Collision - Body Panel Repair (E89)

• 4100 Body Panel Repair General Information
  • 41 0 0 Contents Of Body Repair General Information
  • 41 00... Blind Rivets
    • 1.0 Recommended Tools And Equipment
    • Setting Blind Rivets
  • 41 00... Bonding On Painted Surfaces
    • Notes
    • 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
    • 1.0 Equipment
    • 2.0 Surface Preparation
    • 3.0 Adhesive Application
    • 4.0 Hardening Times
    • 5.0 Subsequent Treatment Of Bonding Surfaces
  • 41 00 505 Checking Front Body Structure
  • 41 00 510 Checking Rear Body Structure
  • 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 Aluminum Parts
  • 41 00... EMC Screws
    • Notes
    • 1. Purpose
    • 2. Aluminum Front End Procedure
    • 3. Steel Body Procedure
  • 99 00... General Instructions On Painting
  • 5114... General Notes For Labelling With Adhesive Films
  • 41 00... Grinding Aluminum 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
      • Notes
      • 2.0 Start-Up
      • 3.0 Mode Of Operation
    • 4.0 Application Examples
    • 5.0 Safety Instructions
  • 41 00... Handling Airbags And Restraint Systems
    • 1.0 Airbags And Restraint Systems
  • 41 00... Handling Electrical And Electronic Equipment
    • 1.0 Battery
    • 2.0 Control Units
    • 3.0 Electrical Wires And Wiring Harnesses
  • 41 00... Information/Warning Labels
  • 41 00... Information On Hazards
    • 1.0 Aluminum
  • 41 00... Information On Metal Filler
    • Notes
    • Storage
    • Shelf Life
    • Surface Pre-Treatment
    • Processing
    • Applying Filler
    • Hardening Time
    • Post-Processing
    • Paintwork
    • Metal Filler Disposal
  • 32 00... Information On Replacing Steering Gear After Accident Damage
    • Situation
    • Procedure
  • 64 00 000 Information On Using Cleaning Agent/Paints (Personal Protection Equipment)
  • 41 00... Information On Vehicle Protection
  • 41 00... Installation Solution For Straight Shank/Hexagon Rivet Nut
  • 41 00... Installing A Cavity Acoustic Baffle (Expanded)
  • 41 00... Installing A Cavity Acoustic Baffle (Not Expanded)
  • 41 00... Materials Science
    • 1. 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
  • 41 00... Notes On Repairing Threads
  • 41 00... Opening Adhesive Bonds
    • 1. Opening Spot-Weld Bonds
    • 2. Opening Adhesive Bonds
    • 3. Opening Adhesive Bonds On Aluminum 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)
    • 2. Opening MAG Weld Seams And MIG Brazing Seams
    • 3. Opening Laser Weld Seams
  • 41 00... Overview Of Adhesive Cartridge Guns
  • 41 00... Overview Of Consumables (Electronic Parts Catalog)
  • 41 00... Position Of Shaped Parts For Cavity Acoustic Baffle
  • 41 00... Procedure For Folding Hardtop After An Accident
  • 41 00... Punch Rivets
  • 41 00... Quality Standard
  • 41 00... Reinforcement Plate (Bonded)
  • 41 00... Reinforcement Plate With Stud Bolt (Bonded)
  • 41 05 800 Releasing Bonded Folded Seam Connections
  • 41 00... Repair Solution For Straight Shank/Hexagon Rivet Nut
  • 41 0 Stage 1 Repair Techniques
  • 41 0 Stage 2 Repair Techniques
  • 41 0 Stage 3 Repair Techniques
  • 41 00... Repairing Plastic Parts
    • 1.0 General Information
    • 2.0 Shaping Plastic Parts
    • 3.0 Bonding Plastic Parts
  • 41 00... Safety At Work
  • 00 Safety Information For Working On Vehicles With Automatic Engine Start-Stop Function (MSA)
  • 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)
  • 41 00... Straightening Aluminum Components In Structure
  • 41 00... Straightening Aluminum Parts On Outer Skin
  • 41 00... Straightening Steel Components In The Structure
  • 41 00... Straightening Steel Parts On Outer Skin
  • 41 00... Use Of Materials In Outer Skin
  • 41 00... Vehicle Identification Number General Information
  • 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
  • 41 00... Workshop Equipment
• 4111 Support Members
  • 41 00... Procedure For Folding Hardtop After An Accident
  • 41 11 141 Replacing Cover For Left Or Right Frame Side Member (Partial Replacement Between A- And B-Pillars)
  • 41 11 155 Replacing Cover For Left Or Right Side Member (Partial Replacement, Door Pillar)
  • 41 21 512 Replacing Inner Door Pillar Section (Door Pillar Removed)
  • 41 11 048 Replacing Front Left Engine Support (Without Wheel Arch) (Partial Replacement Before Bulkhead)
  • 41 11 015 Replacing Front Left Or Right Engine Bracket With Wheel Arch
  • 41 11 516 Replacing Front Left Or Right Support Carrier (Partial Replacement, Front Side Panel Removed)
  • 41 11 733 Replacing Front Luggage Compartment Floor CROSSMEMBER (Luggage Compartment Floor Completely Removed)
  • 41 11 028 Replacing Left Engine Carrier (Partial Replacement Before Front Axle)
  • 41 11 516 Replacing Left Carrier Support Stripping Operations
• 4112 Luggage Compartment Floor
  • 41 00... Procedure For Folding Hardtop After An Accident
  • 41 12 535 Replacing Complete Rear Luggage Compartment Floor (Tail Panel Removed)
  • 41 11 733 Replacing Front Luggage Compartment Floor CROSSMEMBER (Luggage Compartment Floor Completely Removed)
  • 41 12 653 Replacing Left Luggage Compartment Floor Section (Tail Panel And Side Panel Removed)
  • 41 12 557 Replacing Middle Luggage Compartment Floor Section (Tail Panel Removed)
  • 41 12 548 Replacing Rear CROSSMEMBER On Luggage Compartment Floor (Tail Panel Removed)
  • 41 12 557 Replacing Middle Luggage Compartment Floor Stripping Operations (Tail Panel Removed)
• 4114 Wheel Wells
  • 41 00... Procedure For Folding Hardtop After An Accident
  • 41 14 511 Replacing Complete Rear Left Wheel Arch (Rear Left Side Panel Removed)
  • 41 14 020 Replacing Front Left Or Right Wheel Arch
  • 41 21 518 Replacing Left B-Pillar (Rear Left Side Panel Removed)
  • 41 14 502 Replacing Rear Left Outer Wheel Arch Section (Rear Left Side Panel Removed)
  • 41 00... Stamping Vehicle Identification Number (Needle Stamping Unit)
  • 41 00... Wheel Wells Vehicle Identification Number General Information
    • Notes
    • 1. General Notes For Stamped Vehicle Identification Numbers
    • 2. General Notes For Embossed Vehicle Identification Numbers
• 4121 Side Frame And Door Pillars
  • 41 11 141 Replacing Cover For Left Or Right Frame Side Member (Partial Replacement Between A- And B-Pillars)
  • 41 11 155 Replacing Cover For Left Or Right Side Member (Partial Replacement, Door Pillar)
  • 41 21 512 Replacing Door Pillar Inner Section (Door Pillar Removed)
  • 41 21 540 Replacing Front Left Or Right Door Pillar (Front Side Panel Removed)
  • 41 21 518 Replacing Left B-Pillar (Rear Left Side Panel Removed)
• 4132 Dash Cowl
  • 41 00... Procedure For Folding Hardtop After An Accident
  • 41 21 540 Replacing Front Left Or Right Door Pillar (Front Side Panel Removed)
• 4133 Front Trim Panel
  • 41 33 040 Replacing Front Wall
  • 41 33 051 Replacing Left Front Panel
  • 41 33 052 Replacing Right Front 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)
• 4134 Rear Trim Panel
  • 41 11 516 Replacing Front Left Or Right Support Carrier (Partial Replacement, Front Side Panel Removed)
  • 41 12 653 Replacing Left Luggage Compartment Floor Section (Tail Panel And Side Panel Removed)
  • 41 12 557 Replacing Middle Luggage Compartment Floor Section (Tail Panel Removed)
  • 41 12 548 Replacing Rear CROSSMEMBER On Luggage Compartment Floor (Tail Panel Removed)
  • 41 34 041 Replacing Tail Panel
  • 41 34 121 Replacing Complete Tail Panel And Luggage Compartment Floor
  • 41 11 516 Replacing Left Carrier Support Stripping Operations
  • 41 12 557 Replacing Middle Luggage Compartment Floor Stripping Operations (Tail Panel Removed)
  • 41 34 060 Replacing Tail Panel Stripping Operations
• 4135 Side Panels
  • 41 00... Reinforcement Plate With Stud Bolt (Bonded)
  • 41 35 000 Removing And Installing Or Replacing Left Or Right Front Side Panel
  • 41 11 516 Replacing Front Left Or Right Support Carrier (Partial Replacement, Front Side Panel Removed)
  • 41 35 101 Replacing Rear Left Side Panel
  • 41 35 111 Replacing Rear Right Side Panel
• 4151 Front Side Doors
  • 41 51 004 Adjusting Left Or Right Front Door
  • 41 5.... Removing And Installing Door
• 4152 Rear Side Doors
  • 41 5.... Removing And Installing Door
  • 41 5.... Replace Door
• 4161 Front Lid
  • 41 61 014 Adjusting Engine Bonnet/Hood
  • 41 61 014 Adjusting Engine Compartment Lid (For Vehicles With Active Pedestrian Protection AFGS)
  • 41 61... Checking Hinge For Engine Compartment Lid (For Vehicles With Active Pedestrian Protection System)
  • 41 61 000 Removing And Installing Hood/Bonnet
  • 41 61 571 Removing And Installing/Replacing Left Hinge For Engine Compartment Lid, (For Vehicles With Active Pedestrian Protection AFGS)
• 4162 Rear Lid
  • 41 62 014 Adjusting Tailgate
  • 41 00 505 Checking Front Body Structure
  • 41 00 510 Checking Rear Body Structure
  • 41 62 519 Removing And Installing/Replacing Left Or Right Hinge For Rear Lid
  • 41 62 000 Removing And Installing Rear Lid
• 4163 Other Flaps
  • 41 63 000 Removing And Installing Flap For Fuel Filler Neck
  • 41 63 060 Removing And Installing Soft Top Compartment Lid
  • 51 71 360 Removing And Installing/Replacing Seal For Rear Lid
  • 41 63 002 Replacing Cover Bowl