Collision - Body Panel Repair (F01, F02) (AWD)

• Body Repair Safety Information
  • 00 Safety Information For Working On Vehicles With Automatic Engine Start-Stop Function (MSA)
  • 41 00... Safety At Work
    • Notes
    • 1.0 Compressed Air
    • 2.0 Electrical Systems/Devices
    • 3.1 Working With Aluminium Dust
    • 3.2 Removing Sealant
    • 3.3 ARC Welding And Brazing Solder
    • 3.4 Working With Chemical Products (Adhesive, Cleaning Agents, Fillers, Etc.)
  • 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
  • Safety Information
  • 41 00... Procedure For Vehicles With Active Pedestrian Protection After An Accident (AFGS)
  • 41 00... Blind Rivets
    • 1.0 Recommended Tools And Equipment
    • 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
        • 2.2.1 Procedure for new aluminium component
        • 2.2.2 Procedure for previously bonded aluminium component
    • 3.0 Adhesive Application
    • 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 the surface on the vehicle (series status)
      • 3.2 Preparation of the surface on the vehicle (replacement of a bonded component)
      • 3.3 Preparation of surface on new part
    • 4.0 Adhesive Application
    • 5.0 Hardening Times
    • 6.0 Subsequent Treatment
    • 7.0 Disposal Of Adhesive
  • 41 00... Bonding Steel On Steel
    • Notes
    • Overview Of Topics
    • 1.0 Equipment
    • 2.0 Preparing The Surface
    • 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
    • 2.1 Cavity Preservation Of Steel Parts
    • 2.2 Cavity Preservation Of Aluminium Parts
  • 41 00... EMC Screws
    • Notes
    • Purpose
    • Procedure, Aluminium Front End
    • Procedure, Steel Body
  • 41..... Filling Bulkhead Cross Member With Foam
  • 99 00... General Instructions On Paintwork
  • 51 14... General Notes For Labelling With Adhesive Films
    • Notes
    • Preparation
    • Procedure For Applying Labels
  • 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
    • 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
  • 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... Information On Using Cleaning Agent/Paints (Personal Protection Equipment)
  • 41 00... Information On Vehicle Protection
  • 41 00... Information/Warning Labels
  • 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
    • Aluminum
      • 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
  • 61 00... Notes On Handling The High Pressure Cleaner
  • 41 00... Notes On Repairing Threads
  • 41 00... Notes On The Water Drain Hose Of The Slide/Tilt Sunroof
  • 99 00... Notes On Using Temperature-Controlled Infra-Red Radiators
  • 41 00... Opening Adhesive Bonds
    • Opening Spot-Weld Bonds
    • Opening Adhesive Bonds
    • Opening Adhesive Bonds On Aluminium Roofs
    • Opening Adhesive Bonds On Carbon-Fibre-Reinforced Plastic Parts
  • 41 00... Opening Brazed Joints
  • 41 00... Opening Riveted Joints
    • Notes
    • Opening Blind Rivets
      • 1.1 Opening blind rivets (N1 and N2)
      • 1.2 Opening blind rivets (N3 and N6)
    • Opening Punch Rivets
      • 2.1 Opening punch rivets by extraction
      • 2.2 Opening punch rivets by drilling out
  • 41 00... Opening Welded Connections
    • Opening Welding Spots (Resistance Pressure Spot Welding)
      • Notes
      • Procedure
    • Opening MAG Weld Seams And MIG Brazing Seams
      • Procedure
    • Opening Laser Weld Seams
      • Notes
      • Procedure
  • 41 00... Overview Of Adhesive Cartridge Guns
  • 41 00... Overview Of Consumables
    • 1.0 Adhesives
    • 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
    • Setting Punch Rivets
  • 41 00... Quality Standard
    • Notes
    • 41 00... Reinforcement Plate (Bonded)
    • 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
  • 41 0 Stage 1 Repair Methods
    • 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
  • 41 0 Stage 2 Repair Methods
  • 41 0 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
    • General Information
    • Work Materials
    • Preparation
    • Implementation
    • Subsequent Treatment Of Brazed Joints
    • Notes On Melting/Tinning
  • 41 00... Spot-Weld Bonding Steel Components
  • 41 00... Stamping Vehicle Identification Number (Needle Stamping Unit)
  • 41 00... Straightening Aluminium Component On The Outer Skin
    • 1.0 Recommended Tools
    • 2.0 Straightening Outer Skin
  • 41 00... Straightening Aluminium Components In Structure
  • 41 00... Straightening Steel Components In The Structure
  • 41 00... Straightening Steel Components On The Outer Skin
    • 1.0 Recommended Tools
    • 2.0 Straightening Outer Skin
    • 2.1 Straightening The Wheel Arch (Rear Side Panel)
  • 99 00... Touching Up Paintwork Damage
  • 41 00... Use Of Materials In Outer Skin
  • 41 00... Vehicle Identification Number General Information
    • Notes
    • General Notes For Stamped Vehicle Identification Numbers
    • General Notes For Embossed Vehicle Identification Numbers
  • 41 00... Welding In Reinforcement Plate (Sheet Steel)
  • 41 00... Welding Steel Components
    • Notes
    • General Information
    • Work Materials
    • Preparations For MAG And Spot-Welding
    • Welding
    • 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..... Filling Bulkhead Cross Member With Foam
  • 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)
  • 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
    • Removal Of Engine Support With Wheel Arch
    • New Part Preparation
    • Installation Of Engine Support With Wheel Arch
  • 41 11 300 Replacing Left And Right Entrance With Door Post (Partial Replacement, B-Pillar)
    • Notes
    • Removing Entrance Cover With Door Post
    • New Part Preparation
    • Installing Entrance Cover With Door Post
  • 41 11 201 Replacing The Carrier Support Before The Wheel Arch On The Left
• Luggage Compartment Floor
  • 41 12 535 Replace Luggage Compartment Floor And Both Side Members (Tail Panel Trim Removed)
    • Notes
    • 41 12 535 Stripping Operations - Replacing Luggage Compartment Floor And Both Side Members (Tail Panel Removed)
  • 41 12 651 Replacing Left Luggage Compartment Floor Section (Tail Panel Or Side Wall Removed)
    • Notes
    • 41 12 651 Stripping Operations - Replacing Left Luggage Compartment Floor (Tail Panel Or Side Wall Removed)
  • 41 12 557 Replacing Middle Luggage Compartment Floor (Tail Panel Has Been Removed)
    • Notes
    • 41 12 557 Stripping Operations - Replacing Luggage Compartment Floor, Middle (Tail Panel 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 12 548 Stripping Operations - Replacing Rear Crossmember On Luggage Compartment Floor (Tail Panel Removed)
• Wheel Wells
  • 41 00... Vehicle Identification Number General Information (Wheel Wells)
  • 41 00... Stamping Vehicle Identification Number (Needle Stamping Unit)
  • 41 00... Carrying Over Hole Pattern
  • 41 14 531 Replacing Engine Support/Front Left Side Frame Connection (Front Left Wheel Arch Removed)
  • 41 14 020 Replacing Front Left Or Right Wheel Arch
    • Notes
    • 41 14 021 Stripping Operations - Replacing Front Left Wheel Arch
    • 41 14 031 Stripping Operations - Replacing Front Right Wheel Arch
  • 41 14 500 Replacing Outer Section Of Left Or Right Rear Wheel Housing (Side Panel Removed)
  • 41 14 505 Replacing Rear Left Outer Wheel Arch Section (Rear Side Panel Removed)
  • 41 14 504 Replacing Rear Right Outer Wheel Arch Section (Rear Side Panel Removed)
• Side Frame And Door Pillars
  • 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 Stripping Operations - Replacing Roof Outer Skin (Version Without Slide/Tilt Sunroof)
  • 41 31 000 Replace Outer Roof Skin
    • Notes
    • Removing Roof Outer Skin
    • Installing Roof Outer Skin
    • Applying Adhesive
    • Joining And Fixing Roof Outer Skin
    • Applying Adhesive To Nodes On A- And C-Pillars. Removing Excess Adhesive
  • 41 31 010 Replacing Outer Roof Skin (Version With Slide/Tilt Sunroof)
    • Notes
    • Removing Roof Outer Skin
    • Installing Roof Outer Skin
    • Applying Adhesive
    • Joining And Fixing Roof Outer Skin
    • Applying Adhesive To Nodes On A- And C-Pillars. Removing Excess Adhesive
    • 41 31 010 Stripping Operations - Replacing Roof Outer Skin (Version With Slide/Tilt Sunroof)
• Dash Cowl
  • 41 32 031 Replace The A-Pillar On The Outside Left In The Area Of The Windscreen
  • 41 32 000 Replacing Left Or Right Cowl
• Front Trim Panel
  • 41 33 040 Replacing Front Left Or Right Side Wall Holder
• Rear Trim Panel
  • 41 34 041 Replacing Complete Tail Panel
    • Notes
    • 41 34 041 Stripping Operations - Replacing Tail Panel
• Side Panels
  • 41 35 081 Removing And Installing Front Side Panel On Left
  • 41 35 101 Replacing Rear Left Side Panel
    • Notes
    • Removing Side Wall
    • Preparation Of New Part
    • Installing Side Wall
    • 41 35 101 Stripping Operations - Replacing Rear Left Side Panel
• Front Side Doors
  • 41 5.... Adjust Door
  • 41 51.... Notes On Replacing The Door
  • 41 5.... Removing And Installing Door
• Rear Side Doors
  • 41 5.... Adjust Door
  • 41 51.... Notes On Replacing The Door
  • 41 5.... Removing And Installing Door
• Front Lid
  • 41 00... AFGS Active Pedestrian Protection Procedure After Accident
  • 41 61 014 Adjusting Engine Compartment Lid
  • 51 23... Check Actuator
  • 41 61... Check Hinge For Engine Compartment Lid
  • 41 61 543 Repairing Both Hinges For Engine Compartment Lid (Vehicles From 09/11)
  • 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 Hinge For Engine Compartment Lid (Active Pedestrian Protection) (Vehicles From 09/2011)
  • 41 61 071 Removing And Installing/Replacing Left Hinge For Engine Compartment Lid (Active Pedestrian Protection) (Vehicles Up To 09/2011)
  • 41 61 060 Removing And Installing/Replacing Left Hinge For Engine Compartment Lid (Vehicles From 09/2011)
  • 41 61 060 Removing And Installing/Replacing Left Hinge For Engine Compartment Lid (Vehicles Up To 09/2011)
  • 51 23 400 Removing And Installing/Replacing Left Or Right Actuator (Active Pedestrian Protection) (Vehicles From 09/2011)
  • 51 23 400 Removing And Installing/Replacing Left Or Right Actuator (Active Pedestrian Protection) (Vehicles Up To 09/2011)
    • Notes
    • Procedure After Actuator Triggering
      • Notes
      • Removing actuator
      • Installing actuator
  • 51 23 400 Removing And Installing/Replacing Left Or Right Actuator (Active Pedestrian Protection, Not Deployed) (Vehicles Up To 09/2011)
    • Notes
    • Actuator Procedure Not Activated
      • Notes
      • Removing actuator
      • Installing actuator
• Rear Lid
  • 41 62 014 Adjusting Tailgate
  • 41 62 000 Removing And Installing Rear Lid
  • 41 62 043 Removing And Installing/Replacing Hinge For Tailgate
  • 51 24 325 Removing And Installing/Replacing Left Tension Spring For Rear Lid
  • 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