• 2 Door components
  137
• 2.1 Assembly overview - door components
  137
• 2.2 Assembly overview - window regulator
  138
• 2.3 Assembly overview - door handle and door lock
  139
• 2.4 Removing and installing window regulator motor
  141
• 2.5 Removing and installing window regulator
  143
• 2.6 Removing and installing power latching motor
  146
• 2.7 Removing and installing inner door cover
  149
• 2.8 Removing and installing striker pin
  151
• 2.9 Removing and installing cap on door handle
  153
• 2.10 Removing and installing lock cylinder
  159
• 2.11 Removing and installing door handle
  162
• 2.12 Removing and installing mounting bracket
  166
• 2.13 Removing and installing door lock
  168
• 2.14 Removing and installing window channel
  175
• 2.15 Removing and installing window slot outer seal
  178
• 2.16 Removing and installing window slot inner seal
  180
• 3 Central locking
  182
• 3.1 Overview of fitting locations - central locking
  182
• 3.2 Assembly overview - ignition key
  184
• 3.4 Removing and installing tank filler flap locking motor V155
  186
• 3.5 Removing and installing ignition key battery
  187
• Rear doors, door components
  190
• 1 Door
  190
• 1.1 Assembly overview - door
  190
• 1.2 Removing and installing door
  193
• 1.3 Adjusting door
  195
• 1.4 Adjusting striker pin
  198
• 1.5 Removing and installing door arrester
  200
• 1.6 Removing and installing inner door seal
  202
• 1.7 Removing and installing outer door seal
  205
• 2 Door components
  210
• 2.1 Assembly overview - door components
  210
• 2.2 Assembly overview - window regulator
  211
• 2.3 Assembly overview - door handle and door lock
  212
• 2.4 Removing and installing window regulator motor
  214
• 2.5 Removing and installing window regulator
  216
• 2.6 Removing and installing inner door cover
  220
• 2.7 Removing and installing striker pin
  224
• 2.8 Removing and installing cap on door handle
  226
• 2.9 Removing and installing door handle
  230
• 2.10 Removing and installing mounting bracket
  232
• 2.11 Removing and installing door lock
  235
• 2.12 Removing and installing power latching motor V329
  240
• 2.13 Removing and installing window channel
  242
• 2.14 Removing and installing window slot outer seal
  245
• 2.15 Removing and installing window slot inner seal
  247
• Sunroof
  248
• 1 Sliding sunroof
  248
• 1.1 Assembly overview - sliding sunroof
  248
• 1.2 Assembly overview - sunroof roller blind
  250
• 1.3 Assembly overview - wind deflector
  251
• 1.4 Removing and installing sunroof panel
  252
• 1.5 Removing and installing rear sunroof panel
  254
• 1.6 Adjusting sunroof panel
  256
• 1.7 Removing and installing tilt mechanism for sliding sunroof
  258
• 1.8 Removing and installing guide rail for tilt mechanism
  260
• 1.9 Removing and installing sliding sunroof seals
  262
• 1.10 Removing and installing wind deflector
  264
• 1.11 Removing and installing wind deflector bracket
  265
• 1.12 Removing and installing sunroof motor V1
  266
• 1.13 Removing and installing sunroof roller blind motor V260
  266
• 1.14 Removing and installing sunroof roller blind control unit J394
  268
• 1.15 Removing and installing sliding sunroof adjustment control unit J245
  268
• 1.16 Adapting sliding sunroof adjustment control unit J245
  269
• 1.17 Removing and installing sunroof roller blind
  270
• 1.18 Removing and installing sliding sunroof frame
  274
• 2 Water drain hoses
  276
• 2.1 Assembly overview - water drain hoses
  276
• 2.2 Cleaning water drain hoses
  277
• 2.3 Removing and installing water drain hoses
  278
• Bumpers
  282
• 1 Bumper, front
  282
• 1.1 Assembly overview - bumper cover
  282
• 1.2 Assembly overview - impact bar
  286
• 1.3 Removing and installing bumper cover
  288
• 1.4 Removing and installing impact bar
  291
• 1.5 Repairing bumper cover
  292
• 2 Bumper, rear
  296
• 2.1 Assembly overview - bumper cover
  296
• 2.2 Assembly overview - impact bar
  300
• 2.3 Removing and installing bumper cover
  301
• 2.4 Removing and installing impact bar
  305
• 2.5 Repairing bumper cover
  306
• Glazing
  315
• 1 Repair notes
  315
• 1.1 Minimum curing periods for bonded windows
  315
• 1.2 Window repair
  315
• 1.3 Installation instructions for bonded windows
  316
• 1.4 Preparing old undamaged windows for fitting
  317
• 1.5 Preparing new windows for installing
  318
• 1.6 Preparing body flange for fitting
  319
• 1.7 Cleaning off excess adhesive
  320
• 2 Windscreen
  321
• 2.1 Assembly overview - windscreen
  321
• 2.2 Removing and installing windscreen
  322
• 3 Rear windscreen
  330
• 3.1 Assembly overview - rear window
  330
• 3.2 Removing and installing rear window
  331
• 4 Side window
  335
• 4.1 Assembly overview - rear side windows
  335
• 4.2 Removing and installing rear side window
  336
• 5 Door windows
  341
• 5.1 Assembly overview - front door window
  341
• 5.2 Assembly overview - rear door window
  341
• 5.3 Removing and installing front door window
  342
• 5.4 Removing and installing rear door window
  346
• 5.5 Removing and installing fixed front door window
  349
• Exterior equipment
  355
• 1 Radiator grille and front trim
  355
• 1.1 Assembly overview – radiator grille
  355
• 1.2 Removing and installing radiator grille
  356
• 2 Spoiler
  360
• 2.1 Assembly overview - spoiler
  360
• 2.2 Removing and installing spoiler
  360
• 3 Mouldings, trims, extensions
  364
• 3.1 Assembly overview - wheel arch covers
  364
• 3.2 Assembly overview - B-pillar trim
  365
• 3.3 Assembly overview - water deflector
  366
• 3.4 Removing and installing cover
  367
• 3.5 Removing and installing B-pillar trim on door
  375
• 3.6 Removing and installing C-pillar trim on door
  379
• 3.7 Removing and installing trim strip
  381
• 3.8 Removing and installing entry moulding
  382
• 3.9 Removing and installing wheel arch covers
  385
• 3.10 Removing and installing water deflector
  391
• 4 Noise insulation
  392
• 4.1 Assembly overview - noise insulation
  392
• 4.2 Removing and installing noise insulation
  393
• 5 Underbody cladding
  396
• 5.1 Overview of fitting locations - underbody cladding
  396
• 5.2 Assembly overview - bracing on underbody
  398
• 5.3 Removing and installing underbody cladding
  400
• 5.4 Removing and installing tunnel cross-piece
  404
• 5.5 Removing and installing diagonal struts
  406
• 5.6 Removing and installing skid plate
  408
• 6 Roof moulding and roof railing
  410
• 6.1 Assembly overview - roof railing
  410
• 6.2 Removing and installing roof railing
  410
• 7 Exterior mirror
  414
• 7.1 Assembly overview - exterior mirror
  414
• 7.2 Removing and installing exterior mirror
  415
• 7.3 Removing and installing mirror glass
  418
• 7.4 Removing and installing mirror adjustment unit
  420
• 7.5 Removing and installing mirror cover
  422
• 7.6 Removing and installing mirror trim
  424
• 7.7 Removing and installing turn signal
  425
• 7.8 Removing and installing entry light in exterior mirror
  427
• 8 Wheel housing liner
  429
• 8.1 Assembly overview - front wheel housing liner
  429
• 8.2 Assembly overview - rear wheel housing liner
  430
• 8.3 Removing and installing front wheel housing liner
  430
• 8.4 Removing and installing rear wheel housing liner
  432
• 9 Lettering and emblems
  434
• 9.1 Dimensions - lettering and emblems on rear
  434
• 9.2 Dimensions - lettering and emblems on sides
  436
• 9.3 Removing and installing badges at front
  437
• 9.4 Renewing lettering and badges at rear
  440
• 10 Towing bracket
  442
• 10.1 Assembly overview - towing bracket
  442
• 10.2 Removing and installing towing bracket
  442
• 11 Heat shields
  445
• 11.1 Overview of fitting locations - heat shields
  445
• 11.2 Removing and installing underbody heat shield
  449