General body repairs, exterior

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety precautions when working on high-voltage system
  1
• 1.2 Safety precautions when working in the vicinity of high-voltage components
  2
• 2 Repair notes
  3
• 2.1 General information
  3
• 2.2 Contact corrosion
  3
• 3 Hazard classification for the high-voltage system
  4
• Body - front
  5
• 1 Lock carrier
  5
• 1.1 Assembly overview – lock carrier
  5
• 1.2 Removing and installing lock carrier
  6
• 1.3 Moving to and back from service position
  9
• 2 Wings
  12
• 2.1 Assembly overview – wing
  12
• 2.2 Removing and installing wing
  12
• 3 Bulkhead
  16
• 3.1 Assembly overview – bulkhead
  16
• 3.2 Assembly overview – plenum chamber cover
  17
• 3.3 Removing and installing plenum chamber cover
  18
• Bonnet, rear lid
  21
• 1 Bonnet
  21
• 1.1 Assembly overview – bonnet
  21
• 1.2 Assembly overview – Bowden cable
  22
• 1.3 Removing and installing bonnet
  23
• 1.4 Adjusting bonnet
  24
• 1.5 Removing and installing bonnet lock
  28
• 1.6 Removing and installing bonnet lock release lever
  29
• 1.7 Removing and installing striker pin
  31
• 1.8 Removing and installing hinges
  31
• 1.9 Removing and installing insulation
  33
• 1.10 Removing and installing gas strut
  33
• 1.11 Releasing gas from gas strut
  35
• 1.12 Removing and installing Bowden cable
  35
• 2 Rear lid
  37
• 2.1 Assembly overview – rear lid
  37
• 2.2 Removing and installing rear lid
  40
• 2.3 Adjusting rear lid
  41
• 2.4 Removing and installing bonnet lock
  45
• 2.5 Removing and installing operating mechanism
  47
• 2.6 Removing and installing hinges
  51
• 2.7 Removing and installing striker pin
  54
• 2.8 Removing and installing stop for adjusting buffer
  55
• 2.9 Removing and installing rear lid seal
  56
• 2.10 Removing and installing gas strut
  57
• 2.11 Releasing gas from gas strut
  60
• 2.12 Removing and installing rear lid power opening control unit J938
  61
• 3 Tank flap unit
  63
• 3.1 Assembly overview – tank flap unit
  63
• 3.2 Removing and installing fuel tank flap
  63
• Front doors, door components, central locking
  66
• 1 Door
  66
• 1.1 Assembly overview – door
  66
• 1.2 Assembly overview - door seals
  68
• 1.3 Removing and installing inner door seal
  69
• 1.4 Removing and installing outer door seal
  71
• 1.5 Removing and installing door
  72
• 1.6 Adjusting door
  74
• 1.7 Adjusting striker pin
  77
• 1.8 Removing and installing door hinge
  78
• 2 Door components
  81
• 2.1 Assembly overview – assembly carrier
  81
• 2.2 Assembly overview – window regulator
  82
• 2.3 Assembly overview – door handle and door lock
  83
• 2.4 Assembly overview - window channels and window slot (aperture) seals
  85
• 2.5 Removing and installing window regulator motor
  86
• 2.6 Removing and installing window crank
  88
• 2.7 Removing and installing assembly carrier
  88
• 2.8 Removing and installing lock cylinder
  91
• 2.9 Removing and installing door handle
  93
• 2.10 Removing and installing door lock
  96
• 2.11 Removing and installing mounting bracket
  98
• 2.12 Removing and installing striker pin
  99
• 3 Central locking
  101
• 3.1 Overview of fitting locations – central locking system
  101
• 3.2 Assembly overview - ignition key
  104
• 3.3 Removing and installing ignition key battery
  105
• Rear doors, door components
  109
• 1 Sliding door
  110
• 1.1 Assembly overview – sliding door
  110
• 1.2 Removing and installing door seal
  123
• 1.3 Removing and installing sliding door
  127
• 1.4 Adjusting sliding door
  132
• 1.5 Removing and installing striker pin
  139
• 1.6 Removing and installing roller guide
  142
• 1.7 Removing and installing door arrester
  152
• 1.8 Removing and installing hinge
  153
• 1.9 Removing and installing door lock
  155
• 1.10 Removing and installing sliding door remote release mechanism
  158
• 1.11 Removing and installing contact module
  160
• 1.12 Removing and installing door handle
  162
• 1.13 Removing and installing mounting bracket
  163
• 1.14 Removing and installing guide rail
  164
• 1.15 Removing and installing motor for opening sliding door
  171
• 1.16 Removing and installing right electric sliding door sender unit G481
  174
• 2 Cab door - double cab
  176
• 2.1 Assembly overview - cab door
  176
• 2.2 Assembly overview – door handle and door lock
  177
• 2.3 Removing and installing inner door seals
  178
• 2.4 Removing and installing cab door
  179
• 2.5 Adjusting cab door
  181
• 2.6 Removing and installing striker pin
  183
• 2.7 Removing and installing door hinge
  184
• 2.8 Removing and installing door arrester
  185
• 2.9 Removing and installing bumper carrier
  186
• 2.10 Removing and installing door handle
  187
• 2.11 Removing and installing mounting bracket
  190
• 2.12 Removing and installing door lock
  191
• 3 Wing doors
  193
• 3.1 Assembly overview - wing door
  193
• 3.2 Assembly overview - door arrester with opening angle of 250°
  196
• 3.3 Assembly overview – door components
  197
• 3.4 Removing and installing wing door seal
  200
• 3.5 Removing and installing inner seal of wing door
  201
• 3.6 Removing and installing wing door
  202
• 3.7 Adjusting wing door
  204
• 3.8 Removing and installing striker pin
  211
• 3.9 Replacing wing door
  213
• 3.10 Removing and installing wing door hinges
  213
• 3.11 Removing and installing door arrester
  215
• 3.12 Installing stop in wing door for door arrester with opening angle of 250°
  217
• 3.13 Removing and installing wing door locks
  220
• 3.14 Removing and installing release lever
  224
• 3.15 Removing and installing childproof lock
  226
• 3.16 Removing and installing latch carrier
  226
• 3.17 Removing and installing interior door handle
  227
• 3.18 Removing and installing exterior door handle
  228
• 3.19 Removing and installing assembly carrier
  229
• 3.20 Removing and installing light strip
  231
• 3.21 Removing and installing lock cylinder
  232
• Sunroof
  234
• 1 Sliding sunroof
  234
• 1.1 Assembly overview – sliding sunroof
  234
• 1.2 Removing and installing glass panel
  236
• 1.3 Adjusting sunroof panel
  237
• 1.4 Renewing panel seal
  240
• 1.5 Removing and installing wind deflector
  240
• 1.6 Removing and installing sliding headliner
  241
• 1.7 Removing and installing sliding/tilting sunroof drive
  241
• 1.8 Adjusting drive for sliding/tilting sunroof (zero position)
  242
• 1.9 Removing and installing tilt mechanism for sliding sunroof
  243
• 1.10 Removing and installing tilting/sliding sunroof carrier unit
  244
• 1.11 Manual operation
  245
• 2 Water drainage hoses
  246
• 2.1 Cleaning water drain hoses
  246
• Convertible roof, hardtop, canopy
  249
• 1 Convertible top
  249
• 1.1 Assembly overview - canopy frame with canopy
  249
• Bumpers
  252
• 1 Bumper, front
  252
• 1.1 Assembly overview – bumper cover
  252
• 1.2 Removing and installing bumper cover
  255
• 1.3 Repairing bumper cover
  259
• 2 Bumper, rear
  262
• 2.1 Assembly overview – bumper cover
  262
• 2.2 Assembly overview – bumper carrier
  265
• 2.3 Removing and installing bumper cover
  266
• 2.4 Removing and installing bumper carrier
  268
• 2.5 Repairing bumper cover
  269
• Glazing
  275
• 1 Repair notes
  275
• 1.1 Minimum drying times for bonded windows
  275
• 1.2 Window repair
  275
• 1.3 Installation instructions for bonded windows
  276
• 1.4 Preparing old undamaged windows for installing
  277
• 1.5 Preparing new windows for installing
  278
• 1.6 Preparing body flange for installing
  279
• 1.7 Cleaning off excess adhesive
  280
• 2 Windscreen
  282
• 2.1 Assembly overview – windscreen
  282
• 2.2 Removing and installing windscreen
  285
• 3 Side windows
  290
• 3.1 Assembly overview - side windows
  290
• 3.2 Removing and installing rear side window
  293
• 4 Sliding window
  301
• 4.1 Assembly overview - sliding window
  301
• 4.2 Removing and installing sliding window
  301
• 5 Rear windscreen
  308
• 5.1 Assembly overview – rear window
  308
• 5.2 Removing and installing rear window
  311
• 6 Door windows
  320
• 6.1 Removing and installing front door window
  320
• 6.2 Adjusting front door window
  321
• Exterior equipment
  323
• 1 Radiator grille and front trim
  323
• 1.1 Assembly overview – radiator grille
  323
• 1.2 Removing and installing radiator grille
  323
• 2 Spoiler
  325
• 2.1 Removing and installing spoiler
  325
• 3 Mouldings, trims, extensions
  331
• 3.1 Assembly overview - B-pillar trim
  331
• 3.2 Assembly overview - roof railing
  332
• 3.3 Removing and installing trim strip
  332
• 3.4 Removing and installing side member trim
  339
• 3.5 Removing and installing A-pillar trim
  342
• 3.6 Removing and installing roof railing
  343
• 3.7 Renewing roof trim strip
  345
• 4 Noise insulation
  347
• 4.1 Assembly overview - noise insulation
  347
• 4.2 Removing and installing noise insulation
  347
• 5 Underbody cladding
  350
• 5.1 Assembly overview – underbody cladding
  350
• 5.2 Removing and installing underbody cladding
  364
• 6 Trim film and protective film
  370
• 6.1 Renewing decorative film and protective film
  370
• 7 Exterior mirror
  373
• 7.1 Assembly overview – exterior mirror
  373
• 7.2 Removing and installing exterior mirror
  376
• 7.3 Removing and installing mirror glass
  378
• 7.4 Removing and installing mirror frame
  381
• 7.5 Removing and installing mirror cover
  385
• 7.6 Removing and installing mirror mounting
  390
• 7.7 Removing and installing hinge cap
  393
• 7.8 Removing and installing mirror adjustment motor V149/V150
  394
• 8 Wheel housing liner
  397
• 8.1 Assembly overview – front wheel housing liner
  397
• 8.2 Assembly overview – rear wheel housing liner
  398
• 8.3 Removing and installing front wheel housing liner
  398
• 8.4 Removing and installing rear wheel housing liner
  400
• 9 Lettering and badges
  402
• 9.1 Assembly overview – lettering and badges
  402
• 9.2 Dimensions - lettering and badges on rear
  405
• 9.3 General information on renewal of badges and lettering
  409
• 9.4 Renewing lettering and badges at rear
  411
• 9.5 Renewing lettering and badges on sides
  412
• 9.6 Removing and installing lettering and badges for radiator grille
  416
• 10 Special add-on parts
  418
• 10.1 Assembly overview – special add-on parts
  418
• 11 Load floor body
  419
• 11.1 Assembly overview - dropside body
  419
• 11.2 Assembly overview - load floor and side boards/tail board
  420
• 11.3 Assembly overview – skid plate
  424
• 11.4 Assembly overview - rear wheel housing
  425
• 11.5 Assembly overview - tank trim
  426
• 12 Towing bracket
  428
• 12.1 Assembly overview – towing bracket
  428
• 12.2 Removing and installing towing bracket
  431
• 13 Spare wheel bracket
  438
• 13.1 Assembly overview - spare wheel bracket
  438
• 14 Mudflap
  440
• 14.1 Assembly overview - mudflap
  440
• 15 Heat shields
  443
• 15.1 Overview of fitting locations - heat shields
  443
• 15.2 Removing and installing front heat shield
  445
• 15.3 Removing and installing centre heat shield
  447
• 15.4 Removing and installing rear heat shield
  448