Volkswagen ID.3 2020 Workshop Manual – PDF DOWNLOAD

Description

Volkswagen ID.3 2020 Workshop Manual – PDF DOWNLOAD

FILE DETAILS:

Volkswagen ID.3 2020 Workshop Manual – PDF DOWNLOAD 

Language : English
Pages : 2733
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Volkswagen ID.3 2020 Workshop Manual – PDF DOWNLOAD 

D4B80A1B850 Electrical system 1
00 – Technical data 7
1 Safety information and repair notes 7
1 1 Safety information 7
1 2 Repair instructions 7
2 Electrical components 8
2 1 Access to diagnoses 8
27 – Starter, current supply, CCS 9
1 Safety information and repair notes 9
1 1 Safety information 9
1 2 Repair instructions 9
2 Battery 10
2 1 Assembly overview – battery 10
2 2 Removing and installing battery A 10
2 3 Disconnecting and connecting battery 15
2 4 Removing and installing battery tray 18
2 5 Checking battery A 18
2 5 1 Sequence for checking battery A 18
2 5 2 Visual inspection of battery A 18
2 5 3 Checking colour indicator of battery A 19
2 5 4 Checking battery A 20
2 6 Charging battery A 20
2 7 Removing and installing earth wire with battery monitor control unit [J367] 21
2 8 Commissioning battery monitor control unit [J367] 22
90 – Gauges, instruments 23
1 Safety information and repair notes 23
1 1 Safety information 23
1 2 Repair instructions 23
2 Dash panel insert 24
2 1 Assembly overview ? control unit with display unit for driver information system 24
2 2 Assembly overview – head-up display 24
2 3 Removing and installing control unit with display unit for driver information system [J1254] 25
2 4 Removing and installing control unit for head-up display [J898] 26
2 5 Calibrating control unit for head-up display [J898] 29
2 5 1 Calibrating control unit for head-up display [J898], left-hand drive vehicles 29
2 5 2 Calibrating control unit for head-up display [J898], right-hand drive vehicles 30
3 Horn 33
3 1 Assembly overview – horn 33
3 2 Removing and installing horn or dual tone horn [H1] 33
92 – Windscreen wash/wipe system 35
1 Safety information and repair notes 35
1 1 Safety information 35
1 2 Repair instructions 35
2 Windscreen wiper system 36
2 1 Assembly overview – windscreen wiper system 36
2 2 Moving wipers to service position 37
2 3 Removing and installing wiper blade 37
2 4 Removing and installing wiper arms 38
2 5 Adjusting wiper arms 40
2 6 Removing and installing wiper motor 41
2 7 Deactivating APP function 42
2 8 Removing and installing rain and light sensor [G397] 43
3 Windscreen washer system 47
3 1 Assembly overview – windscreen washer system 47
3 2 Removing and installing washer fluid reservoir 48
3 3 Removing and installing washer pump [V59] 49
3 4 Removing and installing spray jets 50
3 5 Adjusting spray jets 51
4 Rear window wiper system 52
4 1 Assembly overview – rear window wiper system 52
4 2 Removing and installing wiper blade 52
4 3 Removing and installing wiper arm 53
4 4 Adjusting wiper arm 54
4 5 Removing and installing rear window wiper motor [V12] 55
5 Rear window washer system 57
5 1 Assembly overview – rear window washer system 57
5 2 Removing and installing spray jet, rear window washer system 57
6 Washer fluid lines 59
6 1 Repairing washer fluid lines 59
6 1 1 Pulling off and fitting washer fluid hoses 59
6 1 2 Repairing smooth tube 59
6 1 3 Repairing corrugated tube 60
94 – Lights, bulbs, switches – exterior 61
1 Safety information and repair notes 61
1 1 Safety information 61
1 2 Repair instructions 61
2 Headlights 62
2 1 Assembly overview – headlight, LED 62
2 1 1 Assembly overview – headlight 62
2 2 Assembly overview – headlight, LED matrix 63
2 2 1 Assembly overview – headlight 63
2 3 Assembly overview – repair kit for headlight housing 65
2 4 Removing and installing headlight 66
2 5 Adjusting headlights 67
2 6 Removing and installing front turn signal bulb [M5]/[M7], LED 68
2 6 1 Removing and installing front turn signal bulb [M5]/[M7] 68
2 7 Removing and installing front turn signal bulb [M5]/[M7], LED matrix 69
2 7 1 Removing and installing front turn signal bulb [M5]/[M7] 69
2 8 Installing repair kit for headlight housing 69
2 9 Removing and installing headlight range control motor [V48]/[V49] 70
2 9 1 Removing and installing headlight range control motor [V48]/[V49] 70
2 10 Removing and installing headlight range control motor [V48]/[V49] 72
2 10 1 Removing and installing headlight range control motor [V48]/[V49] 72
2 11 Removing and installing LED module for daytime running light and side light [L176]/[L177] 74
2 12 Removing and installing output module 1 for LED headlight [A27]/[A31] 76
2 13 Removing and installing light conductor for contour lighting in radiator grille [L362]/[L363] 77
2 14 Removing and installing headlight fan [V407]/[V408] 78
3 Tail lights 80
3 1 Assembly overview – tail light cluster in body 80
3 2 Assembly overview – tail light clusters in rear lid 81
3 3 Removing and installing tail light cluster [MX3]/[MX4] 82
3 4 Removing and installing rear fog light [X3] 82
3 5 Removing and installing trim for tail light cluster 83
4 LED module for charging socket 85
4 1 Removing and installing LED module for charging socket 1 [L263] 85
5 High-level brake light 86
5 1 Assembly overview ? high-level brake light 86
5 2 Removing and installing high-level brake light bulb [M25] 86
6 Entry and start authorisation system 88
6 1 Overview of fitting locations ? entry and start authorisation system 88
6 1 1 Overview of fitting locations – entry and start authorisation system, left-hand drive vehicles 88
6 1 2 Overview of fitting locations – entry and start authorisation system, right-hand drive vehicles 89
6 2 Overview of fitting locations ? keyless entry system 90
6 2 1 Overview of fitting locations – front keyless entry system, LHD vehicles 90
6 2 2 Overview of fitting locations – front keyless entry system, RHD vehicles 91
6 2 3 Overview of fitting locations – rear keyless entry system, LHD vehicles 92
6 2 4 Overview of fitting locations – rear keyless entry system, RHD vehicles 93
6 3 Assembly overview ? control unit for break-in protection 94
6 4 Removing and installing entry and start authorisation control unit [J518] 95
6 4 1 Removing and installing entry and start authorisation control unit [J518], left-hand drive vehicles 95
6 4 2 Removing and installing entry and start authorisation control unit [J518], right-hand drive vehicles 96
6 5 Removing and installing interior aerial 1 for entry and start system [R138] 97
6 6 Removing and installing luggage compartment aerial for entry and start system [R137] 98
6 7 Removing and installing control unit 2 for break-in protection [J1192]/control unit 3 for break-in protection [J1193] 98
6 8 Removing and installing control unit 4 for break-in protection [J1194]/control unit 5 for break-in protection [J1195] 99
6 9 Removing and installing contact sensor for front left exterior door handle [G605] 100
6 10 Removing and installing contact sensor for front right exterior door handle [G606] 100
6 11 Removing and installing entry and start authorisation aerial [R200]/[R201] 100
7 Steering column switch module 102
7 1 Assembly overview – steering column switch module 102
7 2 Removing and installing steering column electronics control unit [J527] 103
7 3 Removing and installing immobiliser reader coil [D2] 104
8 Automatic headlight range control 105
8 1 Assembly overview – automatic headlight range control 105
9 Towing bracket 106
9 1 Assembly overview – socket, trailer detector control unit 106
9 2 Removing and installing trailer detector control unit [J345] 106
10 Additional exterior lights 108
10 1 Removing and installing number plate light [X4]/[X5] 108
10 2 Assembly overview – lights in exterior mirror 108
10 3 Removing and installing exterior mirror turn signal bulb [L131]/[L132] 110
10 4 Removing and installing entry light in exterior mirror [W52]/[W53] 110
10 5 Assembly overview – lights in exterior door handle 111
10 6 Removing and installing bulb for exterior door handle illumination 112
96 – Lights, bulbs, switches – interior 114
1 Safety information and repair notes 114
1 1 Safety information 114
1 2 Repair instructions 114
2 Lights 115
2 1 Overview of fitting locations – lights in dash panel 115
2 2 Overview of fitting locations – lights in front doors 115
2 3 Overview of fitting locations – lights in luggage compartment 116
2 4 Overview of fitting locations – lights in centre console 117
2 5 Overview of fitting locations – lights in roof trim 118
2 6 Removing and installing footwell light [K268]/[K269] 119
2 6 1 Removing and installing front left footwell light [K268] 119
2 6 2 Removing and installing right footwell light [K269] 120
2 7 Removing and installing central locking SAFELOCK function warning lamp [K133] 120
2 8 Removing and installing luggage compartment light [W3] 121
2 9 Removing and installing rear illuminated vanity mirror [W49]/[W50] 122
2 10 Removing and installing dynamic light strip 1 for information in dash panel [L385] 122
2 11 Removing and installing light 1 for front centre console background lighting [L193] 123
2 12 Removing and installing light for dash panel contour lighting 124
2 12 1 Removing and installing light 1 for dash panel contour lighting [L243], driver side 124
2 12 2 Removing and installing light 2 for dash panel contour lighting [L244]/[L245], front passenger side 125
3 Controls 127
3 1 Overview of fitting locations – controls in dash panel 127
3 2 Overview of fitting locations – controls in front doors 128
3 3 Overview of fitting locations – controls in rear doors 129
3 4 Overview of fitting locations – controls in luggage compartment 130
3 5 Overview of fitting locations – controls in roof trim 131
3 6 Removing and installing operating unit for lighting [EX59] 132
3 6 1 Removing and installing operating unit for lighting [EX59], left-hand drive vehicles 132
3 6 2 Removing and installing operating unit for lighting [EX59], right-hand drive vehicles 134
3 7 Removing and installing centre switch module in dash panel [EX22] 135
3 8 Removing and installing operating unit for window regulator in driver door [EX36] 136
3 9 Removing and installing window regulator switch in front passenger door [EX27] 137
3 10 Removing and installing operating unit in rear door, driver side/passenger side [EX60]/[EX61] 137
3 11 Removing and installing starter button [E378] 138
3 12 Removing and installing front roof module [WX3] 139
3 13 Removing and installing rear interior light [WX2] 140
4 Anti-theft alarm system 141
4 1 Assembly overview – interior monitor 141
4 2 Removing and installing alarm horn [H12] 141
4 3 Removing and installing anti-theft alarm sensor [G578] 142
5 Cigarette lighter, socket 144
5 1 Removing and installing 12 V socket [U5/U19] 144
97 – Wiring 145
1 Safety information and repair notes 145
1 1 Safety information 145
1 2 Repair instructions 145
2 Relay carriers, fuse holders, electronics boxes 146
2 1 Overview of fitting locations ? relay carriers, fuse holders, E-boxes 146
2 1 1 Overview of fitting locations – relay carriers, fuse carriers, electronics boxes, left-hand drive vehicles 146
2 1 2 Overview of fitting locations – relay carriers, fuse carriers, electronics boxes, right-hand drive vehicles 146
2 2 Assembly overview ? relay carriers, fuse holders, electronics boxes 147
2 2 1 Assembly overview – fuse holder A 147
2 2 2 Assembly overview ? fuse holder B 148
2 3 Removing and installing electronics box 149
2 4 Removing and installing fuse holder A [SA] 150
2 5 Removing and installing fuse holder B [SB] 152
2 6 Removing and installing fuse holder C [SC] 154
2 6 1 Removing and installing fuse holder C [SC], left-hand drive vehicles 154
2 6 2 Removing and installing bracket for fuse holder C [SC], left-hand drive vehicles 155
2 6 3 Removing and installing fuse holder C [SC], right-hand drive vehicles 155
2 6 4 Removing and installing bracket for fuse holder C [SC], right-hand drive vehicles 156
3 Control units 158
3 1 Overview of fitting locations ? control units 158
3 1 1 Overview of fitting locations – control units, left-hand drive vehicles 158
3 1 2 Overview of fitting locations – control units, right-hand drive vehicles 158
3 2 Assembly overview ? onboard supply control unit 159
3 2 1 Assembly overview – onboard supply control unit, left-hand drive vehicles 159
3 2 2 Exploded view – onboard supply control unit, right-hand drive vehicles 160
3 3 Removing and installing onboard supply control unit [J519] 161
3 3 1 Removing and installing onboard supply control unit [J519], left-hand drive vehicles 161
3 3 2 Removing and installing onboard supply control unit [J519], right-hand drive vehicles 162
3 4 Removing and installing bracket for onboard supply control unit [J519] 163
3 4 1 Removing and installing bracket for onboard supply control unit [J519], left-hand drive vehicles 163
3 4 2 Removing and installing bracket for onboard supply control unit [J519], right-hand drive vehicles 165
3 5 Removing and installing data bus diagnostic interface [J533] 166
3 6 Removing and installing fan for control unit [V274] 166
4 Connector housings 168
4 1 Dismantling connector housings 168
5 Cleaning contact surfaces 169
5 1 Cleaning battery clamp and battery terminal 169
5 2 Anti-corrosion treatment of contact surfaces 170
5 3 Cleaning terminals 171
5 4 Cleaning threaded connections 172
6 Wires 174
6 1 Repairing aerial wires 174
6 2 Repairing wires with a cross section of 0 13 mm² to 6 mm² 178
6 3 Repairing 2 5 mm, 4 mm or 6 mm aluminium wires with a single crimp connector 182
6 4 Repairing a 10 mm² or 16 mm² wire 185
6 5 Repairing Ethernet lines 189
6 6 Section repairs to electrical wiring 189
7 Fibre optic cables 190
7 1 Repairing fibre optic cables 190
7 2 Removing and installing fibre optic cable of wiring harness connector 193
D4B80A4CF81 Body Repairs 195
00 – Technical data 201
1 Basic instructions 201
1 1 Original joint 201
1 2 Used joining techniques 201
2 Vehicle identification data 203
2 1 Vehicle identification number 203
2 2 Type plate 204
2 3 Safety certificate 205
3 Safety information 207
4 Body work for which HV electrical system must be de-energised 208
4 1 The following body work requires the HV electrical system to be de-energised 208
5 If the high-voltage battery is removed, note the following: 209
6 Moulded foam inserts 210
7 Galvanized body parts, high- and higher-strength and hot-formed body panels 212
8 Laser welding 215
9 Straightening bracket set 216
9 1 Overview of setup, entire body 216
10 Portal gauge 218
10 1 Overview of setup, entire body 218
50 – Body – front 220
1 Renewing front longitudinal member end plate 220
1 1 Tools 221
1 2 Removing 221
1 3 Installing 223
1 3 1 Preparing new part 223
1 3 2 Welding in 224
2 Renewing battery carrier 226
2 1 Tools 227
2 2 Removing 227
2 3 Installing 228
2 3 1 Preparing new parts 228
2 3 2 Welding in 229
3 Renewing upper wheel housing longitudinal member – part section 231
3 1 Tools 232
3 2 Removing 232
3 3 Installing 234
3 3 1 Preparing new part 234
3 3 2 Welding in 235
4 Renewing upper inner wheel housing longitudinal member – part section 238
4 1 Tools 239
4 2 Removing 239
4 3 Installing 241
4 3 1 Preparing new part 241
4 3 2 Welding in 242
5 Renewing front wheel housing 245
5 1 Tools 246
5 2 Removing 246
5 3 Installing 249
5 3 1 Preparing new parts 249
5 3 2 Welding in 251
6 Renewing front wheel housing (part section) 255
6 1 Tools 256
6 2 Removing 256
6 3 Installing 259
6 3 1 Preparing new parts 259
6 3 2 Welding in 261
7 Renewing front left longitudinal member (part section) 265
7 1 Tools 266
7 2 Removing 266
7 3 Installing 269
7 3 1 Preparing new part 269
7 3 2 Welding in 271
7 3 3 Renewing studs 274
8 Renewing front right longitudinal member (part section) 276
8 1 Tools 277
8 2 Removing 277
8 3 Installing 280
8 3 1 Preparing new part 280
8 3 2 Welding in 282
8 3 3 Renewing studs 285
9 Renewing front left longitudinal member (part section – second parting cut) 287
9 1 Tools 288
9 2 Removing 288
9 3 Installing 291
9 3 1 Preparing new part 292
9 3 2 Moulded foam inserts 296
9 3 3 Welding in 296
9 3 4 Renewing studs 300
10 Renewing front right longitudinal member (part section – second parting cut) 302
10 1 Tools 303
10 2 Removing 303
10 3 Installing 306
10 3 1 Preparing new part 307
10 3 2 Moulded foam inserts 311
10 3 3 Welding in 311
10 3 4 Renewing studs 315
11 Renewing studs 317
51 – Body – centre 319
1 Renewing roof – vehicles with no panoramic sliding sunroof 319
1 1 Tools 320
1 2 Removing 320
1 3 Installing 324
1 3 1 Preparing new part 324
1 3 2 Bonding roof 326
1 3 3 Adjusting roof depth 330
1 3 4 Welding in 331
2 Renewing roof – vehicles with panoramic sliding sunroof 334
2 1 Tools 335
2 2 Removing 335
2 3 Installing 339
2 3 1 Preparing new part 339
2 3 2 Bonding roof 341
2 3 3 Adjusting roof depth 345
2 3 4 Welding in 346
3 Renewing roof side member 349
3 1 Tools 350
3 2 Removing 351
3 3 Installing 353
3 3 1 Authorised parting cuts on complete side panel 353
3 3 2 Preparing new part 354
3 3 3 Welding in 355
4 Renewing A-pillar 359
4 1 Tools 361
4 2 Removing 361
4 3 Installing 363
4 3 1 Authorised parting cuts on complete side panel 363
4 3 2 Preparing new part 364
4 3 3 Moulded foam inserts 365
4 3 4 Welding in 365
5 Renewing A-pillar reinforcement (part section) 368
5 1 Tools 369
5 2 Removing 369
5 3 Installing 372
5 3 1 Preparing new part 372
5 3 2 Moulded foam inserts 373
5 3 3 Welding in 373
6 Renewing B-pillar 377
6 1 Tools 379
6 2 Type plate 379
6 3 Removing 380
6 4 Installing 382
6 4 1 Authorised parting cuts on complete side panel 382
6 4 2 Preparing new part 383
6 4 3 Moulded foam inserts 384
6 4 4 Welding in 384
7 Renewing B-pillar reinforcement 387
7 1 Tools 388
7 2 Type plate 388
7 3 Removing 389
7 4 Installing 391
7 4 1 Preparing new part 391
7 4 2 Welding in 392
8 Renewing inner B-pillar 395
8 1 Tools 396
8 2 Removing 396
8 3 Installing 398
8 3 1 Preparing new part 398
8 3 2 Welding in 399
9 Renewing outer side member 402
9 1 Tools 403
9 2 Type plate 403
9 3 Removing 404
9 4 Installing 406
9 4 1 Approved parting cuts on outer side member 406
9 4 2 Preparing new part 407
9 4 3 Moulded foam inserts 408
9 4 4 Welding in 408
10 Renewing side member reinforcement 411
10 1 Tools 412
10 2 Removing 412
10 3 Installing 414
10 3 1 Preparing new part 414
10 3 2 Welding in 415
11 Renewing side panel reinforcement (crash bar) 418
11 1 Tools 419
11 2 Removing 419
11 3 Installing 421
11 3 1 Preparing new part 421
11 3 2 Welding in 422
53 – Body – rear 425
1 Renewing rear cross panel 425
1 1 Tools 426
1 2 Removing 426
1 3 Installing 428
1 3 1 Preparing new part 428
1 3 2 Welding in 429
2 Renewing rear cross member 432
2 1 Tools 433
2 2 Removing 433
2 3 Installing 434
2 3 1 Preparing new part 434
2 3 2 Welding in 435
3 Renewing rear floor cross member 438
3 1 Tools 439
3 2 Removing 439
3 3 Installing 441
3 3 1 Preparing new part 441
3 3 2 Welding in 442
4 Renewing centre floor panel (part section) 445
4 1 Tools 446
4 2 Removing 446
4 3 Installing 448
4 3 1 Preparing new part 448
4 3 2 Welding in 449
5 Renewing rear floor panel 452
5 1 Tools 453
5 2 Removing 453
5 3 Installing 455
5 3 1 Preparing new part 455
5 3 2 Welding in 456
6 Renewing longitudinal member cover plate 459
6 1 Tools 460
6 2 Removing 460
6 3 Installing 462
6 3 1 Preparing new part 462
6 3 2 Moulded foam inserts 463
6 3 3 Welding in 463
7 Renewing rear longitudinal member (part section) 466
7 1 Tools 467
7 2 Removing 467
7 3 Installing 469
7 3 1 Preparing new part 469
7 3 2 Welding in 470
8 Renewing rear longitudinal member (second part section) 473
8 1 Tools 474
8 2 Removing 474
8 3 Installing 477
8 3 1 Preparing new part 477
8 3 2 Moulded foam inserts 479
8 3 3 Welding in 479
9 Permitted parting cuts on side panel 483
10 Renewing side panel (part section) 484
10 1 Tools 486
10 2 Removing 486
10 3 Installing 488
10 3 1 Authorised parting cuts on complete side panel 488
10 3 2 Preparing new part 489
10 3 3 Moulded foam inserts 490
10 3 4 Welding in 490
11 Renewing floor panel reinforcement 494
11 1 Tools 495
11 2 Removing 495
11 3 Installing 496
11 3 1 Preparing new part 496
11 3 2 Welding in 497
12 Renewing outer wheel housing liner 499
12 1 Tools 500
12 2 Removing 500
12 3 Installing 503
12 3 1 Preparing new part 503
12 3 2 Welding in 504
D4B80A4D03C General body repairs interior 507
00 – Technical data 515
1 Electrical components 515
1 1 Access to diagnoses 515
68 – Interior equipment 516
1 Safety information and repair notes 516
1 1 Safety information 516
1 2 Repair notes 516
2 Compartments/covers 517
2 1 Overview of fitting locations – compartments/covers 517
2 2 Assembly overview ? dash panel cover on driver side 518
2 2 1 Assembly overview – dash panel trim on driver side, left-hand drive vehicles 518
2 2 2 Assembly overview – dash panel trim on driver side, right-hand drive vehicles 518
2 3 Assembly overview – dash panel trim on front passenger side 519
2 4 Assembly overview – steering column trim 521
2 5 Assembly overview – glove compartment 521
2 6 Removing and installing dash panel cover on driver side 522
2 6 1 Removing and installing dash panel trim on driver side, left-hand drive vehicles 522
2 6 2 Removing and installing dash panel trim on driver side, right-hand drive vehicles 523
2 7 Removing and installing gap cover for dash panel insert 524
2 8 Removing and installing dash panel trim on front passenger side 525
2 9 Removing and installing upper steering column trim 526
2 10 Removing and installing lower steering column trim 527
2 11 Removing and installing glove compartment opener 527
2 12 Removing and installing glove compartment 528
2 13 Removing and installing glove compartment cover 529
2 14 Glove compartment, service position 529
2 15 Removing and installing information electronics cover 530
2 16 Removing and installing restrictor in glove compartment 530
3 Equipment 532
3 1 Assembly overview ? sun visors 532
3 2 Removing and installing sun visor 532
3 3 Removing and installing sun visor centre mount 534
3 4 Removing and installing roof grab handle 534
4 Centre console 537
4 1 Assembly overview – centre console 537
4 2 Removing and installing rear centre console trim 537
4 3 Removing and installing centre console insert 538
4 4 Removing and installing centre console 538
4 5 Removing and installing centre console bracket 539
5 Front centre armrest 541
5 1 Assembly overview ? front centre armrest 541
5 2 Removing and installing front centre armrest 541
6 Interior mirror 543
6 1 Assembly overview – interior mirror 543
6 2 Removing and installing interior mirror 543
6 3 Bonding retaining plate for interior mirror 546
69 – Passenger protection 548
1 Safety information and repair notes 548
1 1 Safety information 548
1 2 Repair notes 548
2 Seat belts 549
2 1 Overview of fitting locations – seat belts and anchorage points 549
2 2 Assembly overview – front three-point seat belt 551
2 3 Assembly overview ? rear outer three-point seat belt 552
2 4 Assembly overview – rear centre three-point seat belt 553
2 5 Assembly overview ? front belt buckle 554
2 6 Assembly overview – rear belt buckle 555
2 7 Removing and installing front three-point seat belt [NX10]/[NX11] 556
2 8 Removing and installing rear three-point seat belt 559
2 8 1 Removing and installing rear outer three-point seat belt 559
2 8 2 Removing and installing rear centre three-point seat belt 560
2 9 Removing and installing rear belt guide 561
2 10 Removing and installing front belt guide 561
2 11 Removing and installing front belt end fitting 562
2 12 Removing and installing rear outer belt end fitting 564
2 13 Removing and installing front belt buckle 564
2 14 Removing and installing rear belt buckle 565
2 14 1 Removing and installing rear right belt buckle 565
2 14 2 Removing and installing rear centre belt buckle 566
3 Child seat anchors 567
3 1 Assembly overview ? front child seat anchors 567
3 2 Assembly overview – rear child seat anchors 567
3 3 Removing and installing front child seat anchors 568
4 Airbag system 570
4 1 Overview of fitting locations – airbag system 570
5 Airbag control unit 573
5 1 Assembly overview ? airbag control unit 573
5 2 Removing and installing airbag control unit [J234] 573
5 2 1 Removing and installing airbag control unit [J234], left-hand drive vehicles 573
5 2 2 Removing and installing airbag control unit J234, right-hand drive vehicles 575
6 Front airbag, driver side 577
6 1 Assembly overview ? front airbag, driver side 577
6 2 Removing and installing airbag unit with airbag igniter on driver side [N95] 577
6 3 Renewing connector on airbag 579
7 Front passenger airbag 582
7 1 Assembly overview – front passenger airbag 582
7 2 Removing and installing front passenger airbag unit with igniter 583
7 3 Removing and installing key-operated switch to deactivate airbag on front passenger side [E224] 585
8 Side airbags 587
8 1 Assembly overview ? front side airbag, outer side 587
8 2 Assembly overview – front side airbag, inner side 587
8 3 Removing and installing front side airbag, outer side 588
8 4 Removing and installing front side airbag, inner side 590
9 Curtain airbags 593
9 1 Assembly overview – curtain airbag 593
9 2 Removing and installing curtain airbag with igniter 593
10 Airbag crash sensors 597
10 1 Assembly overview – airbag crash sensors 597
10 2 Removing and installing front airbag crash sensor 599
10 3 Removing and installing front side airbag crash sensor [G179/G180] 600
10 4 Removing and installing rear side airbag crash sensor [G256/G257] 601
11 Seat occupied recognition 604
11 1 Overview of fitting locations – seat occupied recognition 604
11 2 Removing and installing seat occupied recognition control unit [J706] 604
11 3 Removing and installing front seat occupied sensor [G1067]/[G128] 605
11 4 Removing and installing rear seat occupied sensor [G177/G178/G1010] 606
11 5 Removing and installing rear seat occupied sensor, centre [G1010] 606
70 – Trim, insulation 608
1 Safety information and repair notes 608
1 1 Safety information 608
1 2 Repair notes 608
2 Front door trims 609
2 1 Assembly overview ? front door trim 609
2 2 Removing and installing front door trim 609
2 3 Removing and installing button trim 612
2 4 Removing and installing mirror cover trim 613
3 Rear door trims 614
3 1 Assembly overview ? rear door trim 614
3 2 Removing and installing button trim 614
3 3 Removing and installing rear door trim 615
4 Dash panel 618
4 1 Assembly overview – dash panel 618
4 2 Removing and installing dash panel end cover 619
4 3 Removing and installing loudspeaker trim 619
4 4 Removing and installing dash panel 620
4 5 Removing and installing side defroster vent 622
4 6 Removing and installing centre vent 622
4 7 Removing and installing cover for dash panel/head-up display 623
4 8 Removing and installing tunnel support cover 623
4 9 Removing and installing outer dash panel vents 624
5 Central tube for dash panel 625
5 1 Assembly overview ? central tube for dash panel 625
5 2 Removing and installing dash panel cross member 626
5 3 Removing and installing crash bar 629
5 4 Removing and installing footwell cover on driver side 629
6 Interior trims 630
6 1 Overview of fitting locations – interior trims 630
6 2 Assembly overview ? sill panel moulding 631
6 3 Assembly overview – A-pillar trim 631
6 4 Assembly overview – B-pillar trim 632
6 5 Assembly overview – C-pillar trim 633
6 6 Assembly overview ? foot rest and floor covering 634
6 7 Removing and installing front sill panel moulding 635
6 8 Removing and installing rear sill panel moulding 636
6 9 Removing and installing upper A-pillar trim 637
6 10 Removing and installing lower A-pillar trim 640
6 11 Removing and installing A-pillar gap cover 641
6 12 Removing and installing upper B-pillar trim 641
6 13 Removing and installing lower B-pillar trim 643
6 14 Removing and installing C-pillar trim 644
6 15 Removing and installing floor covering 644
6 16 Removing and installing foot rest 645
7 Roof trims 646
7 1 Assembly overview – moulded headliner 646
7 1 1 Assembly overview – moulded headliner, vehicles with sliding sunroof 646
7 1 2 Assembly overview – moulded headliner, vehicles without sliding sunroof 646
7 2 Removing and installing roof end strip 647
7 3 Removing and installing moulded headliner 648
7 4 Installing roof reinforcement to body 651
8 Luggage compartment trims 654
8 1 Overview of fitting locations – luggage compartment trims 654
8 2 Assembly overview – luggage compartment side trim 654
8 3 Assembly overview – luggage compartment floor 655
8 4 Assembly overview – lower rear lid trim 656
8 5 Assembly overview – upper rear lid trim 657
8 6 Removing and installing lower rear lid trim 658
8 7 Removing and installing upper rear lid trim 659
8 8 Removing and installing luggage compartment side trim 660
8 9 Removing and installing lock carrier trim 661
8 10 Removing and installing support for luggage compartment floor 661
72 – Seat frames 663
1 Safety information and repair notes 663
1 1 Safety information 663
1 2 Repair notes 663
2 Overview of seat variants 664
2 1 Overview of fitting locations – seat variants 664
3 Front seats 665
3 1 Overview of fitting locations ? electrical and electronic components 665
3 1 1 Overview of fitting locations – electrical and electronic components 665
3 1 2 Overview of fitting locations – electrical and electronic components, NAR 667
3 2 Assembly overview ? front seat 669
3 2 1 Assembly overview – front seat, manually adjustable 669
3 2 2 Assembly overview – front seat, electric adjustment 670
3 2 3 Assembly overview – front seat, Top-Sport seat 672
3 2 4 Assembly overview – front seat, Top-Sport 674
3 3 Assembly overview – front backrest 676
3 3 1 Assembly overview – front backrest 676
3 3 2 Assembly overview – front backrest, Top-Sport 677
3 4 Assembly overview – head restraint 679
3 5 Assembly overview ? seat pan 680
3 5 1 Assembly overview – seat pan, manual adjustment 680
3 5 2 Assembly overview – seat pan, electric adjustment 681
3 5 3 Assembly overview ? seat pan, fixed seat 683
3 6 Assembly overview ? seat height adjustment 684
3 6 1 Assembly overview ? seat height adjustment, manual 684
3 6 2 Assembly overview ? seat height adjustment, electrical 685
3 7 Assembly overview ? lumbar support 686
3 8 Assembly overview ? seat rake adjustment 687
3 9 Assembly overview ? seat depth adjustment 688
3 10 Removing and installing front seat 689
3 11 Removing and installing trim for backrest with integrated head restraint 692
3 12 Removing and installing seat longitudinal adjustment handle 693
3 13 Removing and installing seat height adjustment handle 693
3 14 Removing and installing seat height adjuster 694
3 14 1 Removing and installing seat height adjustment unit, manually adjustable 694
3 14 2 Removing and installing seat height adjustment unit, electrically adjustable 695
3 15 Removing and installing seat rake adjustment motor [V243]/[V244] 696
3 16 Removing and installing front backrest 697
3 17 Removing and installing head restraint 698
3 17 1 Removing and installing head restraint 698
3 17 2 Removing and installing integrated head restraint 699
3 18 Removing and installing head restraint guide 699
3 19 Removing and installing lumbar support adjustment switch [E176]/[E177] 700
3 20 Removing and installing backrest adjuster 701
3 21 Securing front seat to seat repair stand 701
3 22 Removing and installing lumbar support 702
3 23 Removing and installing seat adjustment operating unit [E470]/[E471] 703
3 24 Removing and installing bracket for seat trim 704
3 25 Removing and installing inner seat trim 705
3 26 Removing and installing outer seat trim 705
3 26 1 Removing and installing outer seat trim 705
3 26 2 Removing and installing outer seat trim, front passenger seat without height adjustment 707
3 27 Removing and installing seat longitudinal adjustment motor [V28]/[V31] 708
3 28 Removing and installing seat depth adjuster 708
3 29 Removing and installing seat adjustment control unit 711
3 30 Removing and installing operating unit for memory settings [E464]/[E465] 711
3 31 Removing and installing wiring harness for seat frame 712
4 Rear seats 714
4 1 Assembly overview – bench seat/individual seats 714
4 2 Assembly overview ? rear seat backrest 715
4 3 Assembly overview ? locking mechanism 717
4 4 Assembly overview – centre armrest 717
4 5 Removing and installing bench seat/individual seats 718
4 6 Removing and installing seat pan 720
4 7 Removing and installing head restraint 721
4 8 Removing and installing head restraint guide 722
4 9 Removing and installing rear seat backrest 722
4 10 Removing and installing back panel trim 724
4 11 Removing and installing trim for locking mechanism 725
4 12 Removing and installing locking mechanism for rear seat backrest 726
4 13 Removing and installing trim frame for load-through hatch 727
4 14 Removing and installing flap for load-through hatch 728
4 15 Removing and installing centre armrest 729
74 – Seat – padding, covers 731
1 Safety information and repair notes 731
1 1 Safety information 731
1 2 Repair notes 731
2 Front seat covers and padding 732
2 1 Assembly overview ? seat pan cover and padding 732
2 2 Assembly overview ? backrest cover and padding 732
2 3 Assembly overview ? seat heating element 733
2 4 Assembly overview ? backrest heating element 734
2 5 Removing and installing seat pan cover and padding 735
2 6 Removing and installing backrest cover and padding 736
2 7 Separating seat pan cover from seat pan padding 737
2 8 Separating backrest cover from backrest padding 739
2 9 Removing and installing seat heating element [ZX11]/[ZX13] 741
2 10 Removing and installing backrest heating element [Z116]/[Z117] 743
3 Rear seat covers and padding 745
3 1 Assembly overview – rear bench seat cover and padding 745
3 2 Assembly overview ? rear seat backrest cover and padding 745
3 3 Removing and installing cover and padding of rear bench seat 746
3 4 Removing and installing cover and padding of rear seat backrest 747
3 5 Removing and installing intermediate padding, backrest with load-through hatch 750
3 6 Separating rear bench seat cover from padding 750
3 7 Separating rear seat backrest cover from padding 751
D4B80A4D036 General body repairs exterior 753
00 – Technical data 761
1 Safety information and repair notes 761
1 1 Safety information 761
1 2 Repair instructions 761
2 Electrical components 762
2 1 Access to diagnoses 762
3 Repair instructions 763
3 1 Bonding surfaces for self-adhesive components 763
3 1 1 Specifications for installation of self-adhesive components 763
4 General information 765
4 1 General information for use of adhesives 765
5 Technical data 767
5 1 Gaps/shut lines, body – front 767
5 2 Gaps/shut lines, body – side 767
5 3 Gaps/shut lines, body – rear 768
5 4 Gaps/shut lines, body – roof 769
50 – Body – front 771
1 Safety information and repair notes 771
1 1 Safety information 771
1 2 Repair instructions 771
2 Lock carrier 772
2 1 Assembly overview – lock carrier 772
2 2 Removing and installing lock carrier 772
2 3 Removing and installing headlight mounting carrier 773
3 Wings 775
3 1 Assembly overview – wing 775
3 2 Removing and installing wing 776
3 3 Removing and installing wing bracket 778
3 4 Removing and installing end plate 779
3 5 Bracket for deformation element 780
3 5 1 Removing and installing front deformation element bracket 780
3 5 2 Removing and installing rear deformation element bracket 781
4 Bulkhead 782
4 1 Assembly overview – bulkhead 782
4 2 Assembly overview – plenum chamber cover 782
4 3 Removing and installing bulkhead 783
4 4 Removing and installing plenum chamber cover 784
55 – Bonnet, rear lid 786
1 Safety information and repair notes 786
1 1 Safety information 786
1 2 Repair instructions 786
2 Bonnet 787
2 1 Assembly overview – bonnet 787
2 2 Assembly overview – Bowden cable 787
2 3 Removing and installing bonnet 788
2 4 Adjusting bonnet 789
2 5 Removing and installing bonnet lock 790
2 6 Removing and installing bonnet lock operating lever 791
2 7 Removing and installing striker pin 792
2 8 Removing and installing hinge 793
2 9 Adjusting hinges 793
2 10 Adjusting striker pin 794
2 11 Setting adjusting buffers 795
2 12 Adjusting bonnet lock 796
2 13 Removing and installing Bowden cable 796
2 14 Removing and installing bonnet stay 799
3 Rear lid 801
3 1 Assembly overview – rear lid 801
3 1 1 Assembly overview – rear lid 801
3 1 2 Assembly overview – rear lid hinge, vehicles up to WEEK 23/20 803
3 2 Removing and installing rear lid 804
3 2 1 Removing and installing rear lid 804
3 2 2 Renewing rear lid 806
3 3 Adjusting rear lid 808
3 4 Adjust adjustment buffer at bottom 809
3 5 Removing and installing striker pin 810
3 6 Removing and installing hinge 811
3 7 Adjusting striker pin 812
3 8 Removing and installing rear lid lock unit [VX25] 813
3 9 Removing and installing rear lid seal 814
3 10 Removing and installing rear lid handle 815
3 11 Removing and installing adjusting buffer at bottom 816
3 12 Removing and installing gas strut 817
3 13 Preparing gas strut for disposal 818
3 14 Removing and installing ball stud 818
4 Charging flap unit 820
4 1 Assembly overview – charging flap unit 820
4 2 Removing and installing charging flap unit 820
4 3 Removing and installing charging flap 822
4 4 Removing and installing LED module for charging socket 1 [L263] 823
57 – Front doors, door components, central locking 825
1 Safety information and repair notes 825
1 1 Safety information 825
1 2 Repair instructions 825
2 Door 826
2 1 Assembly overview – door 826
2 2 Removing and installing inner door seal 828
2 3 Removing and installing outer door seal 830
2 4 Removing and installing door 830
2 5 Adjusting door 833
2 6 Adjusting striker pin 834
2 7 Removing and installing door hinge, left-hand drive vehicles 835
2 7 1 Removing and installing door hinge 835
2 8 Removing and installing door hinge, right-hand drive vehicles 837
2 8 1 Removing and installing door hinge 837
2 9 Removing and installing door arrester 838
3 Door components 840
3 1 Assembly overview – door components 840
3 2 Assembly overview – assembly carrier 840
3 3 Assembly overview – exterior door handle [EX6]/[EX7] and lock unit [VX21]/[VX22] 841
3 3 1 Assembly overview – exterior door handle [EX6]/[EX7] 841
3 3 2 Assembly overview – lock unit [VX21]/[VX22] 842
3 4 Removing and installing window regulator motor [V147]/[V148] 844
3 5 Removing and installing striker pin 845
3 6 Removing and installing exterior door handle [EX6]/[EX7] 846
3 7 Assembling exterior door handle [EX6]/[EX7] 847
3 8 Removing and installing mounting bracket 848
3 9 Removing and installing lock unit [VX21]/[VX22] 850
3 10 Removing and installing window channel 851
3 11 Removing and installing assembly carrier 852
3 12 Removing and installing window slot inner seal 853
3 13 Removing and installing outer window slot seal 855
3 14 Removing and installing lock cylinder 856
3 15 Removing and installing Bowden cable for exterior door handle 857
3 16 Removing and installing Bowden cable for interior door handle 858
4 Central locking 860
4 1 Overview of fitting locations – central locking system 860
4 2 Removing and installing door control unit [J386]/[J387] 863
4 3 Removing and installing ignition key battery 863
4 4 Removing and installing actuator for high-voltage charging flap lock [F496] 864
58 – Rear doors, door components 865
1 Safety information and repair notes 865
1 1 Safety information 865
1 2 Repair instructions 865
2 Door 866
2 1 Assembly overview – door 866
2 2 Removing and installing door 868
2 3 Adjusting door 870
2 4 Adjusting striker pin 872
2 5 Removing and installing door hinge 873
2 6 Removing and installing door arrester 874
2 7 Removing and installing inner door seal 875
2 8 Removing and installing door joint seal 876
3 Door components 878
3 1 Assembly overview – door components 878
3 2 Assembly overview – assembly carrier 878
3 3 Assembly overview – rear exterior door handle [EX8]/[EX9] and rear door lock unit [VX83]/[VX84] 879
3 4 Removing and installing rear window regulator motor [V471]/[V472] 881
3 5 Removing and installing striker pin 882
3 6 Removing and installing rear exterior door handle [EX8]/[EX9] 883
3 7 Assembling rear exterior door handle [EX8]/[EX9] 884
3 8 Removing and installing mounting bracket 885
3 9 Removing and installing rear door lock unit [VX83]/[VX84] 886
3 10 Removing and installing assembly carrier 887
3 11 Removing and installing window channel 888
3 12 Removing and installing outer window slot seal 890
3 13 Removing and installing window slot inner seal 891
3 14 Removing and installing operating cable for exterior door handle 892
3 15 Removing and installing operating cable for interior door handle 894
60 – Sunroof 896
1 Safety information and repair notes 896
1 1 Safety information 896
1 2 Repair instructions 896
2 Sliding sunroof 897
2 1 Assembly overview – glass panel 897
2 2 Assembly overview – sun blind 897
2 3 Removing and installing frame with sun blind 899
2 4 Dismantling and assembling frame with sun blind 899
2 5 Removing and installing sun blind cables 901
2 6 Removing and installing sun blind 901
2 7 Removing and installing roof system control unit J1355 902
2 8 Adapting roof system adjustment control unit J1355 903
2 9 Manual operation 903
2 10 Removing and installing sun blind drive unit VX455 904
2 11 Removing and installing glass panel 905
2 12 Minimum drying time for bonded glass panels 911
2 13 Installations instructions for bonded glass panels 911
2 13 1 Installation instructions for bonded windows and glass panels 911
2 13 2 Materials for bonded glass panels 912
3 Water drain hoses 914
3 1 Assembly overview – water drain hoses 914
3 2 Cleaning water drain hoses 914
3 3 Removing and installing water drain hoses 915
3 4 Removing and installing water drain hose mounting 916
63 – Bumpers 918
1 Safety information and repair notes 918
1 1 Safety information 918
1 2 Repair instructions 918
2 Bumper, front 919
2 1 Assembly overview – bumper cover 919
2 2 Assembly overview – bumper carrier 921
2 3 Removing and installing bumper cover 922
2 4 Removing and installing bumper carrier 923
2 5 Installing holder for park assist steering sender 925
2 6 Repairing bumper cover 928
2 7 Moving bumper carrier to and back from service position 928
2 8 Removing and installing radar sensor cover 929
2 9 Removing and installing front spoiler bracket 930
2 10 Removing and installing trim 931
2 11 Removing and installing number plate carrier 931
2 12 Removing and installing towing eye cap, one-piece 932
2 13 Removing and installing centre air intake grille 933
3 Bumper, rear 934
3 1 Assembly overview – bumper cover 934
3 2 Assembly overview – bumper carrier 936
3 3 Removing and installing bumper cover 936
3 4 Removing and installing bumper carrier 938
3 5 Repairing bumper cover 938
3 6 Installing retainer for parking aid sender 938
3 7 Removing and installing rear bumper cover spoiler 941
3 8 Removing and installing forced ventilation for passenger compartment 941
3 9 Checking forced ventilation for passenger compartment 942
3 10 Removing and installing number plate carrier 942
64 – Glazing 944
1 Safety information and repair notes 944
1 1 Safety information 944
1 2 Repair instructions 944
2 Repair notes 945
2 1 Minimum drying times for bonded windows 945
2 2 Repairing windows 945
2 3 Installation instructions for bonded windows 945
2 3 1 Installation instructions for bonded windows and glass panels 945
2 3 2 Materials for bonded windows 946
2 4 Preparing undamaged windscreen for installation 947
2 5 Preparing new windows for installing 948
2 6 Preparing body flange for installation 950
2 7 Cleaning off excess adhesive 952
2 8 Preparing flange for installation of rear window 952
2 9 Removing broken window 953
3 Windscreen 955
3 1 Assembly overview – windscreen 955
3 2 Removing and installing windscreen 955
3 3 Removing broken windscreen 961
4 Rear windscreen 962
4 1 Assembly overview – rear window 962
4 2 Removing and installing rear window 962
4 3 Removing broken rear window 966
5 Side windows 967
5 1 Assembly overview – front side window 967
5 2 Removing and installing front side window 967
5 3 Removing broken front side window 969
6 Door windows 970
6 1 Assembly overview – front door window 970
6 2 Assembly overview – rear door window 970
6 3 Assembly overview – fixed rear door window 971
6 4 Removing and installing front door window 972
6 5 Removing and installing rear door window 975
6 6 Removing and installing fixed rear door window 977
66 – Exterior equipment 978
1 Safety information and repair notes 978
1 1 Safety information 978
1 2 Repair instructions 978
2 Spoiler 979
2 1 Assembly overview – spoiler 979
2 2 Removing and installing trim for rear spoiler 979
2 3 Removing and installing side spoiler 981
3 Mouldings, trims, extensions 982
3 1 Assembly overview – bonnet cover 982
3 2 Assembly overview – side member trim 982
3 3 Assembly overview – water deflector 983
3 4 Removing and installing bonnet cover 984
3 5 Removing and installing water deflector 985
3 6 Removing and installing retaining strip 986
3 7 Removing and installing side member trim 987
3 8 Removing and installing A-pillar cover 989
3 9 Removing and installing A-pillar trim 990
3 10 Removing and installing B-pillar trim on door 991
3 10 1 Removing and installing B-pillar trim on front door 991
3 10 2 Removing and installing B-pillar trim on rear door 992
4 Underbody cladding 994
4 1 Assembly overview – underbody cladding, 55, 62 kWh 994
4 1 1 Assembly overview – underbody cladding 994
4 2 Assembly overview – underbody cladding, 82 kWh 996
4 2 1 Assembly overview – underbody cladding 996
4 3 Removing and installing high-voltage battery skid plate, 55, 62 kWh 998
4 3 1 Removing and installing skid plate for high-voltage battery 998
4 4 Removing and installing high-voltage battery skid plate, 82 kWh 1000
4 4 1 Removing and installing high-voltage battery skid plate 1000
4 5 Removing and installing side underbody cladding, 55, 62 kWh 1001
4 5 1 Removing and installing side underbody cladding 1001
4 6 Removing and installing side underbody cladding, 82 kWh 1002
4 6 1 Removing and installing side underbody cladding 1002
4 7 Removing and installing front underbody cladding 1004
4 8 Removing and installing centre underbody cladding 1004
4 9 Removing and installing rear centre underbody cladding 1005
4 10 Removing and installing rear underbody cladding 1006
4 11 Removing and installing skid plate 1006
5 Roof moulding and roof railing 1008
5 1 Assembly overview – roof trim strip 1008
5 2 Removing and installing roof trim strip 1008
5 3 Removing and installing rear roof trim strip 1009
6 Exterior mirror 1012
6 1 Assembly overview – exterior mirror 1012
6 2 Removing and installing exterior mirror [VX4]/[VX5] 1014
6 3 Removing and installing mirror glass 1015
6 4 Removing and installing mirror adjustment unit 1016
6 5 Removing and installing upper mirror cover 1017
6 6 Removing and installing mirror frame 1018
7 Wheel housing liner 1020
7 1 Assembly overview – front wheel housing liner 1020
7 2 Assembly overview – rear wheel housing liner 1020
7 3 Removing and installing front wheel housing liner 1021
7 4 Removing and installing rear wheel housing liner 1023
8 Lettering and emblems 1024
8 1 Assembly overview – lettering and badges 1024
8 2 Removing and installing front badge 1024
8 3 Removing and installing badge at rear 1025
8 4 Removing and installing lettering at rear 1026
8 5 Renewing lettering and badges on sides 1027
9 Bicycle carrier 1029
9 1 Assembly overview – bicycle carrier bracket 1029
9 2 Removing and installing bicycle carrier bracket 1029
10 Trim film and protective film 1031
10 1 Renewing decorative film 1031
D4B80A4E2EB Vehicle specific paint information 1033
54 – Vehicle-specific paintwork information 1037
1 Safety information and repair notes 1037
1 1 Safety information 1037
1 2 Repair instructions 1037
2 Explanation of symbols 1038
2 1 Sanding 1038
2 2 Cavity sealing 1038
2 3 Seam sealing 1038
3 Paintwork structure 1042
3 1 Structure of factory finish, clear coat 1042
3 2 Structure of factory finish, surfacer 1042
3 3 Structure of factory finish, base coat 1043
4 Areas exposed to stone chipping 1045
4 1 Areas exposed to stone chipping – overview 1045
5 Masked sectors 1047
5 1 Masking areas, front body 1047
5 2 Masking areas, rear body 1047
6 Seam sealing 1049
6 1 Seam seals, front body 1049
6 2 Seam sealing: Front wheel housing 1050
6 3 Seam seals, A-pillar 1050
6 4 Seam seals, bonnet, inner side 1051
6 5 Seam seals, roof 1052
6 6 Seam seals, doors 1053
6 7 Seam seals, rear wheel housing 1054
6 8 Seam seals, underbody 1055
6 9 Seam seals, rear cross panel 1056
7 Underseal 1057
7 1 Underseal, body – overview 1057
7 2 Underseal, front body 1057
7 3 Underseal, centre body 1058
7 4 Underseal, rear body 1059
8 Cavity sealing 1061
8 1 Cavity sealing, body – overview 1061
8 2 Cavity sealing, rear body 1061
8 3 Cavity sealing, front body 1061
8 4 Cavity sealing, doors 1062
9 Contrasting colours 1063
9 1 Contrasting colours, roof 1063
9 2 Contrasting colours, rear cross panel 1064
10 Paintwork repair 1065
10 1 Paintwork repair – front bumper 1065
10 2 Paintwork repair, radar sensor cover 1066
D4B80A4E306 Running gear axles steering 1067
00 – Technical data 1073
1 Safety and repair instructions 1073
1 1 Safety information 1073
1 2 Repair instructions 1073
2 Electrical components 1074
2 1 Starting diagnosis 1074
40 – Front suspension 1076
1 Safety information and repair notes 1076
1 1 Safety information 1076
1 2 Repair instructions 1076
2 Front axle 1077
2 1 Overview of fitting locations – front axle 1077
3 Subframe 1078
3 1 Assembly overview – subframe 1078
3 1 1 Assembly overview – subframe 1078
3 2 Removing and installing subframe with steering rack 1079
3 3 Repairing thread in longitudinal member 1085
3 4 Fixing subframe in position 1085
3 5 Taking up weight of subframe using scissor-type assembly platform 1089
3 6 Preparing scissor-type assembly platform 1090
3 7 Supporting components in vehicle front end 1092
4 Suspension strut, upper suspension link 1098
4 1 Exploded view – suspension strut 1098
4 2 Removing and installing suspension strut 1100
4 3 Removing and installing spring 1108
5 Lower suspension link, swivel joint 1114
5 1 Assembly overview – suspension link, swivel joint 1114
5 2 Removing and installing suspension link 1116
5 3 Removing and installing swivel joint 1117
5 4 Removing and installing stone deflector for suspension link 1120
5 5 Renewing suspension link mounting, rear 1120
5 6 Renewing front suspension link mounting 1123
6 Wheel bearing 1126
6 1 Assembly overview ? wheel bearing assembly 1126
6 1 1 Assembly overview – wheel bearing assembly 1126
6 2 Removing and installing wheel bearing housing 1126
6 3 Removing and installing wheel bearing unit 1131
6 4 Loosening and tightening threaded connections of wheel bearings 1133
7 Anti-roll bar 1136
7 1 Exploded view – anti-roll bar 1136
7 2 Removing and installing anti-roll bar 1136
7 3 Removing and installing coupling rod 1138
42 – Rear suspension 1140
1 Safety information and repair notes 1140
1 1 Safety information 1140
1 2 Repair instructions 1140
2 Rear axle 1141
2 1 Overview of fitting locations – rear axle 1141
2 2 Removing and installing rear axle 1143
2 3 Lowering rear axle 1148
2 3 1 Lowering rear axle, front section 1148
2 3 2 Lowering rear axle, rear section 1151
2 4 Securing vehicle to support arms of lifting platform 1153
3 Subframe 1156
3 1 Fixing subframe in position 1156
3 2 Assembly overview – subframe mountings 1158
3 3 Assembly overview – subframe 1159
3 4 Preparing scissor-type assembly platform 1160
3 5 Taking up weight of subframe using scissor-type assembly platform 1163
3 6 Renewing gearbox mounting 1164
3 7 Renewing motor mountings 1171
3 8 Renewing front subframe mountings 1180
3 9 Renewing rear subframe mountings 1187
4 Anti-roll bar 1196
4 1 Assembly overview – anti-roll bar 1196
4 2 Removing and installing anti-roll bar 1198
4 3 Removing and installing coupling rod 1199
5 Suspension link, track rod 1202
5 1 Assembly overview ? suspension link 1202
5 1 1 Assembly overview – upper suspension link 1202
5 1 2 Assembly overview – lower suspension link 1202
5 2 Removing and installing track rod 1203
5 3 Assembly overview – track rod 1205
5 4 Removing and installing stone deflector for spring control arm 1206
5 5 Assembly overview – spring control arm 1207
5 6 Removing and installing spring control arm 1208
5 7 Removing and installing lower suspension link 1211
5 8 Removing and installing upper rear suspension link 1213
5 9 Removing and installing upper front suspension link 1215
6 Suspension strut, shock absorber, spring 1217
6 1 Removing and installing shock absorber 1217
6 2 Renewing shock absorber 1219
6 3 Assembly overview – spring 1222
6 4 Exploded view – shock absorber 1223
6 5 Removing and installing spring 1224
7 Wheel bearing assembly, trailing arm 1229
7 1 Assembly overview – wheel bearing assembly 1229
7 2 Removing and installing wheel bearing housing 1229
7 3 Removing and installing wheel bearing unit 1232
7 4 Raising wheel bearing assembly to unladen position 1234
8 Drive shaft 1237
8 1 Assembly overview – drive shaft 1237
8 2 Removing and installing drive shaft 1238
8 3 Loosening and tightening threaded connections of drive shaft 1245
8 4 Dismantling and assembling drive shaft 1246
8 4 1 Removing and installing outer constant velocity joint 1246
8 4 2 Removing and installing triple roller joint 1248
8 5 Tightening clamp for boot 1252
43 – Self-levelling suspension 1254
1 Safety information and repair notes 1254
1 1 Safety information 1254
1 2 Repair instructions 1254
2 Electronically controlled damping 1255
2 1 Overview of fitting locations – damping control 1255
2 2 Assembly overview – electronically controlled damping control unit 1257
2 3 Removing and installing electronically controlled damping control unit [J250] 1257
2 4 Removing and installing front body acceleration senders G341/G342 1258
2 5 Removing and installing rear body acceleration sender G343 1259
2 6 Exploded view – damping control 1260
3 Vehicle level sender 1262
3 1 Exploded view – front vehicle level senders 1262
3 2 Assembly overview – rear vehicle level senders 1262
3 3 Removing and installing front vehicle level senders G78/G289 1263
3 4 Removing and installing rear vehicle level senders G76/G77 1265
44 – Wheels, tyres, vehicle geometry 1267
1 Safety information and repair notes 1267
1 1 Safety information 1267
1 2 Repair instructions 1267
2 Wheel alignment 1268
2 1 Notes on wheel alignment 1268
2 2 Test requirements 1268
2 3 Specifications for wheel alignment 1268
2 4 Setting vehicle to initial position for wheel alignment 1269
2 5 When does wheel alignment have to be checked? 1270
2 6 Adjusting camber at front wheels 1271
2 7 Adjusting camber at rear wheels 1272
2 8 Adjusting toe setting at rear wheels 1273
2 9 Adjusting toe setting at front wheels 1274
2 10 Checking full steering lock 1274
2 11 Preparations for measurement 1275
3 Wheels, tyres 1276
3 1 Removing wheel 1276
3 2 Installing wheel 1276
48 – Steering 1278
1 Safety information and repair notes 1278
1 1 Safety information 1278
1 2 Repair instructions 1278
2 Steering wheel 1279
2 1 Assembly overview – steering wheel 1279
2 2 Removing and installing steering wheel 1279
3 Steering column 1281
3 1 Removing and installing steering column 1281
3 2 Removing and installing intermediate steering shaft 1284
3 3 Removing and installing control unit for electronic steering column lock [J764] 1286
3 4 Assembly overview – steering column 1290
3 4 1 Assembly overview – steering column, left-hand drive vehicles 1290
3 4 2 Assembly overview – steering column, right-hand drive 1292
4 Steering rack 1295
4 1 Assembly overview ? steering rack 1295
4 1 1 Assembly overview – steering rack, left-hand drive 1295
4 1 2 Assembly overview – steering rack, right-hand drive 1295
4 2 Removing and installing boot 1296
4 3 Removing and installing track rod 1298
4 4 Removing and installing track rod ball joint 1300
4 5 Exploded view – track rods 1302
4 6 Servicing steering rack 1303
4 7 Removing and installing steering rack 1304
4 7 1 Removing and installing steering rack, left-hand drive 1304
4 7 2 Removing and installing steering rack, right-hand drive vehicle 1307
D4B80A4F454 Air conditioning systems with refrigerant R744 – General information 1310
00 – Technical data 1314
1 Safety information 1314
1 1 Safety precautions when working on air conditioning systems 1314
1 2 Safety precautions when handling refrigerants 1314
1 3 Safety measures when working on vehicles with a start/stop system 1315
1 4 Safety precautions when using air conditioner service stations 1315
1 5 Safety precautions when handling refrigerants R1234yf and R134a 1315
1 6 Safety measures for working on vehicles with high-voltage system 1316
1 7 Safety precautions when working in the vicinity of high-voltage components 1316
2 Laws and regulations 1318
2 1 Legal regulations and standards 1318
2 2 Charging refrigerant circuit with different refrigerants 1319
2 3 Occupational health and safety 1319
3 Repair notes 1320
3 1 Rules for cleanliness 1320
3 2 Refrigerant circuit seals 1320
3 3 Refrigerant and refrigerant oil 1320
3 3 1 Refrigerant R134a and R1234yf 1320
3 3 2 Important repair notes for refrigerant and refrigerant oil 1321
3 3 3 Refrigerant R744 (carbon dioxide) 1321
3 3 4 Refrigerant oil 1322
3 4 Handling pressure vessels 1323
3 5 Handling refrigerants 1324
4 Identification 1326
4 1 Notice for refrigerant circuit 1326
5 Technical data 1327
5 1 Refrigerant capacity 1327
5 2 Refrigerant oil capacities 1327
5 2 1 Refrigerant capacity 1327
5 2 2 Refrigerant oil capacities 1327
5 3 Safety data sheets 1327
6 Basic technical and physical properties 1328
6 1 Basics of air conditioning technology 1328
6 1 1 Physical properties of air conditioning system 1328
6 1 2 Pressure and boiling point of refrigerant 1329
6 1 3 Vapour pressure table for refrigerant 1332
6 2 Physical properties 1334
6 2 1 Refrigerant R744 1334
6 2 2 Potential risks with refrigerant R744 1334
6 2 3 Physical and chemical properties of refrigerant R744 1335
6 2 4 Critical point of refrigerant R744 1336
6 2 5 Environmental aspects of refrigerant R744 1336
6 2 6 Colour and odour of refrigerant R744 (carbon dioxide) 1337
6 2 7 Vapour pressure, critical temperature/critical pressure of refrigerant R744 (carbon dioxide) 1337
6 2 8 How R744 refrigerant reacts to metals and plastics 1337
6 2 9 Critical temperature / critical pressure of R744 refrigerant 1337
6 2 10 Water content of refrigerant R744 (carbon dioxide) 1338
6 2 11 Flammability/decomposition of refrigerant R744 (carbon dioxide) 1338
6 2 12 Charge factor of refrigerant R744 1338
6 2 13 Evidence of leaks in a refrigerant circuit with refrigerant R744 (carbon dioxide) 1339
6 2 14 Analysis of refrigerant R744 1339
6 2 15 Returning contaminated R744 refrigerant for analysis, processing or disposal 1339
6 3 Product characteristics 1339
6 4 Function and role of air conditioning system 1340
6 4 1 Principle of operation 1340
6 4 2 Comfort 1340
6 5 Other reference material 1341
87 – Air conditioning system 1342
1 Refrigerant circuit 1342
1 1 System overview – refrigerant circuit 1342
1 2 General description – components of refrigerant circuit 1342
1 2 1 Gas cooler 1342
1 2 2 Evaporator 1343
1 2 3 Accumulator or receiver with dryer 1343
1 2 4 Expansion valve 1344
1 2 5 Refrigerant line with internal heat exchanger 1345
1 2 6 Connection points of components and refrigerant lines 1346
1 2 7 Seals 1347
1 2 8 Pipes and hoses in refrigerant circuit 1348
1 2 9 High-pressure safety valves 1350
1 2 10 Quick-release coupling connections in refrigerant circuit 1351
1 2 11 Connections for pressure and temperature senders in the refrigerant circuit 1353
1 2 12 Refrigerant pressure and temperature sender 1353
1 3 Possible complaints 1354
1 3 1 Prerequisites for investigating a complaint 1354
1 3 2 Possible complaints 1354
1 3 3 Odours from heater and air conditioning unit 1355
1 4 Investigating leaks 1356
1 4 1 General information about investigating leaks in the refrigerant circuit 1356
1 4 2 Detecting leaks in a vacuum test or using the pressure test of the air conditioner service station 1357
1 4 3 Detecting leaks in a pressure test (with forming gas) using leak detector or leak detection spray 1357
1 5 Renewing components 1360
1 5 1 General information about renewing components 1360
1 5 2 Renewing leaking or damaged components of empty refrigerant circuit (apart from air conditioner compressor and receiver) 1361
1 5 3 Renewing leaking or damaged components of charged refrigerant circuit (apart from air conditioner compressor) 1362
1 5 4 Renewing air conditioner compressor with no need to clean refrigerant circuit 1362
1 5 5 Renewing air conditioner compressor due to leaks or internal damage 1364
1 5 6 Renewing receiver (with desiccant bag) with no need to clean refrigerant circuit 1364
1 6 Cleaning refrigerant circuit 1365
1 6 1 General information about cleaning refrigerant circuit 1365
1 6 2 Refrigerant circuit cleaning procedure 1366
1 6 3 Adapters for setting up flushing circuits 1367
1 6 4 Procedure for setting up and flushing refrigerant circuit 1368
1 6 5 General information about blowing through with compressed air 1368
1 6 6 Blowing through refrigerant circuit with compressed air 1369
1 7 Checking pressures with pressure gauge 1370
1 7 1 Display on pressure gauges 1370
1 7 2 Pressure gauges enable the following test and measurement work 1371
2 Working with air conditioner service station 1372
2 1 General information on working with air conditioner service station 1372
2 2 Connecting air conditioner service station to refrigerant circuit 1374
2 3 Purging refrigerant circuit 1375
2 4 Evacuating refrigerant circuit 1377
2 5 Charging refrigerant circuit 1380
2 6 Bringing air conditioning system into service after charging 1383
2 7 Switching off air conditioner service station and separating from refrigerant circuit 1383
2 8 Filling refrigerant into internal pressure vessel 1385
2 9 Connecting and detaching supplied cylinder 1385
2 10 Emptying air conditioner service station 1385
2 11 Cleaning refrigerant circuit 1385
2 12 Filling contaminated refrigerant in a recycling cylinder for analysis, processing or disposal 1385
3 Testing equipment and tools 1386
3 1 Tools and materials available from distribution centre or importer 1386
3 2 Tools and materials available commercially 1386
D4B80A4FFE1 Communication 1388
00 – Technical data 1392
1 Safety information and repair notes 1392
1 1 Safety information 1392
1 2 Repair instructions 1392
2 Electrical components 1393
2 1 Access to diagnoses 1393
91 – Communication 1394
1 Safety information and repair notes 1394
1 1 Safety information 1394
1 2 Repair instructions 1394
2 Fitting locations 1395
2 1 Overview of fitting locations – components/control units in middle section of vehicle 1395
2 2 Overview of fitting locations – components/control units in rear section of vehicle 1397
3 Components/control units 1400
3 1 Removing and installing control unit for front display and information control panel [J685] 1400
3 2 Control unit 1 for information electronics [J794] 1400
3 2 1 Removing and installing control unit 1 for information electronics [J794] 1400
3 2 2 Removing and installing bracket for control unit 1 for information electronics [J794] 1401
3 3 Removing and installing front treble loudspeakers [R20]/[R22] 1403
3 4 Removing and installing bass loudspeaker 1403
3 5 Removing and installing subwoofer [R211] 1404
3 5 1 Removing and installing subwoofer [R211] 1404
3 5 2 Removing and installing subwoofer [R211], spare wheel well 1404
3 6 Removing and installing aerial module 1405
3 7 Removing and installing frequency modulation (FM) frequency filters [R178/R179] 1406
3 8 Removing and installing roof aerial [RX5] 1407
3 9 Removing and installing LTE aerial 1407
3 10 Removing and installing internet access control unit [J666] 1408
3 11 Removing and installing data transmission aerial [R180] 1409
3 12 Removing and installing charging unit 1 for mobile devices [J1146] 1409
3 13 Removing and installing aerial amplifier for mobile telephone [R86] 1410
3 14 Removing and installing multifunction buttons [E440]/[E441] 1410
3 15 Removing and installing control unit for steering wheel contact detection [J1158] 1413
3 16 Removing and installing loudspeaker for emergency call module [R335] 1414
3 17 Removing and installing emergency battery, telematics [A16] 1414
3 18 Removing and installing emergency call module control unit and communication unit [J949] 1415
3 18 1 Removing and installing emergency call module control unit and communication unit [J949], dash panel 1415
3 18 2 Removing and installing emergency call module control unit and communication unit [J949], rear bench seat 1417
3 19 Removing and installing USB connection 1 [U41] 1418
3 20 Removing and installing USB charging socket 1 [U37] 1419
3 21 Removing and installing digital sound package control unit [J525] 1419
3 21 1 Removing and installing digital sound package control unit [J525] 1419
3 21 2 Removing and installing retainer for digital sound package control unit [J525] 1420
4 Multifunction steering wheel 1422
4 1 Assembly overview – multifunction steering wheel 1422
D4B80A49E8C Heating air conditioning system 1423
00 – Technical data 1429
1 Safety information and repair notes 1429
1 1 Safety information 1429
1 2 Repair instructions 1429
2 General notes, R134a/R1234yf 1430
2 1 Type plates 1430
3 General notes, R744 1431
3 1 Type plates 1431
4 Technical data, R134a/1234yf 1432
4 1 Refrigerant capacity 1432
4 2 Refrigerant oil capacities 1432
4 3 Oil distribution 1432
4 4 Refrigerant oil capacities after renewal of components 1432
5 Technical data, R744 1433
5 1 Refrigerant capacity 1433
5 2 Refrigerant oil capacities 1433
5 3 Oil distribution 1433
6 Electrical components 1434
6 1 Access to diagnoses 1434
87 – Air conditioning system 1436
1 Safety information and repair notes 1436
1 1 Safety information 1436
1 2 Repair instructions 1436
2 Overview of fitting locations – air conditioning system, R134a/R1234yf 1437
2 1 Overview of fitting locations – components not located in passenger compartment 1437
2 2 Overview of fitting locations – components located in front section of passenger compartment 1439
3 Overview of fitting locations – air conditioning system, R744 1442
3 1 Overview of fitting locations – components not located in passenger compartment 1442
3 2 Overview of fitting locations – components located in front section of passenger compartment 1444
4 Refrigerant circuit, R134a/R1234yf 1447
4 1 System overview – refrigerant circuit 1447
4 2 Assembly overview – refrigerant lines 1449
4 3 Assembly overview – heat exchanger for high-voltage battery 1451
4 4 Exploded view – condenser 1452
4 5 Removing and installing refrigerant pressure and temperature sender [G395] 1453
4 6 Removing and installing pressure sender for refrigerant circuit G805 1454
4 7 Removing and installing expansion valve 1455
4 8 Detaching and attaching refrigerant line at expansion valve 1456
4 9 Removing and installing condenser 1457
4 10 Removing and installing desiccant bag 1457
4 11 Removing and installing evacuating and charging valve (low-pressure and high-pressure sides) 1459
4 12 Removing and installing refrigerant expansion valve 1 N636 1460
4 13 Removing and installing heat exchanger for high-voltage battery 1462
4 14 Removing and installing refrigerant shut-off valve for heater and air conditioning unit [N541] 1465
4 14 1 Removing and installing refrigerant shut-off valve for heater and air conditioner unit [N541], left-hand drive vehicles 1465
4 14 2 Removing and installing refrigerant shut-off valve for heater and air conditioning unit N541 – right-hand drive vehicles 1467
4 15 Removing and installing refrigerant line 1469
4 15 1 Removing and installing refrigerant line from condenser to expansion valve 1469
4 15 2 Removing and installing refrigerant line from air conditioner compressor [VX81] to expansion valve 1471
4 15 3 Removing and installing refrigerant line from condenser to air conditioner compressor [VX81] 1474
4 15 4 Removing and installing refrigerant line from heat exchanger for high-voltage battery to high-pressure line 1475
4 15 5 Removing and installing refrigerant line from heat exchanger for high-voltage battery to low-pressure line 1476
4 16 Detaching and attaching refrigerant lines at condenser 1477
4 17 Cleaning refrigerant circuit 1478
5 Refrigerant circuit, R744 1481
5 1 System overview – refrigerant circuit 1481
5 2 Assembly overview – refrigerant lines 1483
5 3 Removing and installing refrigerant pressure and temperature sender G395 1485
5 4 Removing and installing gas cooler 1487
5 5 Removing and installing dryer 1487
5 6 Removing and installing evacuating and charging valve (low-pressure and high-pressure sides) 1489
5 7 Removing and installing refrigerant pressure and temperature sender 2 [G826] 1490
5 8 Removing and installing refrigerant pressure and temperature sender 3 G827 1492
5 9 Removing and installing refrigerant pressure and temperature sender 4 G828 1493
5 10 Removing and installing refrigerant pressure and temperature sender 5 [G829] 1495
5 11 Removing and installing pressure limiting valve 1496
5 12 Removing and installing heat exchanger for high-voltage battery 1497
5 13 Removing and installing heat condenser 1499
5 14 Removing and installing refrigerant line 1499
5 14 1 Removing and installing refrigerant line between air conditioner compressor [VX81] and dryer 1499
5 14 2 Removing and installing refrigerant line between air conditioner compressor and valve block N641/N640 1501
5 14 3 Removing and installing refrigerant line between dryer and gas cooler 1503
5 14 4 Removing and installing refrigerant line between gas cooler and refrigerant shut-off valve 2 [N640] 1504
5 14 5 Removing and installing refrigerant line between refrigerant shut-off valve 3 N641 and heat condenser 1505
5 14 6 Removing and installing refrigerant line between expansion valve N638/N637 and evaporator 1507
5 14 7 Removing and installing refrigerant line between heat pump valve unit and evaporator 1508
5 14 8 Removing and installing refrigerant line between expansion valve N636/N696 and heat condenser 1509
5 15 Disconnecting and connecting refrigerant lines on gas cooler 1510
5 16 Cleaning refrigerant circuit 1512
6 Valve unit of heat pump, R744 1515
6 1 Assembly overview – heat pump valve unit 1515
6 2 Removing and installing heat pump valve unit 1519
6 3 Removing and installing refrigerant expansion valve 1 [N636] 1523
6 4 Removing and installing refrigerant expansion valve 2 N637 1524
6 5 Removing and installing refrigerant expansion valve 3 N638 1525
6 6 Removing and installing refrigerant shut-off valve 1 N696 1525
6 7 Removing and installing refrigerant shut-off valve 2 N640 1525
6 8 Removing and installing refrigerant shut-off valve 3 N641 1527
6 9 Removing and installing refrigerant shut-off valve 4 N642 1527
6 10 Removing and installing refrigerant shut-off valve 5 N643 1529
7 Air conditioner compressor, R134a/R1234yf 1530
7 1 Exploded view – air conditioner compressor 1530
7 2 Detaching and attaching refrigerant lines at air conditioner compressor 1530
7 3 Removing and installing air conditioner compressor [VX81] 1531
7 4 Detaching/attaching air conditioner compressor [VX81] from/to bracket 1534
8 Air conditioner compressor, R744 1536
8 1 Exploded view – air conditioner compressor 1536
8 2 Detaching and attaching refrigerant lines at air conditioner compressor 1536
8 3 Removing and installing air conditioner compressor [VX81] 1538
8 4 Detaching/attaching air conditioner compressor [VX81] from/to bracket 1541
9 Control motors 1542
9 1 Overview of fitting locations – control motors at front 1542
9 2 Exploded view – control motors (front) 1543
9 3 Removing and installing control motor for front left temperature flap [VX34] 1545
9 3 1 Removing and installing control motor for front left temperature flap [VX34], LHD vehicles 1545
9 3 2 Removing and installing control motor for front left temperature flap [VX34], right-hand drive vehicles 1546
9 4 Removing and installing control motor for front right temperature flap [VX35] 1548
9 4 1 Removing and installing control motor for front right temperature flap [VX35], left-hand drive vehicles 1548
9 4 2 Removing and installing control motor for front right temperature flap [VX35], right-hand drive vehicles 1549
9 5 Removing and installing control motor for defroster flap VX47 1550
9 6 Removing and installing control motor for front left air distribution flap [VX93] 1551
9 6 1 Removing and installing control motor for front left air distribution flap [VX93], left-hand drive vehicles 1551
9 6 2 Removing and installing control motor for front left air distribution flap [VX93], right-hand drive vehicles 1552
9 7 Removing and installing control motor for front right air distribution flap [VX94] 1554
9 7 1 Removing and installing control motor for front right air distribution flap [VX94], left-hand drive vehicles 1554
9 7 2 Removing and installing control motor for front right air distribution flap [VX94], right-hand drive vehicles 1555
9 8 Removing and installing control motor for fresh air and air recirculation flap [VX96] 1556
9 9 Removing and installing actuator for left air distribution flap 1558
9 10 Removing and installing right air distribution flap actuator 1558
10 Front heater and air conditioning unit, R134a/R1234yf 1560
10 1 Exploded view – heater and air conditioning unit 1560
10 2 Assembly overview – evaporator housing 1560
10 3 Assembly overview – air intake box of heater and air conditioning unit 1561
10 4 Removing and installing heater and air conditioning unit 1563
10 5 Removing and installing evaporator 1566
10 6 Dismantling and assembling heater and air conditioning unit 1567
10 7 Removing and installing dust and pollen filter 1567
10 8 Removing and installing fresh air blower control unit [J126] 1568
10 9 Removing and installing evaporator temperature sensor [G308] 1570
10 10 Removing and installing condensation drain 1570
10 11 Checking condensation drain 1571
10 12 Removing and installing air intake box of heater and air conditioning unit 1572
10 13 Removing and installing air intake cowling 1574
10 14 Removing and installing high voltage heater (PTC) [ZX17] 1576
11 Front heater and air conditioning unit, R744 1580
11 1 Exploded view – heater and air conditioning unit 1580
11 2 Assembly overview – evaporator housing 1580
11 3 Assembly overview – air intake box of heater and air conditioning unit 1581
11 4 Removing and installing heater and air conditioning unit 1583
11 5 Removing and installing evaporator 1587
11 6 Dismantling and assembling heater and air conditioning unit 1587
11 7 Removing and installing dust and pollen filter 1587
11 8 Removing and installing fresh air blower control unit [J126] 1588
11 9 Removing and installing evaporator temperature sensor [G308] 1589
11 10 Removing and installing condensation drain 1589
11 11 Checking condensation drain 1590
11 12 Removing and installing air intake box of heater and air conditioning unit 1591
11 13 Removing and installing air intake cowling 1594
11 14 Removing and installing high voltage heater (PTC) [ZX17] 1596
12 Air duct 1600
12 1 Assembly overview – air duct and air distribution in passenger compartment 1600
12 2 Removing and installing driver side footwell vents 1602
12 2 1 Removing and installing driver side footwell vents, left-hand drive vehicles 1602
12 2 2 Removing and installing driver side footwell vents, right-hand drive vehicles 1602
12 3 Removing and installing front passenger side footwell vents 1603
12 3 1 Removing and installing footwell vent (front passenger side) – left-hand drive vehicles 1603
12 3 2 Removing and installing footwell vent (front passenger side) – right-hand drive vehicles 1603
12 4 Removing and installing rear footwell vent 1604
12 5 Removing and installing fresh air intake 1604
12 6 Removing and installing air duct for defroster vent 1605
12 7 Removing and installing air duct for centre dash panel vent 1605
12 8 Removing and installing air duct for rear centre console vent 1606
12 9 Removing and installing front air duct for dash panel 1606
13 Coolant circuit 1607
13 1 Exploded view – high-voltage heater (PTC) 1607
13 2 Removing and installing PTC heater element 3 [Z132] 1607
14 Operating and display unit 1611
14 1 Overview of fitting locations – operating and display unit 1611
14 2 Removing and installing display unit for front information display and operating unit control unit [J685] 1611
15 Other controlling and regulating components 1612
15 1 Removing and installing external air quality and air humidity sensor G935 1612
15 2 Removing and installing ambient temperature sensor [G17] 1612
15 3 Removing and installing humidity sender for air conditioning system [G260] 1613
15 4 Removing and installing left vent temperature sender [G150[ 1613
15 4 1 Removing and installing left vent temperature sender [G150], left-hand drive vehicles 1613
15 4 2 Removing and installing left vent temperature sender [G150], right-hand drive vehicles 1613
15 5 Removing and installing right vent temperature sender [G151] 1614
15 5 1 Removing and installing right vent temperature sender [G151], left-hand drive vehicles 1614
15 5 2 Removing and installing right vent temperature sender [G151], right-hand drive vehicles 1614
15 6 Removing and installing left footwell vent temperature sender [G261] 1615
15 7 Removing and installing right footwell vent temperature sender [G262] 1616
15 8 Removing and installing sensor for interior carbon dioxide concentration [G929] 1616
15 9 Removing and installing heater and air conditioning system control unit [J979] 1617
15 10 Removing and installing vehicle interior temperature sensor [G1090] 1618
D4B80A49E74 Driver assist systems 1619
00 – Technical data 1623
1 Safety information and repair notes 1623
1 1 Safety information 1623
1 2 Repair instructions 1623
2 Electrical components 1624
2 1 Access to diagnoses 1624
98 – Assist systems 1625
1 Safety information and repair notes 1625
1 1 Safety information 1625
1 2 Repair instructions 1625
2 Fitting locations 1626
2 1 Overview of fitting locations – senders, sensors and control units in front section of vehicle 1626
2 2 Overview of fitting locations – senders, sensors and control units in centre section of vehicle 1627
2 3 Overview of fitting locations – senders, sensors and control units in rear section of vehicle 1627
3 Senders/sensors/control units 1630
3 1 Removing and installing front parking aid senders [G252]/[G253]/[G254]/[G255] 1630
3 2 Removing and installing rear parking aid senders [G203]/[G204]/[G205]/[G206] 1631
3 3 Removing and installing front park assist steering senders [G568]/[G569] 1633
3 4 Removing and installing rear park assist steering senders [G716]/[G717] 1634
3 5 Removing and installing adaptive cruise control unit [J428] 1635
3 6 Removing and installing lane change assist control unit [J769]/[J770] 1636
3 7 Removing and installing lane change assist warning lamp in exterior mirror 1637
3 8 Removing and installing left/right overhead view camera R244/R245 1637
3 9 Removing and installing control unit for overhead view camera [J928] 1638
3 9 1 Removing and installing control unit for overhead view camera [J928] 1638
3 9 2 Removing and installing holder for control unit for overhead view camera [J928] 1639
3 10 Removing and installing front camera for driver assist systems [R242] 1640
3 10 1 Removing and installing front camera for driver assist systems [R242] 1640
3 10 2 Removing and installing windscreen heater for front sensors [Z113] 1640
3 11 Removing and installing front overhead view camera R243 1641
3 12 Removing and installing parking aid control unit [J446] 1642
3 13 Removing and installing reversing camera [R189] 1642
3 14 Removing and installing rear overhead view camera [R246] 1643
4 Adaptive cruise control 1644
4 1 Necessity of calibration 1644
4 2 Adjusting/calibrating adaptive cruise control unit 1646
4 2 1 Dynamic calibration of adaptive cruise control 1646
4 2 2 Static calibration of adaptive cruise control 1646
5 Reversing camera system 1650
5 1 Calibrating reversing camera R189 1650
6 Front camera for driver assist systems 1655
6 1 Calibrating front camera for driver assist systems [R242] 1655
6 1 1 Calibrating front camera for driver assist systems R242, dynamic 1655
6 1 2 Calibrating front camera for driver assist systems R242, static 1655
7 Overhead view camera 1663
7 1 Calibrating overhead view camera system 1663
D4B80A49EE2 Brake system 1665
00 – Technical data 1669
1 Safety information and repair notes 1669
1 1 Repair instructions 1669
1 2 Safety information 1669
2 Identification 1670
2 1 Allocation of PR number – brakes 1670
2 1 1 Front brakes 1670
2 1 2 Rear brakes 1670
3 Technical data 1671
3 1 Technical data for brakes 1671
3 1 1 Brake master cylinder and brake servo 1671
3 1 2 Front brakes 1671
3 1 3 Rear brakes 1672
4 Brake test 1673
4 1 Brake check on single-axle roller dynamometer 1673
4 2 Checking electromechanical parking brake 1673
5 Electrical components 1674
5 1 Access to diagnoses 1674
45 – Anti-lock brake system 1676
1 Safety information and repair notes 1676
1 1 Repair instructions 1676
1 2 Safety information 1676
2 Overview of fitting locations 1677
2 1 Overview of fitting locations – ABS/ESP 1677
3 Control unit and hydraulic unit 1679
3 1 Assembly overview – control unit and hydraulic unit 1679
3 1 1 Assembly overview – control unit and hydraulic unit, left-hand drive vehicles 1679
3 1 2 Assembly overview – control unit and hydraulic unit, right-hand drive 1681
3 2 Removing and installing ABS control unit [J104]/ABS hydraulic unit [N55] 1684
3 2 1 Removing and installing ABS control unit [J104]/ABS hydraulic unit [N55], left-hand drive vehicles 1684
3 2 2 Removing and installing ABS control unit [J104]/ABS hydraulic unit [N55], right-hand drive vehicles 1688
3 3 Separating control unit from and connecting to hydraulic unit 1692
3 4 Connecting brake lines to hydraulic unit 1694
3 4 1 Connecting brake lines to hydraulic unit, left-hand drive vehicles 1694
3 4 2 Connecting brake lines to hydraulic unit, right-hand drive vehicles 1696
4 Sensors 1699
4 1 Assembly overview – speed sensor on front axle 1699
4 2 Assembly overview – speed sensors on rear axle 1699
4 3 Removing and installing speed sensor on front axle [G45]/[G47] 1700
4 4 Removing and installing speed sensor on rear axle [G44]/[G46] 1701
4 5 Checking ABS sensor ring 1702
46 – Brakes – mechanism 1703
1 Safety information and repair notes 1703
1 1 Repair instructions 1703
1 2 Safety information 1703
2 Front brake 1704
2 1 Assembly overview – front brake 1704
2 1 1 Assembly overview – front brake 1704
2 2 Removing and installing brake pads 1706
2 2 1 Removing and installing brake pads 1706
2 3 Removing and installing brake caliper 1711
2 3 1 Removing and installing brake caliper 1711
2 4 Removing and installing brake disc 1713
3 Rear brake 1715
3 1 Assembly overview – rear brake, drum brake 1715
3 2 Assembly overview – brake shoes 1717
3 3 Removing and installing brake shoes 1719
4 Parking brake 1727
4 1 Assembly overview – parking brake 1727
4 2 Removing and installing control unit for electromechanical parking brake [J540] 1727
4 3 Removing and installing parking brake motor [V282]/[V283] 1728
5 Brake pedal 1729
5 1 Assembly overview – brake pedal 1729
5 1 1 Assembly overview – brake pedal, left-hand drive vehicles 1729
5 1 2 Assembly overview – brake pedal, right-hand drive vehicles 1730
5 2 Separating brake pedal from brake servo 1732
5 3 Connecting brake pedal to brake servo 1732
5 4 Removing and installing brake pedal 1733
5 4 1 Removing and installing brake pedal, left-hand drive vehicles 1733
5 4 2 Removing and installing brake pedal, right-hand drive vehicles 1734
5 5 Removing and installing mounting bracket 1734
5 5 1 Removing and installing mounting bracket, left-hand drive vehicles 1734
5 5 2 Removing and installing mounting bracket, right-hand drive vehicles 1737
47 – Brakes – hydraulics 1739
1 Safety information and repair notes 1739
1 1 Repair instructions 1739
1 2 Safety information 1739
2 Brake servo and brake master cylinder 1740
2 1 Assembly overview – brake servo/brake master cylinder 1740
2 1 1 Assembly overview – brake servo/brake master cylinder, left-hand drive vehicles 1740
2 1 2 Assembly overview – brake servo/brake master cylinder, right-hand drive vehicles 1742
2 2 Removing and installing brake servo 1744
2 2 1 Removing and installing brake servo [NX6], left-hand drive vehicles 1744
2 2 2 Removing and installing brake servo [NX6], right-hand drive vehicles 1748
3 Hydraulic system 1754
3 1 Bleeding hydraulic system 1754
3 2 Subsequent bleeding of hydraulic system 1755
3 3 Changing brake fluid 1756
3 4 Checking wheel brake cylinder for leaks 1756
3 5 Leak test 1757
D4B80A51728 1 speed gearbox 0MH 1758
00 – Technical data 1762
1 Identification 1762
1 1 Gearbox identification 1762
2 Repair notes 1763
2 1 General repair instructions 1763
3 Technical data 1764
3 1 Allocation gearbox – engine 1764
3 2 Capacities 1764
34 – Controls, housing 1765
1 Removing and installing gearbox 1765
1 1 Removing gearbox 1765
1 2 Installing gearbox 1765
2 Gearbox housing, clutch housing 1766
2 1 Assembly overview – gearbox housing 1766
2 2 Removing and installing cap 1766
3 Gear oil 1768
3 1 Checking gear oil level 1768
39 – Final drive – differential 1770
1 Oil seals 1770
1 1 Assembly overview – seals 1770
1 2 Renewing left seal 1770
1 3 Renewing right oil seal 1772
D4B80A51731 Electric drive 1773
00 – Technical data 1779
1 Safety information 1779
1 1 Safety measures for working on vehicles with high-voltage system 1779
1 2 Safety precautions when working in the vicinity of high-voltage components 1780
1 3 Safety precautions when using testers and measuring instruments during a road test 1780
1 4 Safety precautions when working on the cooling system 1780
2 Identification 1781
2 1 Engine number/engine data 1781
3 Repair instructions 1782
3 1 Contact corrosion 1782
3 2 Routing and attachment of lines 1782
3 3 Fitting radiator and condensers 1782
3 4 Using impact drivers 1782
3 5 Rules for cleanliness 1783
4 Hazard classification of high-voltage system 1784
10 – Removing and installing engine 1791
1 Removing and installing rear motor 1791
1 1 Assembly overview – motor 1791
1 2 Removing engine 1793
1 3 Securing engine on engine and gearbox support 1800
1 4 Installing engine 1804
2 Rear assembly mountings 1809
19 – Cooling 1810
1 Cooling system/coolant 1810
1 1 Connection diagram – coolant hoses 1810
1 1 1 Connection diagram – coolant hoses, vehicles with R1234yf refrigerant 1810
1 1 2 Connection diagram – coolant hoses, vehicles with R744 refrigerant 1811
1 2 Overview of fitting locations – cooling system 1812
1 3 Assembly overview – cooling system 1814
1 4 Checking cooling system for leaks 1818
1 5 Draining coolant 1821
1 6 Filling cooling system 1822
1 7 Checking filling quality 1832
1 8 Removing and installing coolant expansion tank 1834
2 Coolant pump, regulation of cooling system 1837
2 1 Assembly overview – electric coolant pump 1837
2 2 Removing and installing coolant pump for high-voltage battery -V590- 1838
2 3 Removing and installing coolant pump for low-temperature circuit -V468- 1840
2 4 Assembly overview – coolant valves 1841
2 5 Removing and installing mixing valve for high-voltage battery pre-heating -V683- 1842
2 6 Removing and installing temperature sensor -G18- 1845
2 7 Removing and installing coolant temperature sender 1 for high-voltage battery -G898- 1845
2 8 Removing and installing coolant temperature sender 2 for high-voltage battery -G899- 1847
3 Radiator, radiator fan 1849
3 1 Assembly overview – radiator/radiator fan 1849
3 2 Assembly overview – radiator cowl and radiator fan 1849
3 3 Removing and installing radiator module 1850
3 4 Dismantling and assembling radiator module 1852
3 5 Removing and installing radiator cowl with radiator fan 1855
3 6 Removing and installing radiator fan -V7- 1856
3 7 Removing and installing control motor for radiator roller blind -V711- 1857
93 – Electric drive systems 1859
1 High-voltage components 1859
1 1 Overview of fitting locations – high-voltage components 1859
2 Warning stickers 1860
2 1 Checking warning stickers 1860
3 High-voltage battery unit 1865
3 1 Visual inspection of high-voltage battery 1 -AX2- 1865
3 2 Diagnosis of high-voltage battery 1 -AX2- 1866
3 3 Leakage test of high-voltage battery 1 -AX2- 1866
3 4 Searching for leaks from high-voltage battery 1867
3 5 Removing and installing high-voltage battery 1 -AX2- 1867
3 5 1 Removing and installing high-voltage battery 1 -AX2- 48, 55, 62 kWh 1867
3 5 2 Removing and installing high-voltage battery 1 -AX2-, 82 kWh 1878
3 6 Raising high-voltage battery 1 -AX2- 1887
3 7 Opening high-voltage battery 1 -AX2- 1890
3 8 Closing high-voltage battery 1 -AX2- 1891
3 9 Voltage and insulation measurement 1896
3 10 Opening electrical circuit 1898
3 10 1 Opening electrical circuit, 48, 55 kWh 1898
3 10 2 Opening electrical circuit, 62 kWh 1900
3 10 3 Opening electrical circuit, 82 kWh 1902
3 11 Removing and installing switching unit for high-voltage battery 1905
3 11 1 Removing and installing switching unit for high-voltage battery, 48, 55, 62 kWh 1905
3 11 2 Removing and installing switching unit for high-voltage battery, 82 kWh 1907
3 12 Removing and installing battery regulation control unit -J840- 1910
3 13 Charging and discharging battery modules 1911
3 14 Renewing lower part of battery housing 1912
4 High-voltage battery components 1914
4 1 Overview of fitting locations – battery modules 1914
4 1 1 Overview of fitting locations – battery modules, 48, 55 kWh 1914
4 1 2 Overview of fitting locations – battery modules, 62 kWh 1915
4 1 3 Overview of fitting locations – battery modules, 82 kWh 1916
4 2 Assembly overview – high-voltage battery 1918
4 2 1 Assembly overview – high-voltage battery, 48, 55, 62 kWh, in situ 1918
4 2 2 Assembly overview – high-voltage battery, 82 kWh, in situ 1920
4 2 3 Assembly overview – high-voltage battery, removed 1922
4 2 4 Assembly overview – high-voltage battery, battery modules 1922
4 2 5 Assembly overview – high-voltage battery, connection diagram for battery modules 1923
4 2 6 Assembly overview – high-voltage battery, 48, 55, 62 kWh, switching unit 1924
4 2 7 Assembly overview – high-voltage battery, 82 kWh, switching unit 1925
4 2 8 Assembly overview – high-voltage battery, connecting element 1926
4 3 Removing battery module 1929
4 4 Installing battery module 1934
4 5 Removing and installing battery modules control unit 1939
4 6 Removing and installing connecting element 1941
4 6 1 Removing and installing connecting element, 48, 55 kWh 1941
4 6 2 Removing and installing connecting element, 62 kWh 1944
4 6 3 Removing and installing connecting element, 82 kWh 1946
4 7 Removing and installing switching unit for high-voltage battery, negative terminal -SX7- 1949
4 7 1 Removing and installing switching unit for high-voltage battery, negative terminal -SX7-, 48, 55, 65 kWh 1949
4 7 2 Removing and installing switching unit for high-voltage battery, negative terminal -SX7-, 82 kWh 1951
4 8 Removing and installing switching unit for high-voltage battery, positive terminal -SX8- 1953
4 8 1 Removing and installing switching unit for high-voltage battery, positive terminal -SX8-, 48, 55, 62 kWh 1953
4 8 2 Removing and installing switching unit for high-voltage battery, positive terminal -SX8-, 82 kWh 1955
5 Power and control electronics for electric drive 1957
5 1 Assembly overview – power and control electronics for electric drive 1957
5 2 Removing and installing power and control electronics for electric drive 1957
6 Electric drive motor 1966
6 1 Assembly overview – electric drive motor 1966
6 2 Calibrating three-phase current drive -VX54- 1968
6 3 Removing and installing drive motor rotor position sender 1 -G713- 1968
6 4 Leak testing of electric drive motor 1969
7 Engine control unit 1979
7 1 Assembly overview – motor control unit 1979
7 2 Removing and installing engine control unit -J623- 1979
7 3 Removing and installing bracket for engine/motor control unit -J623- 1980
8 De-energising high-voltage system 1981
9 Re-energising high-voltage system 1983
10 Potential equalisation lines 1984
10 1 Overview of fitting locations – potential equalisation lines 1984
11 Charging socket 1985
11 1 Assembly overview – charging socket 1985
11 1 1 Assembly overview – charging socket, AC/DC charging socket Combo 2 1985
11 2 Removing and installing high-voltage battery charging socket 1 -UX4- 1986
11 2 1 Removing and installing high-voltage battery charging socket 1 -UX4- 1986
11 3 Manual release mechanism for charging socket 1988
11 3 1 Removing and installing actuator for high-voltage charging socket lock 1 -F498- 1988
12 Charging unit for high-voltage battery 1990
12 1 Assembly overview – charging unit for high-voltage battery 1990
12 2 Removing and installing charging unit 1 for high-voltage battery -AX4- 1990
13 Vehicle noise/engine sound 1996
13 1 Overview of fitting locations – vehicle noise/engine sound 1996
13 2 Removing and installing engine sound generator module 1 -RX21- 1996
14 Accelerator pedal 1998
14 1 Assembly overview – accelerator module 1998
14 2 Removing and installing accelerator pedal module -GX2- 1998
15 Voltage converter -A19- 2000
15 1 Assembly overview – voltage converter -A19- 2000
15 2 Removing and installing voltage converter -A19- 2000
D4B80A83477 Wheels and Tyres Guide 2002
44 – Wheels, tyres, vehicle geometry 2006
1 General information 2006
2 Wheels, tyres 2007
2 1 Tightening torque for wheel bolts 2007
3 Wheel and tyre combinations 2008
3 1 Determining the correct wheel and tyre combinations according to WLTP 2008
3 2 Breakdown of version key (D2) 2010
3 2 1 Version key (D2) type approval number (K): e1*2007/46*2033*00 2010
3 2 2 Version key (D2) type approval number (K): e1*2007/46*2033*01 2010
3 2 3 Version key (D2) type approval number (K): e1*2007/46*2033*02 2010
3 2 4 Version key (D2) type approval number (K): e1*2007/46*2033*03 to e1*2007/46*2033*08 2011
3 2 5 Version key (D2) type approval number (K): e1*2007/46*2033*09 to e1*2007/46*2033*11 2011
3 3 Possible wheel and tyre combinations 2012
3 3 1 Type approval number (K): e1*2007/46*2033*00 2012
3 3 2 Type approval number (K): e1*2007/46*2033*01 2012
3 3 3 Type approval number (K): e1*2007/46*2033*02 2013
3 3 4 Type approval number (K): e1*2007/46*2033*03 and e1*2007/46*2033*04 2014
3 3 5 Type approval number (K): e1*2007/46*2033*05 2015
3 3 6 Type approval no (K): e1*2007/46*2033*06 to e1*2007/46*2033*08 2016
3 3 7 Type approval no (K): e1*2007/46*2033*09 to e1*2007/46*2033*11 2017
3 4 Wheel assignment 2019
3 4 1 7 5 J X 18 offset 50 2019
3 4 2 7 5 J X 19 offset 50 2020
3 4 3 7 5 J x 20 offset 44 2020
3 5 Temporary spare wheel 2021
D4B807E3B5B Body Repairs General Body Repairs 2022
1 Safety instructions 2026
1 1 Part removal 2026
1 2 Battery and welding operation 2026
1 3 Electronic control unit 2026
1 3 1 Processing of the electronic control unit after repair dueto a traffic accident 2026
1 4 Paint, glass, soft pad and trim 2027
1 5 Fuel tank or fuel delivery pipeline 2027
1 6 Air conditioner 2027
1 6 1 Remedial measures: 2027
1 7 Airbag System 2028
1 8 Check the seat belts 2028
1 8 1 Belt body 2029
1 8 2 Automatic retractor (locking function) 2029
1 8 3 Visual inspection of the seat belt buckle 2030
1 8 4 Seat belt buckle function 2030
1 8 5 Seat belt guide member and tongue 2031
1 8 6 Fixing piece and fixing point 2031
1 9 Safety specifications for the seat belt tensioner 2031
1 10 Body repair on a vehicle equipped with the seat belt tensioners 2032
1 10 1 The following vehicles have been equipped with: 2032
1 11 Perform cutting off, correcting and/or leveling on a vehicleequipped with airbags 2033
1 12 Remove the front seats with a side airbag 2033
2 Basic instruction 2034
2 1 Diagnosis of the accident vehicle 2034
2 2 Condition of the body and/or the parts for delivery to thepainting workshop 2034
2 3 Correction 2034
2 4 Cutting 2034
2 5 Body-cut part and part section 2034
2 6 Original connection 2035
2 7 Galvanized body parts 2035
2 8 Remove the rest part 2035
2 9 New parts 2035
2 10 Parts 2035
2 11 Molded foam plastic pads 2036
3 Symbolic interpretation 2037
3 1 Symbolic interpretation for welding 2037
3 2 Symbolic interpretation for the operation method 2037
3 2 1 Grinding 2038
3 2 2 Thinning 2038
3 2 3 Punching 2038
3 2 4 Drilling 2039
3 2 5 Polishing 2039
3 2 6 Cavity corrosion protection 2039
3 2 7 Bonding 2040
3 2 8 Precise sealing 2040
4 Body repair tools 2041
4 1 Flaring tool -V A G 1317- 2041
4 2 Punching pliers -V A G 1329- 2041
4 3 Basic equipment -V A G 1366/3- 2041
4 4 Bottom protection layer spray gun -V A G 1379- 2042
4 5 Electric blower -V A G 1416- 2042
4 6 Door tensioner -V A G 1438- 2042
4 7 Body equipment component -V A G 1439- 2043
4 8 Pneumatic cutting knife -V A G 1523 A- 2043
4 9 Air chisel -V A G 1577- 2043
4 10 Edge closing iron block -V A G 1585- 2044
4 11 Welding fume ventilator -V A G 1586- 2044
4 12 Welding spot releasing device -V A G 1731- 2044
4 13 Pneumatic spray gun -V A G 1761/1- 2045
4 14 Pneumatic punching and thinning pliers -VAS 1996- 2045
4 15 Pneumatic adhesive spray gun -V A G 2005- 2045
4 16 Door hinge correction tool 2046
4 17 Hose kit 5023 for the inert gas protection welding 2046
4 18 Angle grinder -VAS 5174- 2046
4 19 Angle grinder -VAS 5175- 2047
4 20 Wire brush -VAS 5182- 2047
5 Body bonding 2048
5 1 Transporter 1991 → 2048
5 1 1 Separation process: 2048
5 1 2 Bonding process: 2048
5 2 Bonding types 2048
5 2 1 Bonding-strong 2048
5 2 2 Bonding-spot welding 2049
5 3 Repair method for replacing the parts 2049
5 3 1 Spot welding and bonding 2049
5 3 2 Plug welding and bonding (if spot welding is impossible) 2049
5 3 3 Welding fume ventilator 2050
5 3 4 Preparations 2050
5 3 5 Trimming 2050
6 Corrosion protection measures 2051
6 1 Corrosion protection 2051
7 Waste disposal instructions 2052
7 1 Waste disposal 2052
7 2 Air pressure tappet exhaust 2052
7 3 Airbag 2053
7 3 1 Waste disposal 2053
8 Contact corrosion protection 2054
8 1 Connection of aluminum alloy/magnesium alloy with steel 2054
9 Steel plate repair 2055
9 1 High-strength body plate 2055
9 2 Galvanized body parts 2055
9 2 1 Preparations 2055
9 2 2 Part cutting 2056
9 2 3 Connection process 2056
9 3 Welding on the galvanized body steel plate 2056
9 3 1 Inert gas protection plug welding SG of the galvanized steelplate 2056
9 3 2 Resistance pressure spot welding RP of the galvanized steelplate 2057
9 3 3 Welding transformer 2057
9 3 4 Welding clamp 2057
9 4 Tearing test 2057
10 Aluminum repair 2058
10 1 Painting 2058
10 2 Surface treatment 2058
10 3 Leveling 2059
10 4 Temperature control for heating 2059
11 Plastic repair method 2060
11 1 Material 2060
11 2 Repairing the pit 2061
11 3 Repairing the scratch 2062
11 4 Repair the crack 2064
11 5 Repairing the small hole (the diameter is more than 30 mm) 2065
11 6 Plastic repair (glass fibre material) 2066
11 7 Repair process 2067
11 7 1 Repairing the breakage position 2067
11 7 2 Repairing the surface damage 2069
12 Glass repair 2070
12 1 Repairing the windshield 2070
12 1 1 Premises 2070
12 1 2 Required special tools, operating equipment, testing instrumentsand auxiliary tools 2071
12 1 3 Repair description 2072
D4B80609EAF Air conditioning systems with refrigerant R1234yf – General information 2076
00 – Technical data 2082
1 Safety information 2082
1 1 Safety precautions when working on air conditioning systems 2082
1 2 Safety precautions when handling refrigerants 2083
1 3 Safety measures when working on vehicles with a start/stop system 2083
1 4 Safety precautions when using air conditioner service stations 2083
1 5 Safety measures for working on vehicles with high-voltage system 2084
1 6 Safety precautions when working in the vicinity of high-voltage components 2085
1 7 Safety precautions when working on pressure vessels 2085
2 Laws and regulations 2086
2 1 Legal regulations and standards 2086
2 2 Charging refrigerant circuit with different refrigerants 2087
2 3 Occupational health and safety 2088
3 Repair notes 2089
3 1 Rules for cleanliness 2089
3 2 Refrigerant circuit seals 2089
3 3 Refrigerant and refrigerant oil 2090
3 3 1 Important repair notes for refrigerant and refrigerant oil 2090
3 3 2 Refrigerant oil 2091
3 4 Handling pressure vessels 2092
3 5 Handling refrigerants 2093
4 Identification 2095
4 1 Notice for refrigerant circuit 2095
5 Technical data 2096
5 1 Refrigerant capacity 2096
5 2 Refrigerant oil capacities 2096
5 3 Safety data sheets 2096
6 Basic technical and physical properties 2097
6 1 Basics of air conditioning technology 2097
6 1 1 Physical properties of air conditioning system 2097
6 1 2 Pressure and boiling point of refrigerant 2098
6 1 3 Vapour pressure table for refrigerant 2099
6 2 Physical properties 2101
6 2 1 Refrigerant R1234yf 2101
6 2 2 Potential risks with refrigerant R1234yf 2101
6 2 3 Physical and chemical properties of refrigerant R1234yf 2102
6 2 4 Critical point 2102
6 2 5 Environmental aspects of refrigerant R1234yf 2103
6 2 6 Trade names and designations of refrigerant R1234yf 2103
6 2 7 Colour and odour of R1234yf refrigerant 2104
6 2 8 Vapour pressure of R1234yf refrigerant 2104
6 2 9 Physical properties of R1234yf refrigerant 2104
6 2 10 How R1234yf refrigerant reacts to metals and plastics 2104
6 2 11 Critical temperature / critical pressure of R1234yf refrigerant 2105
6 2 12 Water content of R1234yf refrigerant 2105
6 2 13 Flammability / decomposition of R1234yf refrigerant 2105
6 2 14 Charge factor of refrigerant R1234yf 2105
6 2 15 Evidence of leaks in a refrigerant circuit with R1234yf refrigerant 2106
6 2 16 Analysis of refrigerant R1234yf 2106
6 2 17 Returning contaminated R1234yf refrigerant for analysis, processing or disposal 2107
6 3 Product characteristics 2108
6 4 Function and role of air conditioning system 2108
6 4 1 Principle of operation 2108
6 4 2 Comfort 2109
6 4 3 Environmental aspects 2109
6 5 Other reference material 2110
87 – Air conditioning system 2111
1 Refrigerant circuit 2111
1 1 System overview – refrigerant circuit 2111
1 1 1 System overview – refrigerant circuit with expansion valve and receiver 2111
1 1 2 System overview – refrigerant circuit with restrictor and reservoir 2113
1 1 3 System overview – refrigerant circuit with electrically driven air conditioner compressor (with and without battery cooling module) 2114
1 2 General description – components of refrigerant circuit 2117
1 2 1 Layout and function of refrigerant circuit 2117
1 2 2 Mechanical air conditioner compressor 2118
1 2 3 Electrical air conditioner compressor for hybrid vehicles 2121
1 2 4 Condenser 2124
1 2 5 evaporator 2125
1 2 6 Reservoir 2127
1 2 7 Heat exchanger for heat pump mode 2127
1 2 8 Liquid receiver 2128
1 2 9 Restrictor 2128
1 2 10 Receiver 2130
1 2 11 Expansion valve (with and without shut-off valve) 2132
1 2 12 Refrigerant shut-off valves 2134
1 2 13 Refrigerant line with internal heat exchanger 2136
1 2 14 Quick release couplings of refrigerant lines 2137
1 2 15 Seals 2138
1 2 16 Pipes and hoses in refrigerant circuit 2139
1 2 17 High-pressure safety valve 2139
1 2 18 Non-return valves 2141
1 2 19 Quick-release coupling connections in refrigerant circuit 2142
1 2 20 Connections with valve for switches in refrigerant circuit 2146
1 2 21 Pressure senders and switches in refrigerant circuit 2147
1 2 22 Refrigerant pressure and temperature sender 2148
1 2 23 Air conditioner compressor regulating valve -N280- 2151
1 2 24 Refrigerant temperature sender 2152
1 3 Possible complaints 2153
1 3 1 Prerequisites for investigating a complaint 2153
1 3 2 Possible complaints 2153
1 3 3 Odours from heater and air conditioning unit 2155
1 4 Investigating leaks 2157
1 4 1 General information about investigating leaks in the refrigerant circuit 2157
1 4 2 Searching for leaks in refrigerant circuits using an electronic leak detector 2158
1 4 3 Searching for leaks with UV leak detection system 2159
1 4 4 Detecting leaks in a vacuum test using air conditioner service station, or in a pressure test 2165
1 4 5 Detecting leaks in a pressure test (with nitrogen or compressed air) 2166
1 5 Renewing components 2168
1 5 1 General information about renewing components 2168
1 5 2 Renewing leaking or damaged components of empty refrigerant circuit (apart from air conditioner compressor and receiver) 2169
1 5 3 Renewing leaking or damaged components of charged refrigerant circuit (apart from air conditioner compressor and receiver) 2171
1 5 4 Renewing air conditioner compressor with no need to clean refrigerant circuit 2172
1 5 5 Renewing air conditioner compressor due to leaks or internal damage 2175
1 5 6 Renewing desiccant cartridge / receiver after cleaning refrigerant circuit 2176
1 5 7 Renewing receiver with no need to clean refrigerant circuit 2178
1 5 8 Renewing desiccant cartridge / desiccant bag with no need to clean refrigerant circuit 2179
1 6 Cleaning refrigerant circuit 2180
1 6 1 General information about cleaning refrigerant circuit 2180
1 6 2 Preparations for cleaning refrigerant circuit (flushing with R1234yf refrigerant) 2182
1 6 3 Refrigerant circuit cleaning procedure 2186
1 6 4 Principle circuit diagrams for cleaning (flushing circuits) – refrigerant circuit with expansion valve and receiver 2186
1 6 5 Principle circuit diagrams for cleaning (flushing circuits) – refrigerant circuit with restrictor and receiver (without high-voltage system) 2191
1 6 6 Adapters for setting up flushing circuits 2194
1 6 7 General information about blowing through with compressed air or nitrogen 2207
1 6 8 Blowing through refrigerant circuit with compressed air or nitrogen 2211
1 7 Checking pressures with pressure gauge 2212
1 7 1 Display on pressure gauges 2212
1 7 2 Pressure gauges enable the following test and measurement work 2213
2 Working with air conditioner service station 2216
2 1 Working with air conditioner service station 2217
2 2 Connecting air conditioner service station to refrigerant circuit 2219
2 3 Performing gas analysis of refrigerant 2222
2 4 Purging refrigerant circuit 2225
2 5 Evacuating refrigerant circuit 2228
2 6 Charging refrigerant circuit 2234
2 7 Bringing air conditioning system into service after charging 2237
2 8 Switching off air conditioner service station and separating from refrigerant circuit 2239
2 9 Charging refrigerant in reservoir 2241
2 10 Emptying air conditioner service station 2242
2 11 Cleaning electrical air conditioning compressor 2242
2 12 Cleaning refrigerant circuit 2245
2 13 Filling contaminated refrigerant in a recycling cylinder for analysis, processing or disposal 2248
2 13 1 Filling contaminated refrigerant into recycling cylinder using extraction unit -VAS 581 011- 2248
2 13 2 Filling contaminated refrigerant into recycling cylinder using extraction unit -VAS 581 007- 2249
2 14 Checking pressures 2253
2 14 1 General information on checking pressures in the refrigerant circuit 2253
2 14 2 Pressures and temperatures in refrigerant circuit 2255
2 14 3 Checking pressures in the refrigerant circuit with the ignition switched off 2259
2 14 4 Checking pressures with air conditioning system switched on – vehicles with mechanical air conditioning compressor 2266
2 14 5 Checking pressures with air conditioning system switched on – vehicles with electrical air conditioning compressor 2288
3 Testing equipment and tools 2341
3 1 Tools and materials available from distribution centre or importer 2341
3 2 Tools and materials available commercially 2341
D4D807A125B 1 speed gearbox 0MH rear 2343
00 – Technical data 2347
1 Safety information and repair notes 2347
1 1 Safety information 2347
1 2 Repair instructions 2347
2 Identification 2348
2 1 Gearbox identification 2348
3 Technical data 2349
3 1 Allocation gearbox ? motor 2349
3 2 Capacities 2349
34 – Controls, housing 2350
1 Safety information and repair notes 2350
1 1 Safety information 2350
1 2 Repair instructions 2350
2 Removing and installing gearbox 2351
2 1 Removing gearbox 2351
2 2 Installing gearbox 2351
3 Gearbox housing, clutch housing 2352
3 1 Assembly overview – gearbox housing 2352
3 2 Removing and installing cap 2352
4 Gear oil 2354
4 1 Checking gear oil level 2354
39 – Final drive – differential 2356
1 Safety information and repair notes 2356
1 1 Safety information 2356
1 2 Repair instructions 2356
2 Seals 2357
2 1 Assembly overview ? seals 2357
2 2 Renewing left seal 2357
2 3 Renewing right seal 2358
D4D807B3D51 Electric rear wheel drive EIP220 and all wheel drive EIA200 EIP220 2359
00 – Technical data 2365
1 Safety information and repair notes 2365
1 1 Safety information 2365
1 2 Repair instructions 2365
2 Identification 2366
2 1 Motor designation 2366
2 2 Motor data 2367
2 2 1 Motor data EBJA 2367
2 2 2 Motor data EBJC 2367
2 2 3 Motor data EBJD 2368
2 2 4 Motor data EBRA 2368
3 Electrical components 2369
3 1 Access to diagnoses 2369
4 Hazard classification of high-voltage system 2371
4 1 Classification of dangers of the high-voltage system 2371
10 – Removing and installing engine 2380
1 Safety information and repair notes 2380
1 1 Safety information 2380
1 2 Repair instructions 2380
2 Removing and installing front motor 2381
2 1 Assembly overview – front motor 2381
2 1 1 Assembly overview – front motor, left-hand drive vehicles 2381
2 1 2 Assembly overview – front motor, right-hand drive vehicles 2384
2 2 Removing front motor 2387
2 2 1 Removing front motor, left-hand drive vehicles 2387
2 2 2 Removing front motor, right-hand drive vehicles 2388
2 3 Securing motor to engine and gearbox support, front motor 2390
2 4 Installing front motor 2392
2 4 1 Installing front motor, left-hand drive vehicles 2392
2 4 2 Installing front motor, right-hand drive vehicles 2394
3 Removing and installing rear motor 2397
3 1 Assembly overview – rear motor 2397
3 2 Removing rear motor 2399
3 3 Securing motor to engine and gearbox support, rear motor 2404
3 4 Installing rear motor 2407
4 Front assembly mountings 2411
4 1 Removing and installing motor mountings 2411
4 2 Removing and installing gearbox mountings 2411
5 Rear assembly mountings 2412
5 1 Removing and installing assembly mountings 2412
19 – Cooling 2413
1 Safety information and repair notes 2413
1 1 Safety information 2413
1 2 Repair instructions 2413
2 Cooling system/coolant 2414
2 1 Connection diagram – coolant hoses, refrigerant R744 2414
2 1 1 Connection diagram – coolant hoses, rear-wheel drive 2414
2 1 2 Connection diagram – coolant hoses, four-wheel drive 2414
2 2 Connection diagram – coolant hoses, refrigerant R1234yf 2415
2 2 1 Connection diagram – coolant hoses, rear-wheel drive 2415
2 2 2 Connection diagram – coolant hoses, four-wheel drive 2416
2 3 Overview of fitting locations – cooling system, rear-wheel drive 2417
2 3 1 Overview of fitting locations – cooling system 2417
2 4 Overview of fitting locations – cooling system, all-wheel drive 2419
2 4 1 Overview of fitting locations – cooling system 2419
2 5 Assembly overview – cooling system, rear-wheel drive 2421
2 5 1 Assembly overview – cooling system 2421
2 6 Assembly overview – cooling system, all-wheel drive 2426
2 6 1 Assembly overview – cooling system 2426
2 7 Checking cooling system for leaks 2431
2 8 Removing and installing coolant expansion tank 2434
2 9 Checking filling quality 2435
2 10 Draining coolant 2437
2 10 1 Draining coolant 2437
2 10 2 Draining coolant with cooling system service unit VAS 531 011 2439
2 11 Filling cooling system 2441
2 11 1 Filling cooling system with cooling system charge unit VAS 6096 2441
2 11 2 Filling cooling system with cooling system service unit VAS 531 011 2448
3 Coolant pump/coolant regulation 2450
3 1 Assembly overview – electric coolant pump 2450
3 2 Assembly overview – coolant valves 2450
3 3 Exploded view – coolant temperature senders 2451
3 4 Removing and installing coolant pump for high-voltage battery [V590], rear-wheel drive 2453
3 4 1 Removing and installing coolant pump for high-voltage battery V590 2453
3 5 Removing and installing coolant pump for high-voltage battery [V590], all-wheel drive 2455
3 5 1 Removing and installing coolant pump for high-voltage battery V590 2455
3 6 Removing and installing coolant pump for low-temperature circuit V468 2456
3 7 Removing and installing mixing valve for high-voltage battery pre-heating [V683] 2457
3 8 Removing and installing mixing valve 2 for high-voltage battery [V696] pre-heating, heat pump 2458
3 8 1 Removing and installing mixing valve 2 for high-voltage battery pre-heating V696 2458
3 9 Removing and installing temperature sensor [G18] 2460
3 10 Removing and installing coolant temperature sender 1 for high-voltage battery G898 2461
3 11 Removing and installing coolant temperature sender 2 for high-voltage battery G899 2462
4 Radiator, radiator fan 2464
4 1 Assembly overview – radiator/radiator fan 2464
4 2 Assembly overview – radiator cowl and radiator fan 2464
4 3 Removing and installing radiator module 2465
4 4 Dismantling and assembling radiator module 2467
4 5 Removing and installing radiator cowl with radiator fan 2471
4 6 Removing and installing radiator fan [VX57] 2472
4 7 Removing and installing control motor for radiator roller blind [V711], ID 3 2473
4 7 1 Removing and installing control motor for radiator roller blind [V711] 2473
4 8 Removing and installing control motor for radiator roller blind [V711], ID 4 2474
4 8 1 Removing and installing control motor for radiator roller blind [V711] 2474
93 – Electric drive systems 2476
1 Safety information and repair notes 2476
1 1 Safety information 2476
1 2 Repair instructions 2476
2 High-voltage components 2477
2 1 Overview of fitting locations – high-voltage components, all-wheel drive 2477
2 1 1 Overview of fitting locations – high-voltage components 2477
2 2 Overview of fitting locations – high-voltage components, rear-wheel drive 2479
2 2 1 Overview of fitting locations – high-voltage components 2479
3 Warning stickers 2482
3 1 Checking warning stickers 2482
3 1 1 Checking warning stickers 2482
3 2 Checking warning stickers 2487
3 2 1 Checking warning stickers 2487
4 High-voltage battery unit 2493
4 1 Assembly overview – high-voltage battery, installed, 48, 55, 62 kWh 2493
4 1 1 Assembly overview – high-voltage battery, installed 2493
4 2 Assembly overview – high-voltage battery, installed, 82 kWh 2494
4 2 1 Assembly overview – high-voltage battery, installed 2494
4 3 Visual inspection of high-voltage battery 1 [AX2] 2496
4 4 Diagnosis of high-voltage battery 1 [AX2] 2496
4 5 Checking high-voltage battery for leaks 2496
4 6 Leakage test of high-voltage battery 1 [AX2] 2497
4 7 Removing and installing high-voltage battery 1 [AX2], 48, 55, 62 kWh 2498
4 7 1 Removing and installing high-voltage battery 1 [AX2] 2498
4 8 Removing and installing high-voltage battery 1 [AX2], 82 kWh 2508
4 8 1 Removing and installing high-voltage battery 1 [AX2] 2508
4 9 Raising high-voltage battery 1 [AX2] 2518
4 10 Opening high-voltage battery 1 AX2 2520
4 11 Sealing high-voltage battery 1 [AX2], 48, 55, 62 kWh 2521
4 11 1 Sealing high-voltage battery 1 [AX2] 2521
4 12 Sealing high-voltage battery 1 [AX2], 82 kWh 2524
4 12 1 Sealing high-voltage battery 1 [AX2] 2524
4 13 Voltage and insulation measurement, 48, 55, 62 kWh 2526
4 13 1 Voltage and insulation measurement 2526
4 14 Voltage and insulation measurement, 82 kWh 2529
4 14 1 Voltage and insulation measurement 2529
4 15 Opening electrical circuit, 48, 55 kWh 2531
4 15 1 Interrupting electrical circuit 2531
4 16 Opening electrical circuit, 62 kWh 2534
4 16 1 Opening electrical circuit 2534
4 17 Opening electrical circuit, 82 kWh 2537
4 17 1 Interrupting electrical circuit 2537
4 18 Removing and installing battery regulation control unit [J840] 2540
4 19 Charging and discharging battery modules 2541
4 20 Checking whether upper part of battery housing can be reused 2542
4 21 Renewing lower part of battery housing 2544
4 22 Renewing high-voltage battery 1 [AX2] 2546
5 High-voltage battery components 2548
5 1 Overview of fitting locations – battery modules, 48, 55 kWh 2548
5 1 1 Overview of fitting locations – battery modules 2548
5 2 Overview of fitting locations – battery modules, 62 kWh 2549
5 2 1 Overview of fitting locations – battery modules 2549
5 3 Overview of fitting locations – battery modules, 82 kWh 2551
5 3 1 Overview of fitting locations – battery modules 2551
5 4 Overview of fitting locations – battery connectors 2553
5 5 Assembly overview – high-voltage battery, removed, 48, 55, 62 kWh 2553
5 5 1 Assembly overview – high-voltage battery, removed 2553
5 6 Assembly overview – high-voltage battery, removed, 82 kWh 2556
5 6 1 Assembly overview – high-voltage battery, removed 2556
5 7 Assembly overview – high-voltage battery, battery modules 2559
5 8 Assembly overview – switching unit for high-voltage battery, 48, 55, 62 kWh 2560
5 8 1 Assembly overview – switching unit for high-voltage battery 2560
5 9 Assembly overview – switching unit for high-voltage battery, 82 kWh 2561
5 9 1 Assembly overview – switching unit for high-voltage battery 2561
5 10 Assembly overview – high-voltage battery, connecting element, 48, 55, 62 kWh 2562
5 10 1 Assembly overview – high-voltage battery, connector strip 2562
5 11 Assembly overview – high-voltage battery, connecting element, 82 kWh 2564
5 11 1 Assembly overview – high-voltage battery, connector strip 2564
5 12 Removing battery module 2565
5 13 Installing battery module 2569
5 14 Removing and installing battery modules control unit 2572
5 15 Removing and installing connecting element, 48, 55 kWh 2574
5 15 1 Removing and installing connector strip 2574
5 16 Removing and installing connecting element, 62 kWh 2576
5 16 1 Removing and installing connector strip 2576
5 17 Removing and installing connecting element, 82 kWh 2578
5 17 1 Removing and installing connector strip 2578
5 18 Removing and installing switching unit for high-voltage battery, negative terminal [SX7], 48, 55, 62 kWh 2581
5 18 1 Removing and installing switching unit for high-voltage battery, negative terminal SX7 2581
5 19 Removing and installing switching unit for high-voltage battery, negative terminal [SX7], 82 kWh 2583
5 19 1 Removing and installing switching unit for high-voltage battery, negative terminal SX7 2583
5 20 Removing and installing switching unit for high-voltage battery, positive terminal [SX8], 48, 55, 62 kWh 2585
5 20 1 Removing and installing switching unit for high-voltage battery, positive terminal SX8 2585
5 21 Removing and installing switching unit for high-voltage battery, positive terminal [SX8], 82 kWh 2587
5 21 1 Removing and installing switching unit for high-voltage battery, positive terminal SX8 2587
6 Power and control electronics for electric drive 2589
6 1 Assembly overview – power and control electronics for electric drive, rear-wheel drive 2589
6 1 1 Assembly overview – power and control electronics for electric drive [JX1] 2589
6 2 Assembly overview – power and control electronics for electric drive, all-wheel drive 2589
6 2 1 Assembly overview – power and control electronics 2 for electric drive [JX4] 2589
6 2 2 Assembly overview – power and control electronics for electric drive [JX1] 2589
6 3 Removing and installing power and control electronics for electric drive, rear-wheel drive 2589
6 3 1 Removing and installing power and control electronics for electric drive [JX1] 2589
6 4 Removing and installing power and control electronics for electric drive, all-wheel drive 2601
6 4 1 Removing and installing power and control electronics for electric drive [JX1] 2601
6 4 2 Removing and installing power and control electronics 2 for electric drive [JX4] 2611
7 Electric drive motor 2616
7 1 Calibrating three-phase current drive [VX54- 2616
7 2 Leak test for rear electric drive motor 2616
7 3 Assembly overview – electric drive motor 2625
7 3 1 Assembly overview – electric drive motor, rear motor 2625
7 3 2 Assembly overview – electric drive motor, front motor 2627
7 4 Removing and installing drive motor rotor position sender, rear-wheel drive 2630
7 4 1 Removing and installing drive motor rotor position sender 1 [G713] 2630
7 5 Removing and installing drive motor rotor position sender, all-wheel drive 2631
7 5 1 Removing and installing drive motor rotor position sender 1 [G713] 2631
7 5 2 Removing and installing rotor position sender 1 for drive motor 2 [G1147] 2633
8 Motor control unit 2637
8 1 Assembly overview – motor control unit 2637
8 2 Removing and installing motor control unit [J623] 2637
8 3 Removing and installing bracket for motor control unit [J623] 2638
9 De-energising high-voltage system 2639
9 1 De-energising high-voltage system 2639
10 Re-energise high-voltage system 2640
10 1 Re-energising high-voltage system 2640
11 Potential equalisation lines 2641
11 1 Overview of fitting locations – potential equalisation lines, all-wheel drive 2641
11 1 1 Overview of fitting locations – potential equalisation lines 2641
11 2 Overview of fitting locations – potential equalisation lines, rear-wheel drive 2642
11 2 1 Overview of fitting locations – potential equalisation lines 2642
12 Charging socket 2643
12 1 Assembly overview – charging socket 2643
12 2 Removing and installing high-voltage battery charging socket 1 [UX4] 2643
12 3 Removing and installing actuator for high-voltage charging socket lock 1 [F498] 2646
13 Charging unit for high-voltage battery 2648
13 1 Assembly overview – charging unit for high-voltage battery, rear-wheel drive 2648
13 1 1 Assembly overview – charging unit for high-voltage battery 2648
13 2 Assembly overview – charging unit for high-voltage battery, all-wheel drive 2649
13 2 1 Assembly overview – charging unit for high-voltage battery 2649
13 3 Removing and installing charging unit 1 for high-voltage battery [AX4], rear-wheel drive 2651
13 3 1 Removing and installing charging unit 1 for high-voltage battery [AX4] 2651
13 4 Removing and installing charging unit 1 for high-voltage battery [AX4], all-wheel drive 2655
13 4 1 Removing and installing charging unit 1 for high-voltage battery [AX4] 2655
14 Vehicle noise/engine sound 2659
14 1 Overview of fitting locations – driving sound/motor sound 2659
14 2 Removing and installing engine sound generator module 1 [RX21] 2659
14 3 Removing and installing engine sound generator module 2 [RX22] 2660
14 3 1 Removing and installing engine sound generator module 2 [RX22] 2660
15 Accelerator pedal 2662
15 1 Assembly overview – accelerator module 2662
15 2 Removing and installing accelerator pedal module [GX2] 2662
16 Voltage converter 2664
16 1 Assembly overview – voltage converter, rear-wheel drive 2664
16 1 1 Assembly overview – voltage converter 2664
16 2 Assembly overview – voltage converter, all-wheel drive 2664
16 2 1 Assembly overview – voltage converter 2664
16 3 Removing and installing voltage converter, rear-wheel drive 2665
16 3 1 Removing and installing voltage converter 2665
16 4 Removing and installing voltage converter, all-wheel drive 2668
16 4 1 Removing and installing voltage converter 2668
17 High-voltage cables 2670
17 1 Unplugging high-voltage connectors 2670
D4D807BC2FF Safety information and repair notes 2671
00 – Technical data 2675
1 Safety information 2675
1 1 General safety information 2675
1 2 Safety measures for working on vehicles with high-voltage system 2675
1 3 Safety precautions when working on the cooling system 2676
1 4 Safety precautions when working on air conditioning systems 2677
1 5 Safety measures during road test with testing and measuring instruments 2677
1 6 Safety precautions when working on passenger protection systems 2678
1 7 Safety precautions when working with chemical substances 2679
1 8 Safety precautions when working with compressed gas cylinders 2679
1 9 Safety precautions when working with batteries 2679
2 Repair notes 2680
2 1 Laws, specifications, guidelines and risk assessments 2680
2 2 Notes on the application of the workshop manual 2680
2 3 Spare parts, servicing materials and consumables 2680
2 4 Transport and storage 2682
2 5 Qualification 2683
2 6 Environmental protection 2683
2 7 Rules for cleanliness 2683
2 8 Identification labels 2683
2 9 Bolts and nuts 2684
2 10 Using power tools 2684
2 11 Contact corrosion 2685
2 12 Gaskets and seals 2685
2 13 Bonding surfaces 2686
2 14 Unplugging electrical connectors 2686
2 15 Routing and attachment of lines 2686
2 16 Retaining rings 2687
2 17 Working on refrigerant circuit 2687
2 18 Work on seat occupied recognition for front passenger airbag deactivation 2687
2 19 Battery 2688
2 20 Assessing accident vehicles 2688
2 20 1 Assessing accident vehicles, basic information 2688
2 20 2 Assessing accident vehicles, running gear 2688
2 20 3 Assessing accident vehicles, passenger protection systems 2689
D4D809D5F1A Electrical system General information 2693
27 – Starter, current supply, CCS 2697
1 Battery 2697
1 1 Checking battery 2697
1 1 1 Checking battery, 12 V 2697
1 1 2 Checking open-circuit voltage 2698
1 2 Charging battery 2699
1 2 1 Charging battery 2699
1 2 2 Service charging 2699
1 2 3 Totally discharged batteries 2700
92 – Windscreen wash/wipe system 2702
1 Washer fluid lines 2702
1 1 Pulling off and fitting washer fluid hoses 2702
1 2 Repairing smooth tube 2702
1 3 Repairing corrugated tube 2702
97 – Wiring 2704
1 Wires and lines 2704
1 1 Repairing wiring harnesses 2704
1 1 1 Repair notes on airbag and belt tensioner lines 2704
1 1 2 Repair notes on CAN bus wires 2704
1 1 3 Repair notes on FlexRay wires 2705
1 1 4 Repairing wires with a cross section of 0 13 mm² to 6 mm² 2707
1 1 5 Repairing wires with a cross section of 10 mm² or 16 mm² 2710
1 1 6 Repairing 2 5 mm, 4 mm or 6 mm aluminium wires with a single crimp connector 2713
1 1 7 Repairing Ethernet lines 2717
1 1 8 Section repairs to electrical wiring 2717
1 1 9 Fitting single wire seals 2717
1 2 Repairing fibre optic cables 2718
1 2 1 Repairing fibre optic cables 2718
1 2 2 Removing and installing fibre optic cable of wiring harness connector 2721
1 3 Repair of aerial wires 2722
1 3 1 Repairing aerial wires 2722
2 Cleaning contact surfaces 2728
2 1 Cleaning battery clamp and battery terminal 2728
2 2 Anti-corrosion treatment of contact surfaces 2729
2 3 Cleaning terminals 2729
2 4 Cleaning threaded connections 2730
3 Connector housing 2732
3 1 Dismantling connector housings 2732
3 2 Repairing contacts in connector housings 2732
4 ESD workplace 2733
4 1 Repair notes on ESD workplace 2733

S.V 28/01/2025