Collision - Body Panel Repair (F01, F02)

• Body Repair Safety Information
  • 00 Safety Information For Working On Vehicles With Automatic Engine Start-Stop Function (MSA)
    • Notes
    • Observe Safety Precautions When Working On MSA Vehicles
    • MSA Function Is Deactivated By
    • When Working With Diagnosis Tools
  • 41 00... Safety At Work
    • 1.1 Working With Aluminium Dust
    • 1.2 Removing Sealant
    • 1.3 ARC Welding And Brazing
      • Notes
      • 1.4 Working with chemical products (adhesive, cleaning agents, fillers, etc.)
    • First Aid
  • 41 00... Information On Hazards
    • 1.0 Aluminium
  • 41 00... Handling Airbags And Restraint Systems
    • 1.0 Airbags And Restraint Systems
• Body Repair General Information
  • 41 00... AFGS Active Pedestrian Protection Procedure After Accident
    • Notes
    • Procedure If AFGS Was Activated
    • Procedure If AFGS Was Not Activated
  • 41 00... Blind Rivets
    • 1.0 Recommended Tools And Equipment
      • Notes
      • Setting blind rivets
  • 41 00... Bonding Aluminium On Steel
    • Notes
    • Overview Of Topics
    • 1.0 Equipment
    • 2.0 Preparation Of Surface
      • 2.1 Steel surface
      • 2.2 Aluminium surface
    • 3.0 Adhesive Application
      • Notes
      • 3.1 Bonding in conjunction with repair elements (expanding elements)
      • 3.2 Bonding in conjunction with rivets
    • 4.0 Hardening Times
    • 5.0 Subsequent Treatment
  • 41 00... Bonding On Painted Surfaces
    • Notes
    • Overview Of Topics
    • 1.0 Equipment
    • 2.0 Expiry Date Of Consumables
    • 3.0 Preparation Of Surface
      • 3.1 Preparation of surface on vehicle
      • 3.2 Preparation of surface on new part
    • 4.0 Adhesive Application
    • 5.0 Hardening Times
    • 6.0 Subsequent Treatment
    • 7.0 Disposing Of Adhesive
  • 41 00... Bonding Steel On Steel
    • Notes
    • Overview Of Topics
    • 1.0 Equipment
    • 2.0 Surface Preparation
    • 3.0 Adhesive Application
    • 4.0 Hardening Times
    • 5.0 Subsequent Treatment Of Bonding Surfaces
  • 41 00... Carrying Over Hole Pattern
  • 41 00... Corrosion Protection
    • Notes
    • 1.0 Removing And Applying Sealing Materials
      • 1.1 Removing sealing materials
      • 1.2 Applying sealing materials
    • 2.0 Cavity Preservation Of Sheet-Metal Parts
      • Notes
      • 2.1 Cavity preservation of steel parts
      • 2.2 Cavity preservation of aluminium parts
  • 41 00... EMC Screws
    • Notes
    • 1. Purpose
    • 2. Procedure, Aluminium Front End
    • 3. Procedure, Steel Body
  • 41 14 021 Filling Bulkhead Cross-Member With Foam
  • 99 00... General Instructions On Painting
  • 41 00... Grinding Aluminium Parts
    • 1.0 Recommended Tools And Equipment
    • 2.0 Grinding Outer Shell And Structure
  • 41 00... Grinding Steel Parts
    • 1.0 Recommended Tools And Equipment
    • 2.0 Grinding Outer Shell And Structure
  • 41 00... Gun For Cavity Sealing
    • Notes
    • 1.0 Scope Of Delivery
    • 2.0 Start-Up
    • 3.0 Mode Of Operation
    • 4.0 Application Examples
    • 5.0 Safety Instructions
  • 41 00... Handling Electrical And Electronic Equipment
    • 1.0 Battery
    • 2.0 Control Units
    • 3.0 Electrical Wires And Wiring Harnesses
    • 4.0 Optical Fibres
  • 41 00... Information/Warning Labels
  • 41 00... Information On Metal Filler
    • Notes
    • Storage
    • Shelf Life
    • Surface Pre-Treatment
    • Processing
    • Applying Filler
    • Hardening Time
    • Post-processing
    • Paintwork
    • Metal Filler Disposal
  • 64 00 000 Information On Using Cleaning Agent/Paints (Personal Protection Equipment)
    • Notes
    • First Aid
    • Recycling
  • 41 00... Information On Vehicle Protection
  • 41 00... Installation Solution For Straight Shank/Hexagon Rivet Nut
    • Notes
    • Hexagon/Straight Shank Rivet Nut (Up To Thread 8) With Hand Rivet Gun Zs308
    • Hexagon/Straight Shank Rivet Nut (Up To Thread M12) With Hand Rivet Gun Mb512
  • 41 00... Installing A Cavity Acoustic Baffle (Expanded)
  • 41 00... Installing A Cavity Acoustic Baffle (Not Expanded)
  • 41 00... Installing A Cavity Sealing With 2-Component PU Cavity Foam
    • Notes
    • Information On Dangers/Hazards
    • Processing Instructions
  • 41 00... Materials Science
    • 1. Aluminum
      • 1.1 Chassis and suspension components
      • 1.2 Material influences
      • 1.3 Machining properties
      • 1.4 Mounting
  • 41 00... Notes On Adhesive K1
    • Notes
    • Storage
    • Shelf Life
    • Surface Pre-Treatment
    • Required Cartridge Gun
    • Preparing The Glue Cartridge
    • Adhesive Application
    • Hardening Time
    • Disposal Of Adhesive
  • 41 00... Notes On Adhesive K2
    • Notes
    • Storage
    • Shelf Life
    • Surface Pre-Treatment
    • Required Cartridge Gun
    • Preparing The Glue Cartridge
    • Adhesive Application
    • Hardening Time
    • Disposal Of Adhesive
  • 41 00... Notes On Adhesive K3
    • Notes
    • Storage
    • Shelf Life
    • Surface Pre-Treatment
    • Required Cartridge Gun
    • Preparing The Glue Cartridge
    • 2-Component Adhesive Application
    • Hardening Time
    • Adhesive Disposal
  • 41 00... Notes On Adhesive K4
    • Notes
    • Storage
    • Shelf Life
    • Surface Pre-Treatment
    • Required Cartridge Gun
    • Preparing The Glue Cartridge
    • 2-Component Adhesive Application
    • Hardening Time
    • Disposal Of Adhesive
  • 41 00... Notes On Adhesive K5
    • Notes
    • Storage
    • Shelf Life
    • Surface Pre-Treatment
    • Required Cartridge Gun
    • Preparing The Glue Cartridge
    • Adhesive Application
    • Hardening Time
    • Disposal Of Adhesive
  • 41 00... Notes On Cleaning Agent R1
  • 41 00... Opening Adhesive Bonds
    • 1. Opening Spot-Weld Bonds
    • 2. Opening Adhesive Bonds
    • 3. Opening Adhesive Bonds On Aluminium Roofs
    • 4. Opening Adhesive Bonds On Carbon-Fibre-Reinforced Plastic Parts
  • 41 00... Opening Brazed Joints
  • 41 00... Opening Riveted Joints
    • Notes
    • 1. Opening Blind Rivets
      • 1.1 Opening blind rivets (N1 and N2)
      • 1.2 Opening blind rivets (N3 and N6)
    • 2. Opening Punch Rivets
      • 2.1 Opening punch rivets by extraction
      • 2.2 Opening punch rivets by drilling out
  • 41 00... Opening Weld Joints
    • 1. Opening Weld Spots (Resistance Pressure Spot Welding)
      • Notes
      • Procedure
    • 2. Opening MAG Weld Seams And MIG Brazing Seams
      • Procedure
    • 3. Opening Laser Weld Seams
      • Notes
      • Procedure
  • 41 00... Overview Of Adhesive Cartridge Guns
  • 41 00... Overview Of Consumables
    • 1.0 Adhesives
      • Notes
      • 1.1 Primer
      • 1.2 Cleaning agent
      • 1.3 Fillers
      • 2.1 Rivets
      • 2.2 Plastic nuts
    • 3.0 Primer
    • 4.0 Sealant
    • 5.0 Cavity Preservation
    • 6.0 Cavity Foam
    • 7.0 EMC Screw (Electromagnetic Compatibility)
    • 8.0 Twist Drill
  • 41 00... Position Of Shaped Parts For Cavity Sealing
  • 41 00... Punch Rivets
    • Notes
    • 1.0 Recommended Tools And Equipment
      • Notes
      • Setting punch rivets
  • 41 00... Quality Standard
  • 41 00... Reinforcement Plate (Bonded)
    • Notes
    • Preparation Of New Part
    • Installing Reinforcement Plate
  • 41 00... Reinforcement Plate With Stud Bolt (Bonded)
    • Notes
    • Preparation Of New Part
    • Procedure For Using Universal Reinforcement Plate
    • Installing Reinforcement Plate
  • 41 05 800 Releasing Bonded Folded Seam Connections
  • 41 00... Repair Solution For Straight Shank/Hexagon Rivet Nut
    • Protection Measures
    • Hexagon/Straight Shank Rivet Nut (Up To Thread M8) With Hand Rivet Gun ZS308
    • Hexagon/Straight Shank Rivet Nut (Up To Thread M12) With Hand Rivet Gun MB512
  • 410 Stage 1 Repair Methods
    • Notes
    • All Work As Part Of Which Screwed Body Components Must Be Replaced
    • All Procedures During Which Repairs Are To Be Done On The Outer Skin
  • 410 Stage 2 Repair Methods
  • 410 Stage 3 Repair Methods
  • 41 00... Repairing Clips For Roof Strip
    • Notes
    • 1.0 Information On Dangers/Hazards
    • 1.0 Equipment
    • 2.0 Preparing The Surface
    • 3.0 Applying The Adhesive
    • 4.0 Hardening Period
  • 41 00... Repairing Plastic Parts
    • 1.0 General Information
    • 2.0 Shaping Plastic Parts
    • 3.0 Bonding Plastic Parts
  • 41 00... Replacing Blind Rivets
  • 41 00... Separating Cut Determination With A Template
  • 41 00... Setting Blind Rivet Nuts And Bolts
  • 41 00... Soldering Steel Components
    • Notes
    • 1. General information
    • 2. Work materials
    • 3. Preparation
    • 4. Implementation
    • 5. Subsequent Treatment Of Brazed Joints
    • 6. Notes On Melting/Tinning
  • 41 00... Spot-Weld Bonding Steel Parts
  • 41 00... Stamping Vehicle Identification Number (Needle Stamping Unit)
    • Notes
    • Procedure For Additional Vehicle Identification Number
  • 41 00... Straightening Aluminium Components In Structure
  • 41 00... Straightening Aluminium Parts On Outer Skin
    • 1.0 Recommended Tools
    • 2.0 Straightening Outer Shell
  • 41 00... Straightening Steel Components In The Structure
  • 41 00... Straightening Steel Parts On Outer Skin
    • 1.0 Recommended Tools
    • 2.0 Straightening Outer Shell
  • 41 00... Use Of Materials In Outer Skin
  • 41 00... Vehicle Identification Number General Information
    • Notes
    • 1. General Notes For Stamped Vehicle Identification Numbers
    • 2. General Notes For Embossed Vehicle Identification Numbers
  • 41 00... Welding In Reinforcement Plate (Steel Plate)
  • 41 00... Welding Steel Components
    • Notes
    • 1. General Information
    • 2. Work Materials
    • 3. Preparations For MAG And Spot-Welding
    • 4. Welding
    • 5. Subsequent treatment Of Weld Joints
  • 41 00... Working With 2-Component PU Cavity Foam
    • Notes
    • Information On Dangers/Hazards
    • Application Instructions
  • 41 00... Workshop Equipment
• Support Members
  • 41 11 150 Cover For Frame Side Member (Part Replacement Between A And B Pillar)
  • 41 11 542 Cover For Side Member At Rear (Rear Side Panel Removed)
    • Notes
    • Removal
    • Preparation Of New Part
    • Installation
    • 41 14 021 Filling Bulkhead Cross-Member With Foam
  • 51 11... Overview Of Front Bumper
  • 41 11 091 Replacing Left Engine Support In Front Of Bulkhead
  • 41 11 095 Replacing Left Engine Support In Front Of Wheel Arch
  • 41 11 015 Replacing Left Engine Support With Wheel Arch
    • Notes
    • Preparation Of New Part
  • 41 14 531 Replacing Engine Support/Front Left Side Frame Connection (Front Left Wheel Arch Removed)
    • Notes
    • To Remove Engine Support Side Frame Connection
    • New Part Preparation
    • To Install Engine Support Side Frame Connection
  • 41 11 043 Replacing Front Section Of Left Engine Support
    • Notes
    • Preparation Of New Part
  • 41 11 300 Replacing Left And Right Entrance With Door Post (Partial Replacement, B-Pillar)
  • 41 14 500 Replacing Outer Section Of Left Or Right Rear Wheel Housing (Side Panel Removed)
    • Notes
    • Removal Of Outer Wheel Arch Section
    • Preparation Of New Part
    • Installation Of Outer Wheel Arch Section
  • 41 11 201 Replacing The Carrier Support Before The Wheel Arch On The Left
  • 41 14 021 Replacing Front Left Wheel Arch Stripping Operations
• Luggage Compartment Floor
  • 41 12 535 Replace Luggage Compartment Floor And Both Side Members (Tail Panel Trim Removed)
    • Notes
    • Removing Side Members And Luggage Compartment Floor
    • New Part Preparation
    • Installation Of Side Member
    • Installation Of Luggage Compartment Floor
  • 41 12 651 Replacing Left Section Luggage Compartment Floor (Tail Panel Or Side Wall Removed)
    • Notes
    • Removal Of Luggage Compartment Floor
    • New Part Preparation
    • Installation Of Luggage Compartment Floor
  • 41 12 557 Replacing Middle Luggage Compartment Floor (Tail Panel Has Been Removed)
  • 41 12 548 Replacing Rear Cross Member On Luggage Compartment Floor (Tail Panel Removed)
    • Notes
    • Removing Cross Member
    • New Part Preparation
    • Installing Cross Member
  • 41 12 651 Replacing Left Luggage Compartment Floor Stripping Operations (Tail Panel Or Side Panel Removed)
  • 41 12 535 Replacing Luggage Compartment Floor And Both Side Members Stripping Operations (Tail Panel Removed)
  • 41 12 557 Replacing Middle Luggage Compartment Floor Stripping Operations (Tail Panel Removed)
  • 41 12 548 Replacing Rear CROSSMEMBER On Luggage Compartment Floor Stripping Operations (Tail Panel Removed)
• Wheel Wells
  • 41 00... Carrying Over Hole Pattern
  • 41 11 015 Replacing Left Engine Support With Wheel Arch
    • Notes
    • Preparation Of New Part
  • 41 14 531 Replacing Engine Support/Front Left Side Frame Connection (Front Left Wheel Arch Removed)
    • Notes
    • To Remove Engine Support Side Frame Connection
    • New Part Preparation
    • To Install Engine Support Side Frame Connection
  • 41 14 020 Replacing Front Left Wheel Arch
  • 41 14 500 Replacing Outer Section Of Left Or Right Rear Wheel Housing (Side Panel Removed)
    • Notes
    • Removal Of Outer Wheel Arch Section
    • Preparation Of New Part
    • Installation Of Outer Wheel Arch Section
  • 41 14 505 Replacing Rear Left Outer Wheel Arch Section (Rear Side Panel Removed)
    • Notes
    • Removal Of Outer Wheel Arch Section
    • Preparation Of New Part
    • Installation Of Outer Wheel Arch Section
  • 41 14 504 Replacing Rear Right Outer Wheel Arch Section (Rear Side Panel Removed)
    • Notes
    • Removal Of Outer Wheel Arch Section
    • Preparation Of New Part
    • Installation Of Outer Wheel Arch Section
  • 41 00... Stamping Vehicle Identification Number (Needle Stamping Unit)
    • Notes
    • Procedure For Additional Vehicle Identification Number
    • Stamping Second Vehicle Identification Number
  • 41 11 021 Replacing Front Left Wheel Arch Stripping Operations
  • 41 11 031 Replacing Front Right Wheel Arch Stripping Operations
  • 41 00... General Vehicle Identification Number
    • Notes
    • 1. General Notes For Stamped Vehicle Identification Numbers
    • 2. General Notes For Embossed Vehicle Identification Numbers
• Side Frame And Door Pillars
  • 41 11 150 Cover For Frame Side Member (Part Replacement Between A And B Pillar)
  • 41 14 531 Replacing Engine Support/Front Left Side Frame Connection (Front Left Wheel Arch Removed)
    • Notes
    • To Remove Engine Support Side Frame Connection
    • New Part Preparation
    • To Install Engine Support Side Frame Connection
  • 41 21 510 Replacing Front Left Door Post (Front Side Panel Removed)
• Outer Roof Skin
  • 41 00... Repairing Clips For Roof Strip
    • Notes
    • 1.0 Information On Dangers/Hazards
    • 1.0 Equipment
    • 2.0 Preparing The Surface
    • 3.0 Applying The Adhesive
    • 4.0 Hardening Period
  • 41 31 000 Replace Roof Outer Skin
    • Notes
    • Removing Roof Outer Skin
    • Installing Roof Outer Skin
    • 1. Applying Adhesive
    • 2. Joining And Fixing Roof Outer Skin
    • 3. Applying Adhesive To Nodes On A- And C-Pillars. Removing Excess Adhesive
  • 41 31 010 Replacing Roof Outer Skin (Version With Slide/Tilt Sunroof)
    • Notes
    • Removing Roof Outer Skin
    • Installing Roof Outer Skin
    • 1. Applying Adhesive
    • 2. Joining And Fixing Roof Outer Skin
    • 3. Applying Adhesive To Nodes On A- And C-Pillars. Removing Excess Adhesive
  • 41 31 010 Replacing Roof Outer Skin Stripping Operations (Version With Slide/Tilt Sunroof)
  • 41 31 000 Replacing Roof Outer Skin Stripping Operations (Version Without Slide/Tilt Sunroof)
• Dash Cowl
  • 41 32 031 Replace The A-Pillar On The Outside Left In The Area Of The Windscreen
  • 41 21 510 Replacing Front Left Door Post (Front Side Panel Removed)
• Front Trim Panel
  • 41 33 040 Replacing Front Left Or Right Side Wall Holder
    • Notes
    • Removal Of Side Wall Holder (Variant 1):
    • Removal Of Side Wall Holder (Variant 2):
• Rear Trim Panel
  • 41 34 041 Replacing Complete Tail Panel
    • Notes
    • Removing Rear Trim Panel
    • Preparation Of New Part
    • Installing Rear Trim Panel
  • 41 12 651 Replacing Left Luggage Compartment Floor Section (Tail Panel Or Side Wall Removed)
    • Notes
    • Removal Of Luggage Compartment Floor
    • New Part Preparation
    • Installation Of Luggage Compartment Floor
  • 41 12 548 Replacing Rear Cross Member On Luggage Compartment Floor (Tail Panel Removed)
    • Notes
    • Removing Cross Member
    • New Part Preparation
    • Installing Crossmember
  • 41 35 101 Replacing Rear Left Side Panel Stripping Operations
  • 41 34 041 Replacing Complete Tail Panel Stripping-Down Operations
• Side Panels
  • 41 11 542 Cover For Side Member At Rear (Rear Side Panel Removed)
    • Notes
    • Removal
    • Preparation Of New Part
    • Installation
  • 41 00... Reinforcement Plate With Stud Bolt (Bonded)
    • Notes
    • Preparation Of New Part
    • Procedure For Using Universal Reinforcement Plate
    • Installing Reinforcement Plate
  • 41 35 081 Removing And Installing Front Side Wall On Left
    • Notes
    • Replacement
  • 41 35 101 Replacing Left Rear Side Wall
    • Notes
    • Removing Side Wall
    • Preparation Of New Part
    • Installing Side Wall
  • 41 14 500 Replacing Outer Section Of Left Or Right Rear Wheel Housing (Side Panel Removed)
    • Notes
    • Removal Of Outer Wheel Arch Section
    • Preparation Of New Part
    • Installation Of Outer Wheel Arch Section
  • 41 35 101 Replacing Rear Left Side Panel Stripping Operations
• Front Side Doors
  • 41 5.... Adjust Door
    • Notes
    • After Setting
  • 41 5.... Removing And Installing Door
• Rear Side Doors
  • 41 5.... Adjust Door
    • Notes
    • After Setting
  • 41 5.... Removing And Installing Door
• Front Lid
  • 41 00... AFGS Active Pedestrian Protection Procedure After Accident
    • Notes
    • Procedure If AFGS Was Activated
    • Procedure If AFGS Was Not Activated
  • 41 61 014 Adjusting Engine Compartment Lid
    • Notes
    • Height Adjustment At Hinge
    • Height Adjustment At Retaining Hooks
    • After Installation
  • 51 23... Check Actuator
  • 41 61... Check Hinge For Engine Compartment Lid
  • 51 23... Checking Hood/Bonnet Locks
  • 41 61 000 Removing And Installing Engine Compartment Lid
  • 41 61 010 Removing And Installing Engine Compartment Lid (Active Pedestrian Protection AFGS)
  • 41 61 071 Removing And Installing/Replacing Left Hinge For Engine Compartment Lid (Active Pedestrian Protection) (Up To 09/ 2011)
  • 41 61 071 Removing And Installing/Replacing Hinge For Engine Compartment Lid (Active Pedestrian Protection) (From 09/ 2011)
  • 41 61 060 Removing And Installing/Replacing Left Hinge For Engine Compartment Lid (Up To 09/ 2011)
  • 41 61 060 Removing And Installing/Replacing Left Hinge For Engine Compartment Lid (From 09/ 2011)
  • 51 23 400 Removing And Installing/Replacing Left Or Right Actuator (Active Pedestrian Protection) (Up To 09/ 2011)
    • Notes
    • Procedure After Actuator Triggering
    • Removing Actuator
    • Installing Actuator
  • 51 23 400 Removing And Installing/Replacing Left Or Right Actuator (Active Pedestrian Protection) (From 09/ 2011)
  • 51 23 400 Removing And Installing/Replacing Left Or Right Actuator (Active Pedestrian Protection, Not Deployed) (Up To 09/ 2011)
    • Notes
    • Actuator Procedure Not Activated:
      • Notes
      • Removing actuator
      • Installing actuator
  • 41 61 543 Repairing Both Hinges For Engine Compartment Lid (From 09/ 2011)
• Rear Lid
  • 41 62 014 Adjusting Tailgate
    • Notes
    • After Installation
  • 41 62 000 Removing And Installing Rear Lid (Tailgate)
  • 41 62 043 Removing And Installing/Replacing Left Hinge For Tailgate
  • 51 24 325 Removing And Installing/Replacing Left Tension Spring For Rear Lid (Tailgate)
  • 51 24 326 Removing And Installing/Replacing Right Tension Spring With Damper For Tailgate
• Other Flaps
  • 41 63 000 Removing And Installing Flap For Fuel Filler Neck
  • 41 63 003 Replacing Cover Bowl
    • Notes
    • Preparation Of New Part