General body repairs, exterior

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 2 Repair notes
  2
• 2.1 Repair notes for special installations
  2
• 3 Hazard classification for high-voltage system
  6
• Body - front
  7
• 1 Lock carrier
  7
• 1.1 Assembly overview – lock carrier
  7
• 1.2 Removing and installing lock carrier
  8
• 1.3 Moving to and back from service position
  9
• 2 Wings
  13
• 2.1 Assembly overview – wing
  13
• 2.2 Removing and installing wing
  13
• 3 Bulkhead
  19
• 3.1 Assembly overview – bulkhead
  19
• 3.2 Assembly overview – plenum chamber cover
  19
• 3.3 Removing and installing plenum chamber bulkhead
  20
• 3.4 Removing and installing plenum chamber cover
  23
• 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
  28
• 1.5 Removing and installing rear lid lock
  33
• 1.6 Removing and installing bonnet lock operating lever
  34
• 1.7 Removing and installing striker pin
  35
• 1.8 Removing and installing hinges
  36
• 1.9 Removing and installing insulation
  37
• 1.10 Removing and installing gas strut
  38
• 1.11 Releasing gas from gas strut
  41
• 1.12 Removing and installing Bowden cable
  42
• 2 Rear lid
  44
• 2.1 Assembly overview – rear lid
  44
• 2.2 Removing and installing rear lid
  46
• 2.3 Adjusting rear lid
  47
• 2.4 Removing and installing rear lid lock
  53
• 2.5 Removing and installing operating mechanism
  54
• 2.6 Removing and installing hinges
  55
• 2.7 Removing and installing striker pin
  59
• 2.8 Removing and installing rear lid seal
  60
• 2.9 Removing and installing gas strut
  60
• 2.10 Releasing gas from gas strut
  62
• 3 Tank flap unit
  63
• 3.1 Assembly overview - tank flap unit
  63
• 3.2 Removing and installing tank flap unit
  64
• 4 Roof load flap
  68
• 4.1 Assembly overview – roof load flap
  68
• 4.2 Assembly overview - cross member
  70
• 4.3 Removing and installing roof load flap
  71
• 4.4 Removing and installing roof load flap lock cover
  73
• 4.5 Removing and installing hinge
  74
• 4.6 Removing and installing gas strut
  76
• 4.7 Removing and installing seal
  80
• 4.8 Removing and installing roof load flap stop buffer on cross member
  81
• 4.9 Removing and installing cross member
  82
• 4.10 Adjusting cross member
  83
• 4.11 Removing and installing cross member attachments
  84
• Front doors, door components, central locking
  90
• 1 Door
  90
• 1.1 Assembly overview – door
  90
• 1.2 Assembly overview - door seals
  93
• 1.3 Removing and installing inner door seal
  94
• 1.4 Removing and installing outer door seal
  95
• 1.5 Removing and installing door
  97
• 1.6 Adjusting door
  101
• 1.7 Adjusting striker pin
  102
• 1.8 Removing and installing door hinge
  104
• 2 Door components
  108
• 2.1 Assembly overview – door components
  108
• 2.2 Assembly overview – window regulator
  109
• 2.3 Assembly overview – door handle and door lock
  110
• 2.4 Assembly overview - window channels and window slot (aperture) seals
  111
• 2.5 Removing and installing window regulator motor V14/V15
  112
• 2.6 Removing and installing window regulator
  114
• 2.7 Removing and installing window crank
  115
• 2.8 Removing and installing inner door cover
  116
• 2.9 Removing and installing striker pin
  118
• 2.10 Removing and installing door handle
  118
• 2.11 Removing and installing mounting bracket
  119
• 2.12 Removing and installing door lock
  121
• 2.13 Removing and installing window slot inner seal
  122
• 2.14 Removing and installing window slot outer seal
  123
• 2.15 Removing and installing lock cylinder
  124
• 2.16 Removing and installing cap on door handle
  127
• 3 Central locking
  133
• 3.1 Overview of fitting locations – central locking system
  133
• 3.2 Assembly overview - ignition key
  135
• 3.3 Removing and installing ignition key battery
  137
• Rear doors, door components
  141
• 1 Door components
  141
• 1.1 Assembly overview – door components
  141
• 1.2 Removing and installing door components
  150
• 1.3 Removing and installing door handle
  180
• 1.4 Removing and installing mounting bracket
  183
• 1.5 Removing and installing door lock
  184
• 2 Sliding door
  187
• 2.1 Assembly overview – sliding door
  187
• 2.2 Removing and installing sliding door
  191
• 2.3 Adjusting sliding door
  194
• 3 Wing door
  204
• 3.1 Assembly overview - wing door
  204
• 3.2 Assembly overview – wing door hinges
  205
• 3.3 Removing and installing wing door
  206
• 3.4 Adjusting wing door
  208
• 3.5 Removing and installing hinges
  214
• Sunroof
  217
• Bumpers
  218
• 1 Bumper, front
  218
• 1.1 Assembly overview – bumper cover
  218
• 1.2 Assembly overview – bumper carrier
  221
• 1.3 Removing and installing bumper cover
  222
• 1.4 Repairing bumper cover
  224
• 2 Bumper, rear
  233
• 2.1 Assembly overview – bumper cover
  233
• 2.2 Assembly overview – bumper carrier
  237
• 2.3 Removing and installing bumper cover
  238
• 2.4 Removing and installing bumper carrier
  241
• 2.5 Repairing bumper cover
  242
• Glazing
  249
• 1 Repair instructions
  249
• 1.1 Minimum drying times for bonded windows
  249
• 1.2 Window repair
  249
• 1.3 Installation instructions for bonded windows
  250
• 1.4 Preparing old undamaged windows for installing
  251
• 1.5 Preparing new windows for installing
  252
• 1.6 Preparing body flange for installing
  253
• 1.7 Cleaning off excess adhesive
  254
• 2 Windscreen
  256
• 2.1 Assembly overview – windscreen
  256
• 2.2 Removing and installing windscreen
  257
• 3 Rear windscreen
  262
• 3.1 Assembly overview – rear window
  262
• 3.2 Removing and installing rear window
  265
• 4 Side windows
  271
• 4.1 Assembly overview - front side windows
  271
• 4.2 Assembly overview - rear side windows
  272
• 4.3 Removing and installing front side window
  275
• 4.4 Removing and installing rear side window
  276
• 5 Door windows
  287
• 5.1 Assembly overview - rear door window
  287
• 5.2 Removing and installing front door window
  288
• 5.3 Removing and installing rear door window
  292
• Exterior equipment
  303
• 1 Radiator grille and front trim
  303
• 1.1 Assembly overview – radiator grille
  303
• 1.2 Removing and installing radiator grille
  304
• 2 Spoiler
  306
• 2.1 Removing and installing spoiler
  306
• 3 Mouldings, trims, extensions
  311
• 3.1 Assembly overview - trim strip and covers
  311
• 3.2 Assembly overview - heat shield
  312
• 3.3 Removing and installing trim strip
  312
• 3.4 Removing and installing step moulding
  313
• 3.5 Removing and installing underbody heat shield
  316
• 3.6 Removing and installing trim insert for side member extension
  318
• 3.7 Removing and installing side member trim
  320
• 3.8 Removing and installing wheel arch covers
  323
• 4 Noise insulation
  330
• 4.1 Assembly overview - noise insulation
  330
• 4.2 Removing and installing noise insulation
  331
• 5 Underbody cladding
  334
• 5.1 Assembly overview - bracing on underbody
  334
• 5.2 Removing and installing tunnel cross-piece
  335
• 6 Trim film and protective film
  337
• 6.1 Renewing protective films
  337
• 7 Roof moulding and roof railing
  340
• 7.1 Assembly overview - roof railing
  340
• 7.2 Removing and installing roof railing
  341
• 8 Exterior mirror
  347
• 8.1 Assembly overview – exterior mirror
  347
• 8.2 Removing and installing exterior mirror
  349
• 8.3 Removing and installing mirror glass
  353
• 8.4 Removing and installing housing frame
  356
• 8.5 Removing and installing mirror cover
  357
• 8.6 Removing and installing mirror frame, passenger car type
  360
• 9 Wheel housing liner
  362
• 9.1 Assembly overview – front wheel housing liner
  362
• 9.2 Assembly overview – rear wheel housing liner
  363
• 9.3 Removing and installing front wheel housing liner
  363
• 9.4 Removing and installing rear wheel housing liner
  365
• 10 Lettering and emblems
  368
• 10.1 Assembly overview – lettering and badges
  368
• 10.2 Dimensions - lettering and emblems on rear
  370
• 10.3 Removing and installing lettering
  374
• 10.4 Renewing lettering and badges on sides
  375
• 10.5 Renewing lettering and badges at rear
  379
• 10.6 Removing and installing lettering and emblems for radiator grille
  383
• 11 Special add-on parts
  385
• 11.1 Assembly overview – special add-on parts
  385
• 11.2 Removing and installing front and rear door trim
  387
• 12 Towing bracket
  390
• 12.1 Assembly overview – towing bracket
  390
• 12.2 Removing and installing towing bracket
  394
• 13 Spare wheel bracket
  397
• 13.1 Assembly overview - spare wheel bracket
  397