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
• 1.2 Safety precautions when working on the cooling system
  1
• 2 Repair instructions
  3
• 2.1 Pipe/wire routing and attachment
  3
• 2.2 Contact corrosion
  3
• 2.3 Nuts and bolts
  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
  8
• 2 Wings
  11
• 2.1 Assembly overview – wing
  11
• 2.2 Removing and installing wing
  12
• 3 Bulkhead
  15
• 3.1 Assembly overview – bulkhead
  15
• 3.2 Assembly overview – plenum chamber insulation
  18
• 3.3 Assembly overview – plenum chamber cover
  19
• 3.4 Removing and installing plenum chamber cover
  21
• 3.5 Removing and installing plenum chamber insulation
  21
• 3.6 Removing and installing plenum chamber bulkhead insulation
  22
• 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
  26
• 1.4 Adjusting bonnet
  27
• 1.5 Removing and installing bonnet lock
  31
• 1.6 Removing and installing bonnet lock operating lever
  32
• 1.7 Removing and installing striker pin
  32
• 1.8 Removing and installing hinges
  33
• 1.9 Removing and installing insulation
  34
• 1.10 Removing and installing gas strut
  35
• 1.11 Releasing gas from gas strut
  38
• 1.12 Removing and installing Bowden cable
  38
• 2 Rear lid
  40
• 2.1 Assembly overview – rear lid
  40
• 2.2 Removing and installing rear lid
  43
• 2.3 Adjusting rear lid
  44
• 2.4 Removing and installing bonnet lock
  48
• 2.5 Removing and installing operating mechanism
  50
• 2.6 Removing and installing hinges
  52
• 2.7 Removing and installing striker pin
  54
• 2.8 Removing and installing stop for adjusting buffer
  56
• 2.9 Removing and installing rear lid seal
  57
• 2.10 Removing and installing gas strut
  57
• 2.11 Releasing gas from gas strut
  60
• 2.12 Removing and installing rear lid control unit J605
  61
• 2.13 Removing and installing rear lid power opening control unit J938
  62
• 3 Tank flap unit
  64
• 3.1 Assembly overview – tank flap unit
  64
• 3.2 Removing and installing tank flap unit
  64
• 3.3 Removing and installing fuel tank flap
  66
• Front doors, door components, central locking
  67
• 1 Door
  67
• 1.1 Assembly overview – door
  67
• 1.2 Assembly overview - door seals
  69
• 1.3 Removing and installing inner door seal
  70
• 1.4 Removing and installing outer door seal
  72
• 1.5 Removing and installing door
  73
• 1.6 Adjusting door
  75
• 1.7 Adjusting striker pin
  78
• 1.8 Removing and installing door hinge
  79
• 2 Door components
  82
• 2.1 Assembly overview – assembly carrier
  82
• 2.2 Assembly overview – window regulator
  83
• 2.3 Assembly overview – door handle and door lock
  84
• 2.4 Assembly overview - window channels and window slot (aperture) seals
  86
• 2.5 Removing and installing window regulator motor
  87
• 2.6 Removing and installing assembly carrier
  88
• 2.7 Removing and installing lock cylinder
  91
• 2.8 Removing and installing door handle
  93
• 2.9 Removing and installing door lock
  94
• 2.10 Removing and installing Bowden cable for exterior door handle
  97
• 2.11 Removing and installing mounting bracket
  102
• 2.12 Removing and installing striker pin
  103
• 3 Central locking
  105
• 3.1 Overview of fitting locations – central locking system
  105
• 3.2 Removing and installing ignition key battery
  108
• Rear doors, door components
  110
• 1 Sliding door
  111
• 1.1 Assembly overview – sliding door
  111
• 1.2 Removing and installing door seal
  124
• 1.3 Removing and installing outer door seal
  128
• 1.4 Removing and installing sliding door
  129
• 1.5 Adjusting sliding door
  133
• 1.6 Removing and installing striker pin
  140
• 1.7 Removing and installing roller guide
  141
• 1.8 Removing and installing door arrester
  150
• 1.9 Removing and installing door lock
  151
• 1.10 Removing and installing sliding door remote release mechanism
  154
• 1.11 Removing and installing contact module
  156
• 1.12 Removing and installing door handle
  158
• 1.13 Removing and installing mounting bracket
  159
• 1.14 Removing and installing power latching motor V329
  160
• 1.15 Removing and installing guide rail
  161
• 1.16 Removing and installing sliding door opening motor V323
  167
• 1.17 Removing and installing sliding sunroof adjustment control unit J558
  168
• 1.18 Removing and installing right electric sliding door sender unit G481
  169
• 2 Cab door - double cab
  171
• 2.1 Assembly overview - cab door
  171
• 2.2 Assembly overview – door handle and door lock
  172
• 2.3 Removing and installing inner door seal
  173
• 2.4 Removing and installing cab door
  174
• 2.5 Adjusting cab door
  176
• 2.6 Removing and installing striker pin
  177
• 2.7 Removing and installing door hinges
  178
• 2.8 Removing and installing door arrester
  179
• 2.9 Removing and installing door handle
  180
• 2.10 Removing and installing mounting bracket
  182
• 2.11 Removing and installing door lock
  183
• 2.12 Removing and installing Bowden cable for exterior door handle
  185
• 3 Wing doors
  188
• 3.1 Assembly overview - wing door
  188
• 3.2 Assembly overview - door arrester with opening angle of 250°
  191
• 3.3 Assembly overview – door components
  192
• 3.4 Removing and installing wing door seal
  194
• 3.5 Removing and installing door seal
  194
• 3.6 Removing and installing inner seal of wing door
  196
• 3.7 Removing and installing wing door
  196
• 3.8 Adjusting wing door
  198
• 3.9 Removing and installing upper striker pin
  205
• 3.10 Removing and installing lower striker pin
  206
• 3.11 Replacing wing door
  207
• 3.12 Removing and installing hinges
  207
• 3.13 Removing and installing door arrester
  209
• 3.14 Installing stop in wing door for door arrester with opening angle of 250°
  210
• 3.15 Removing and installing wing door locks
  213
• 3.16 Removing and installing release lever
  217
• 3.17 Removing and installing exterior door handle
  219
• 3.18 Removing and installing release element
  220
• 3.19 Removing and installing light strip
  221
• 3.20 Removing and installing lock cylinder
  222
• Sunroof
  223
• 1 Sliding sunroof
  223
• Convertible roof, hardtop, canopy
  224
• 1 Load floor body
  224
• 1.1 Contact corrosion
  224
• 1.2 Assembly overview - canopy frame with canopy
  224
• 1.3 Assembly overview - dropside body
  227
• 1.4 Assembly overview - dropside floor and side boards/tail board
  227
• 1.5 Assembly overview – skid plate
  231
• 1.6 Assembly overview - rear wheel housing
  232
• 1.7 Assembly overview - tank trim
  233
• 1.8 Assembly overview - aerodynamic trim panel
  234
• Bumpers
  236
• 1 Bumper, front
  236
• 1.1 Assembly overview – bumper cover
  236
• 1.2 Assembly overview – bumper carrier
  240
• 1.3 Removing and installing bumper cover
  241
• 1.4 Repairing bumper cover
  246
• 1.5 Removing and installing bumper carrier
  251
• 2 Bumper, rear
  254
• 2.1 Assembly overview – bumper cover
  254
• 2.2 Assembly overview - attachments
  256
• 2.3 Removing and installing bumper cover
  257
• 2.4 Removing and installing bumper carrier
  259
• 2.5 Removing and installing attachments
  261
• 2.6 Repairing bumper cover
  263
• Glazing
  271
• 1 Repair instructions
  271
• 1.1 Minimum drying times for bonded windows
  271
• 1.2 Window repair
  271
• 1.3 Installation instructions for bonded windows
  272
• 1.4 Preparing old undamaged windows for installing
  273
• 1.5 Preparing new windows for installing
  274
• 1.6 Preparing body flange for installing
  275
• 1.7 Cleaning off excess adhesive
  276
• 2 Windscreen
  278
• 2.1 Assembly overview – windscreen
  278
• 2.2 Removing and installing windscreen
  281
• 3 Side windows
  286
• 3.1 Assembly overview - side windows
  286
• 3.2 Removing and installing rear side window
  289
• 4 Sliding window
  297
• 4.1 Assembly overview - sliding window
  297
• 4.2 Removing and installing sliding window
  297
• 5 Rear windscreen
  301
• 5.1 Assembly overview – rear window
  301
• 5.2 Removing and installing rear window
  304
• 6 Door windows
  313
• 6.1 Removing and installing front door window
  313
• 6.2 Adjusting front door window
  314
• Exterior equipment
  316
• 1 Radiator grille and front trim
  316
• 1.1 Assembly overview – radiator grille
  316
• 1.2 Removing and installing radiator grille
  316
• 2 Spoiler
  318
• 2.1 Removing and installing spoiler
  318
• 3 Mouldings, trims, extensions
  324
• 3.1 Assembly overview - B-pillar trim
  324
• 3.2 Removing and installing trim strip
  324
• 3.3 Removing and installing side member trim
  327
• 3.4 Removing and installing A-pillar trim
  331
• 4 Noise insulation
  332
• 4.1 Assembly overview - noise insulation
  332
• 4.2 Removing and installing noise insulation
  332
• 5 Underbody cladding
  335
• 5.1 Overview of fitting locations - underbody cladding
  335
• 5.2 Assembly overview – underbody cladding
  338
• 5.3 Removing and installing underbody cladding
  353
• 6 Trim film and protective film
  373
• 6.1 Renewing decorative film and protective film
  373
• 7 Roof moulding and roof railing
  376
• 7.1 Assembly overview - roof railing
  376
• 7.2 Removing and installing roof railing
  376
• 7.3 Removing and installing roof trim strip
  379
• 8 Exterior mirror
  380
• 8.1 Assembly overview – exterior mirror
  380
• 8.2 Removing and installing exterior mirror
  383
• 8.3 Removing and installing mirror glass
  385
• 8.4 Removing and installing mirror frame
  387
• 8.5 Removing and installing mirror cover
  392
• 8.6 Removing and installing mirror adjustment motor V149/V150
  395
• 8.7 Removing and installing mirror mounting
  397
• 8.8 Removing and installing hinge cap
  401
• 9 Wheel housing liner
  403
• 9.1 Assembly overview – front wheel housing liner
  403
• 9.2 Assembly overview – rear wheel housing liner
  404
• 9.3 Removing and installing front wheel housing liner
  404
• 9.4 Removing and installing rear wheel housing liner
  406
• 10 Lettering and badges
  408
• 10.1 Assembly overview – lettering and badges
  408
• 10.2 Dimensions - lettering and badges on rear
  413
• 10.3 General information on renewal of badges and lettering
  416
• 10.4 Renewing lettering and badges at rear
  418
• 10.5 Renewing lettering and badges on sides
  419
• 10.6 Removing and installing lettering and badges for radiator grille
  424
• 11 Special add-on parts
  425
• 11.1 Assembly overview – special add-on parts
  425
• 12 Towing bracket
  426
• 12.1 Assembly overview – towing bracket
  426
• 12.2 Removing and installing towing bracket
  429
• 13 Spare wheel bracket
  437
• 13.1 Assembly overview - spare wheel bracket
  437
• 13.2 Removing and installing spare wheel bracket
  438
• 14 Mudflap
  440
• 14.1 Assembly overview - mudflap
  440
• 14.2 Removing and installing mudflaps
  442
• 15 Heat shields
  446
• 15.1 Overview of fitting locations - heat shields
  446
• 15.2 Removing and installing front heat shield
  449
• 15.3 Removing and installing centre heat shield
  452
• 15.4 Removing and installing rear heat shield
  456