Collision - Body Panel Repair (E70)

• Body Panel Repair
  • 41 0 0 Contents Of Body Repair General Information
  • 41... 0 Notes On The Repair Technique Used
  • 41 00... Blind Rivets
    • Recommended Tools And Equipment
    • Setting Blind Rivets
  • 41 00... Bonding Aluminum On Steel
    • Notes
    • Overview Of Topics
    • 1.0 Equipment
    • 2.0 Preparation Of Surface
      • 2.1 Steel surface
      • 2.2 Aluminum surface
        • 2.2.1 Procedure for new aluminum component
        • 2.2.2 Procedure for previously bonded aluminum component
    • 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 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
      • Notes
      • 2.1 Cavity preservation of steel parts
      • 2.2 Cavity preservation of aluminum parts
  • 41 00... EMC Screws
    • Notes
    • 1. Purpose
    • 2. Procedure, Aluminum Front End
    • 3. Procedure, Steel Body
  • 41 00... General Cementing Instructions
    • Notes
    • Expiry Date Of Adhesive
    • 2-Component Adhesive Application
    • Adhesive Disposal
  • 99 00... General Instructions On Paintwork
  • 51 14... General Notes For Labelling With Adhesive Films
    • Notes
    • 1. Preparation
    • 2. Procedure For Applying Labels
  • 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
    • 2.0 Start-Up
    • 3.0 Mode Of Operation
    • 4.0 Application Examples
    • 5.0 Safety Instructions
  • 41 00... Handling 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
    • 4.0 Optical Fibers
  • 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... Information On Using Cleaning Agent/Paints (Personal Protection Equipment)
    • Notes
    • Recycling
  • 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
    • 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
  • 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
    • Notes
    • Remedy
  • 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 Welded Connections
    • 1. Opening Welding 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
    • 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... Overview Of Spring Support Repair Elements
  • 41 00... Position Of Shaped Parts For Cavity Acoustic Baffle
  • 41 00... Punch Rivets
    • Notes
    • 1.0 Recommended Tools And Equipment
    • 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... Removing And Installing Rivet Heads
  • 41 00... Repair Solution For Straight Shank/Hexagon Rivet Nut
    • Notes
    • 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
  • 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
    • Notes
    • 1.0 Compressed Air
    • 2.0 Electrical Systems/Devices
    • 3.1 Working With Aluminum Dust
    • 3.2 Removing Sealant
    • 3.3 ARC Welding And Brazing Solder
    • 3.4 Working With Chemical Products (Adhesive, Cleaning Agents, Fillers, Etc.)
  • 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
  • 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 Components
  • 41 00... Stamping Vehicle Identification Number
  • 41 00... Straightening Aluminum Component On The Outer Skin
    • 1.0 Recommended Tools
    • 2.0 Straightening outer skin
  • 41 00... Straightening Aluminum Components
    • 1.0 Recommended Tools
    • 2.0 Straightening Outer Skin
    • 3.0 Straightening Structure
  • 41 00... Straightening Aluminum Components In Structure
  • 41 00... Straightening Steel Components In The Structure
    • Notes
    • - The Body Must Be Anchored As Follows For Reshaping
  • 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)
  • 41 00... Straightening Steel Parts
    • 1.0 Recommended Tools
    • 2.0 Straightening Outer Shell
    • 3.0 Straightening Structure
    • The Body Must Be Anchored As Follows For Reshaping
  • 99 00... Touching Up Paintwork Damage
  • 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 And Soldering Steel Parts
    • Notes
    • A. Welding Steel Parts
      • 1. General information
      • 2. Work materials
      • 3. Preparations for MAG and spot-welding
      • 4. Welding
      • 5. Subsequent treatment of weld joints
    • B. Soldering Steel Parts
      • 1. General Information
      • 2. Work materials
      • 3. Preparations for brazing/tinning
      • 4. Brazing/tinning
      • 5. Subsequent treatment of brazed joints
  • 41 00... Welding In Reinforcement Plate (Sheet Steel)
  • 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
    • Notes
    • Repair Stage 1
    • Repair Stage 2
    • Repair Stage 3
• Support Members
  • 41... 0 Notes On The Repair Technique Used In The Main Group 41
  • 41 11 150 Cover For Frame Side Member (Part Replacement Between A And B Pillar)
  • 41 11 516 Replace Left Carrier Support (Partial Replacement, Front Side Panel Removed)
  • 41 11 301 Replacing Cover For Longitudinal Member With Left Door Pillar (Partial Replacement B-Pillar)
  • 41 11 015 Replacing Left Engine Carrier With Wheel Arch
    • Notes
    • Preparation Of New Part
  • 41 11 028 Replacing Left Engine Support (Partial Replacement Before Front Axle)
• Luggage Compartment Floor
  • 41... 0 Notes On The Repair Technique Used In The Main Group 41
  • 41 12 535 Replace Luggage Compartment Floor And Both Side Members (Tail Panel Trim Removed)
    • Notes
    • Removing Luggage Compartment Floor
    • Preparation Of New Part
    • Installing Side Members
    • Installing Luggage Compartment Floor
  • 41 12 651 Replacing Left Luggage Compartment Floor (Tail Panel Or Side Wall Removed)
    • Notes
    • Removal Of Luggage Compartment Floor
    • New Part Preparation
    • Installation Of Luggage Compartment Floor
  • 41 12 560 Replacing Luggage Compartment Floor (Tail Panel Has Been Removed)
    • Notes
    • Removal Of Luggage Compartment Floor
    • New Part Preparation
    • Installation Of Luggage Compartment Floor
  • 41 12 535 Replacing Complete Luggage Compartment Floor Stripping Operations (Tail Panel Removed)
  • 41 12 651 Replacing Left Luggage Compartment Floor Stripping Operations (Tail Panel Or Side Panel Removed)
  • 41 12 557 Replacing Luggage Compartment Floor, Middle Stripping Operations (Tail Panel Removed)
• Wheel Wells
  • 41... 0 Notes On The Repair Technique Used In The Main Group 41
  • 41 00... Carrying Over Hole Pattern
    • Notes
    • Necessary Preliminary Tasks
  • 41 00... Overview Of Spring Support Repair Elements
  • 41 14 502 Replacing Complete Rear Left Wheel Arch (Rear Left Side Panel Removed)
    • Notes
    • Preparation Of New Part
  • 41 11 015 Replacing Left Engine Carrier With Wheel Arch
    • Notes
    • Preparation Of New Part
  • 41 14 021 Replacing Front Left Wheel Arch
  • 41 14 502 Replacing Rear Left Outer Wheel Arch Section (Rear Left Side Panel Removed)
    • Notes
    • Preparation Of New Part
  • 41 00... Stamping Vehicle Identification Number
  • 41 00... Wheel Wells Vehicle Identification Number General Notes
    • Notes
    • 1. General Notes For Stamped Vehicle Identification Numbers
    • 2. General Notes For Embossed Vehicle Identification Numbers
• Side Frame And Door Pillars
  • 41... 0 Notes On The Repair Technique Used In The Main Group 41
  • 41 11 150 Cover For Frame Side Member (Part Replacement Between A And B Pillar)
  • 41 11 301 Replacing Cover For Longitudinal Member With Left Door Pillar (Partial Replacement B-Pillar)
  • 41 21 510 Replacing Front Left Door Pillar (Front Side Panel Removed)
    • Notes
    • Preparation Of New Part
• Roof Frame
  • 41... 0 Notes On The Repair Technique Used In The Main Group 41
• Outer Roof Skin
  • 41... 0 Notes On The Repair Technique Used In The Main Group 41
  • 41 31 000 Replacing Outer Roof Skin (Normal Roof)
    • Notes
    • Installing Roof Outer Skin
  • 41 31 010 Replacing Outer Roof Skin (Version With Panorama Glass Roof)
    • Notes
    • Removing Roof Outer Skin
    • Preparation Of New Part
    • Installing Roof Outer Skin
  • 41 31 010 Replacing Outer Roof Skin Stripping Operations (Version With Slide/Tilt Sunroof)
  • 41 31 010 Replacing Outer Roof Skin Stripping Operations (Version Without Slide/Tilt Sunroof)
• Dash Cowl
  • 41... 0 Notes On The Repair Technique Used In The Main Group 41
  • 41 21 510 Replacing Front Left Door Pillar (Front Side Panel Removed)
    • Notes
    • Preparation Of New Part
• Front Trim Panel
  • 41... 0 Notes On The Repair Technique Used In The Main Group 41
  • 41 33 040 Replacing Front Left Or Right Side Wall Holder
• Rear Trim Panel
  • 41... 0 Notes On The Repair Technique Used In The Main Group 41
  • 41 34 060 Replacing Outer And Inner Tail Panel Sections
    • Notes
    • Removing Outer And Inner Tail Panel Sections
    • Preparation Of New Part
    • Installing Outer And Inner Tail Panel Sections
  • 41 34 038 Replacing Outer Tail Panel Section
    • Notes
    • Removing Rear Trim Panel
    • Preparation Of New Part
    • Installing Rear Trim Panel
  • 41 34 060 Replacing Outer And Inner Tail Panel Sections Stripping Operations
  • 41 34 038 Replacing Outer Tail Panel Section Stripping-Down Operations
• Side Panels
  • 41... 0 Notes On The Repair Technique Used In The Main Group 41
  • 41 00... Reinforcement Plate With Stud Bolt (Bonded)
    • Notes
    • Preparation Of New Part
    • Procedure For Using Universal Reinforcement Plate
    • Installing Reinforcement Plate
  • 41 35... Removing And Installing Left Front Side Wall (Up To 03/2010)
  • 41 35... Removing And Installing Left Front Side Wall (As Of 03/2010)
  • 41 35 575 Removing And Installing/Replacing Front Left Side Panel Module Carrier
  • 41 35 050 Replacing Front Left Side Panel
  • 41 35 101 Replacing Rear Left Side Panel
    • Notes
    • Removing Side Panel
    • New Part Preparation
    • Installing Side Wall
  • 41 35 101 Replacing Rear Left Side Panel Stripping Operations
• Front Side Doors
  • 41 5.... Removing And Installing Door
  • 41 5.... Replace Door
  • 41 5.... Adjust Door
    • Important:
• Rear Side Doors
  • 41 5.... Removing And Installing Door
  • 41 5.... Replace Door
  • 41 52 101 Replacing Rear Left Or Right Door
  • 41 5.... Adjust Door
• Front Lid
  • 41 61 014 Adjusting Engine Compartment Lid
    • Notes
    • After Setting
  • 41 61 000 Removing And Installing Hood/Bonnet
  • 41 61 001 Replacing Engine Compartment Lid
    • Necessary Preliminary Tasks
• Rear Lid
  • 41 62 033 Adjusting Rear Lid Lower Section
  • 41 62 030 Adjusting Upper Rear Lid Section
  • 41 62 007 Removing And Installing Lower Rear Lid Section
  • 41 62 005 Removing And Installing Upper Rear Lid Section
• Other Flaps
  • 41 63 000 Removing And Installing Flap For Fuel Filler Neck
  • 41 63 003 Replacing Cover Bowl