Volkswagen ID.4 2021 Workshop Manual – PDF DOWNLOAD

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Volkswagen ID.4 2021 Workshop Manual – PDF DOWNLOAD

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Volkswagen ID.4 2021 Workshop Manual – PDF DOWNLOAD 

Language : English
Pages : 2830
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Volkswagen ID.4 2021 Workshop Manual – PDF DOWNLOAD 

D4D807A38A2 Body Repairs 1
00 – Technical data 7
1 ID 4 Workshop Manual – Body repairs 7
2 Basic instructions 8
2 1 Original joint 8
2 2 Used joining techniques 8
3 Vehicle identification data 9
3 1 Vehicle identification number 9
3 2 Type plate 10
3 3 Safety certificate 11
4 Safety information 13
5 The following body work requires the HV electrical system to be de-energised 14
6 When the high-voltage battery is removed, observe the following: 15
7 Moulded foam inserts 16
8 Galvanized body parts, high- and higher-strength and hot-formed body panels 18
9 Laser welding 21
10 Gaps/shut lines 22
10 1 Body, front 22
10 2 Body, centre 23
10 3 Body – rear 25
11 Body dimensions 27
11 1 Preliminary work for determining body dimensions 27
11 2 Body, front 27
11 3 Body, centre 28
11 3 1 Windscreen aperture 28
11 3 2 Distance between A-pillars 29
11 3 3 Distance between B and C-pillars 30
11 3 4 Front door aperture 31
11 3 5 Rear door aperture 32
11 4 Body – rear 33
11 5 Floor panel, front 34
11 6 Floor panel, centre 35
11 7 Floor panel, rear 36
12 Straightening bracket set 38
12 1 Overview of setup, entire body 38
13 Portal gauge 40
13 1 Overview of setup, entire body 40
50 – Body – front 42
1 ID 4 Workshop Manual – Body repairs 42
2 Overview of parts 43
3 Renewing front longitudinal member cross panel 44
3 1 Tools 45
3 2 Removing 45
3 3 Installing 47
3 3 1 Preparing new part 47
3 3 2 Welding in 48
4 Renewing battery tray reinforcement 50
4 1 Tools 51
4 2 Removing 51
4 3 Installing 52
4 3 1 Preparing new parts 52
4 3 2 Welding in 53
5 Renewing upper wheel housing longitudinal member – part section 55
5 1 Tools 56
5 2 Removing 56
5 3 Installing 58
5 3 1 Preparing new part 58
5 3 2 Welding in 59
6 Renewing upper inner wheel housing longitudinal member 62
6 1 Tools 63
6 2 Removing 63
6 3 Installing 65
6 3 1 Preparing new part 65
6 3 2 Welding in 66
7 Renewing front wheel housing 69
7 1 Tools 70
7 2 Removing 70
7 3 Installing 73
7 3 1 Preparing new parts 73
7 3 2 Welding in 77
8 Renewing front wheel housing (part section) 81
8 1 Tools 82
8 2 Removing 82
8 3 Installing 85
8 3 1 Preparing new parts 85
8 3 2 Welding in 89
9 Renewing front left longitudinal member, part section 93
9 1 Tools 94
9 2 Removing 94
9 3 Installing 97
9 3 1 Preparing new part 97
9 3 2 Welding in 99
10 Renewing front right longitudinal member, part section 102
10 1 Tools 103
10 2 Removing 103
10 3 Installing 106
10 3 1 Preparing new part 106
10 3 2 Welding in 108
11 Renewing front left longitudinal member (part section – second parting cut) 111
11 1 Tools 112
11 2 Removing 112
11 3 Installing 115
11 3 1 Preparing new part 115
11 3 2 Moulded foam inserts 119
11 3 3 Welding in 119
12 Renewing front right longitudinal member (part section – second parting cut) 124
12 1 Tools 125
12 2 Removing 125
12 3 Installing 128
12 3 1 Preparing new part 128
12 3 2 Moulded foam inserts 132
12 3 3 Welding in 132
13 Renewing studs 137
51 – Body – centre 139
1 ID 4 Workshop Manual – Body repairs 139
2 Overview of parts 140
3 Renewing roof – vehicles without glass panel 141
3 1 Tools 142
3 2 Removing 142
3 3 Installing 146
3 3 1 Preparing new part 146
3 3 2 Bonding roof 148
3 3 3 Adjusting roof depth 152
3 3 4 Welding in 153
4 Renewing roof – vehicles with glass panel 156
4 1 Tools 157
4 2 Removing 157
4 3 Installing 161
4 3 1 Preparing new part 161
4 3 2 Bonding roof 163
4 3 3 Adjusting roof depth 167
4 3 4 Welding in 168
5 Renewing roof side member 171
5 1 Tools 172
5 2 Removing 173
5 3 Installing 175
5 3 1 Authorised parting cuts on complete side panel 175
5 3 2 Preparing new part 176
5 3 3 Welding in 177
6 Renewing A-pillar 181
6 1 Tools 183
6 2 Removing 183
6 3 Installing 185
6 3 1 Authorised parting cuts on complete side panel 185
6 3 2 Preparing new part 186
6 3 3 Moulded foam inserts 187
6 3 4 Welding in 187
7 Renewing A-pillar reinforcement (part section) 191
7 1 Tools 192
7 2 Removing 192
7 3 Installing 196
7 3 1 Preparing new part 196
7 3 2 Moulded foam inserts 198
7 3 3 Welding in 198
8 Renewing B-pillar 202
8 1 Tools 204
8 2 Type plate 204
8 3 Safety certificate 205
8 4 Removing 206
8 5 Installing 207
8 5 1 Authorised parting cuts on complete side panel 207
8 5 2 Preparing new part 208
8 5 3 Moulded foam inserts 209
8 5 4 Welding in 209
9 Renewing B-pillar reinforcement 213
9 1 Tools 214
9 2 Type plate 214
9 3 Safety certificate 215
9 4 Removing 216
9 5 Installing 218
9 5 1 Preparing new part 218
9 5 2 Welding in 219
10 Renewing outer side member 222
10 1 Tools 223
10 2 Type plate 223
10 3 Safety certificate 224
10 4 Removing 225
10 5 Installing 227
10 5 1 Approved parting cuts on outer side member 227
10 5 2 Preparing new part 228
10 5 3 Moulded foam inserts 229
10 5 4 Welding in 229
11 Renewing side member reinforcement 233
11 1 Tools 234
11 2 Removing 234
11 3 Installing 236
11 3 1 Preparing new part 236
11 3 2 Welding in 237
12 Renewing side panel reinforcement, crash bar 240
12 1 Tools 241
12 2 Removing 241
12 3 Installing 243
12 3 1 Preparing new part 243
12 3 2 Welding in 244
53 – Body – rear 247
1 ID 4 Workshop Manual – Body repairs 247
2 Overview of parts 248
3 Renewing rear cross panel 249
3 1 Tools 250
3 2 Removing 250
3 3 Installing 252
3 3 1 Preparing new part 252
3 3 2 Welding in 253
4 Renewing rear cross member 256
4 1 Tools 257
4 2 Removing 257
4 3 Installing 258
4 3 1 Preparing new part 258
4 3 2 Welding in 260
5 Renewing sealing channel support 263
5 1 Tools 264
5 2 Removing 264
5 3 Installing 265
5 3 1 Preparing new part 265
5 3 2 Welding in 266
6 Renewing rear floor cross member 268
6 1 Tools 269
6 2 Removing 269
6 3 Installing 271
6 3 1 Preparing new part 271
6 3 2 Welding in 272
7 Renewing centre floor panel (part section) 275
7 1 Tools 276
7 2 Removing 276
7 3 Installing 278
7 3 1 Preparing new part 278
7 3 2 Welding in 279
8 Renewing rear floor panel 282
8 1 Tools 283
8 2 Removing 283
8 3 Installing 285
8 3 1 Preparing new part 285
8 3 2 Welding in 286
9 Renewing longitudinal member cover plate 289
9 1 Tools 290
9 2 Removing 290
9 3 Installing 292
9 3 1 Preparing new part 292
9 3 2 Moulded foam inserts 293
9 3 3 Welding in 293
10 Renewing rear longitudinal member (part section) 296
10 1 Tools 297
10 2 Removing 297
10 3 Installing 300
10 3 1 Preparing new part 300
10 3 2 Welding in 301
11 Renewing rear longitudinal member (second part section) 305
11 1 Tools 306
11 2 Removing 306
11 3 Installing 310
11 3 1 Preparing new part 310
11 3 2 Moulded foam inserts 313
11 3 3 Welding in 313
12 Permitted parting cuts on side panel 318
13 Renewing side panel, part section 319
13 1 Tools 321
13 2 Removing 321
13 3 Installing 323
13 3 1 Authorised parting cuts on complete side panel 323
13 3 2 Preparing new part 324
13 3 3 Moulded foam inserts 325
13 3 4 Welding in 325
14 Renewing floor panel reinforcement 329
14 1 Tools 330
14 2 Removing 330
14 3 Installing 331
14 3 1 Preparing new part 331
14 3 2 Welding in 332
15 Renewing outer wheel housing liner 334
15 1 Tools 335
15 2 Removing 335
15 3 Installing 338
15 3 1 Preparing new part 338
15 3 2 Welding in 339
D4B80A4F454 Air conditioning systems with refrigerant R744 – General information 342
00 – Technical data 346
1 Safety information 346
1 1 Safety precautions when working on air conditioning systems 346
1 2 Safety precautions when handling refrigerants 346
1 3 Safety measures when working on vehicles with a start/stop system 347
1 4 Safety precautions when using air conditioner service stations 347
1 5 Safety precautions when handling refrigerants R1234yf and R134a 347
1 6 Safety measures for working on vehicles with high-voltage system 348
1 7 Safety precautions when working in the vicinity of high-voltage components 348
2 Laws and regulations 350
2 1 Legal regulations and standards 350
2 2 Charging refrigerant circuit with different refrigerants 351
2 3 Occupational health and safety 351
3 Repair notes 352
3 1 Rules for cleanliness 352
3 2 Refrigerant circuit seals 352
3 3 Refrigerant and refrigerant oil 352
3 3 1 Refrigerant R134a and R1234yf 352
3 3 2 Important repair notes for refrigerant and refrigerant oil 353
3 3 3 Refrigerant R744 (carbon dioxide) 353
3 3 4 Refrigerant oil 354
3 4 Handling pressure vessels 355
3 5 Handling refrigerants 356
4 Identification 358
4 1 Notice for refrigerant circuit 358
5 Technical data 359
5 1 Refrigerant capacity 359
5 2 Refrigerant oil capacities 359
5 2 1 Refrigerant capacity 359
5 2 2 Refrigerant oil capacities 359
5 3 Safety data sheets 359
6 Basic technical and physical properties 360
6 1 Basics of air conditioning technology 360
6 1 1 Physical properties of air conditioning system 360
6 1 2 Pressure and boiling point of refrigerant 361
6 1 3 Vapour pressure table for refrigerant 364
6 2 Physical properties 366
6 2 1 Refrigerant R744 366
6 2 2 Potential risks with refrigerant R744 366
6 2 3 Physical and chemical properties of refrigerant R744 367
6 2 4 Critical point of refrigerant R744 368
6 2 5 Environmental aspects of refrigerant R744 368
6 2 6 Colour and odour of refrigerant R744 (carbon dioxide) 369
6 2 7 Vapour pressure, critical temperature/critical pressure of refrigerant R744 (carbon dioxide) 369
6 2 8 How R744 refrigerant reacts to metals and plastics 369
6 2 9 Critical temperature / critical pressure of R744 refrigerant 369
6 2 10 Water content of refrigerant R744 (carbon dioxide) 370
6 2 11 Flammability/decomposition of refrigerant R744 (carbon dioxide) 370
6 2 12 Charge factor of refrigerant R744 370
6 2 13 Evidence of leaks in a refrigerant circuit with refrigerant R744 (carbon dioxide) 371
6 2 14 Analysis of refrigerant R744 371
6 2 15 Returning contaminated R744 refrigerant for analysis, processing or disposal 371
6 3 Product characteristics 371
6 4 Function and role of air conditioning system 372
6 4 1 Principle of operation 372
6 4 2 Comfort 372
6 5 Other reference material 373
87 – Air conditioning system 374
1 Refrigerant circuit 374
1 1 System overview – refrigerant circuit 374
1 2 General description – components of refrigerant circuit 374
1 2 1 Gas cooler 374
1 2 2 Evaporator 375
1 2 3 Accumulator or receiver with dryer 375
1 2 4 Expansion valve 376
1 2 5 Refrigerant line with internal heat exchanger 377
1 2 6 Connection points of components and refrigerant lines 378
1 2 7 Seals 379
1 2 8 Pipes and hoses in refrigerant circuit 380
1 2 9 High-pressure safety valves 382
1 2 10 Quick-release coupling connections in refrigerant circuit 383
1 2 11 Connections for pressure and temperature senders in the refrigerant circuit 385
1 2 12 Refrigerant pressure and temperature sender 385
1 3 Possible complaints 386
1 3 1 Prerequisites for investigating a complaint 386
1 3 2 Possible complaints 386
1 3 3 Odours from heater and air conditioning unit 387
1 4 Investigating leaks 388
1 4 1 General information about investigating leaks in the refrigerant circuit 388
1 4 2 Detecting leaks in a vacuum test or using the pressure test of the air conditioner service station 389
1 4 3 Detecting leaks in a pressure test (with forming gas) using leak detector or leak detection spray 389
1 5 Renewing components 392
1 5 1 General information about renewing components 392
1 5 2 Renewing leaking or damaged components of empty refrigerant circuit (apart from air conditioner compressor and receiver) 393
1 5 3 Renewing leaking or damaged components of charged refrigerant circuit (apart from air conditioner compressor) 394
1 5 4 Renewing air conditioner compressor with no need to clean refrigerant circuit 394
1 5 5 Renewing air conditioner compressor due to leaks or internal damage 396
1 5 6 Renewing receiver (with desiccant bag) with no need to clean refrigerant circuit 396
1 6 Cleaning refrigerant circuit 397
1 6 1 General information about cleaning refrigerant circuit 397
1 6 2 Refrigerant circuit cleaning procedure 398
1 6 3 Adapters for setting up flushing circuits 399
1 6 4 Procedure for setting up and flushing refrigerant circuit 400
1 6 5 General information about blowing through with compressed air 400
1 6 6 Blowing through refrigerant circuit with compressed air 401
1 7 Checking pressures with pressure gauge 402
1 7 1 Display on pressure gauges 402
1 7 2 Pressure gauges enable the following test and measurement work 403
2 Working with air conditioner service station 404
2 1 General information on working with air conditioner service station 404
2 2 Connecting air conditioner service station to refrigerant circuit 406
2 3 Purging refrigerant circuit 407
2 4 Evacuating refrigerant circuit 409
2 5 Charging refrigerant circuit 412
2 6 Bringing air conditioning system into service after charging 415
2 7 Switching off air conditioner service station and separating from refrigerant circuit 415
2 8 Filling refrigerant into internal pressure vessel 417
2 9 Connecting and detaching supplied cylinder 417
2 10 Emptying air conditioner service station 417
2 11 Cleaning refrigerant circuit 417
2 12 Filling contaminated refrigerant in a recycling cylinder for analysis, processing or disposal 417
3 Testing equipment and tools 418
3 1 Tools and materials available from distribution centre or importer 418
3 2 Tools and materials available commercially 418
D4B807E3B5B Body Repairs General Body Repairs 420
1 Safety instructions 424
1 1 Part removal 424
1 2 Battery and welding operation 424
1 3 Electronic control unit 424
1 3 1 Processing of the electronic control unit after repair dueto a traffic accident 424
1 4 Paint, glass, soft pad and trim 425
1 5 Fuel tank or fuel delivery pipeline 425
1 6 Air conditioner 425
1 6 1 Remedial measures: 425
1 7 Airbag System 426
1 8 Check the seat belts 426
1 8 1 Belt body 427
1 8 2 Automatic retractor (locking function) 427
1 8 3 Visual inspection of the seat belt buckle 428
1 8 4 Seat belt buckle function 428
1 8 5 Seat belt guide member and tongue 429
1 8 6 Fixing piece and fixing point 429
1 9 Safety specifications for the seat belt tensioner 429
1 10 Body repair on a vehicle equipped with the seat belt tensioners 430
1 10 1 The following vehicles have been equipped with: 430
1 11 Perform cutting off, correcting and/or leveling on a vehicleequipped with airbags 431
1 12 Remove the front seats with a side airbag 431
2 Basic instruction 432
2 1 Diagnosis of the accident vehicle 432
2 2 Condition of the body and/or the parts for delivery to thepainting workshop 432
2 3 Correction 432
2 4 Cutting 432
2 5 Body-cut part and part section 432
2 6 Original connection 433
2 7 Galvanized body parts 433
2 8 Remove the rest part 433
2 9 New parts 433
2 10 Parts 433
2 11 Molded foam plastic pads 434
3 Symbolic interpretation 435
3 1 Symbolic interpretation for welding 435
3 2 Symbolic interpretation for the operation method 435
3 2 1 Grinding 436
3 2 2 Thinning 436
3 2 3 Punching 436
3 2 4 Drilling 437
3 2 5 Polishing 437
3 2 6 Cavity corrosion protection 437
3 2 7 Bonding 438
3 2 8 Precise sealing 438
4 Body repair tools 439
4 1 Flaring tool -V A G 1317- 439
4 2 Punching pliers -V A G 1329- 439
4 3 Basic equipment -V A G 1366/3- 439
4 4 Bottom protection layer spray gun -V A G 1379- 440
4 5 Electric blower -V A G 1416- 440
4 6 Door tensioner -V A G 1438- 440
4 7 Body equipment component -V A G 1439- 441
4 8 Pneumatic cutting knife -V A G 1523 A- 441
4 9 Air chisel -V A G 1577- 441
4 10 Edge closing iron block -V A G 1585- 442
4 11 Welding fume ventilator -V A G 1586- 442
4 12 Welding spot releasing device -V A G 1731- 442
4 13 Pneumatic spray gun -V A G 1761/1- 443
4 14 Pneumatic punching and thinning pliers -VAS 1996- 443
4 15 Pneumatic adhesive spray gun -V A G 2005- 443
4 16 Door hinge correction tool 444
4 17 Hose kit 5023 for the inert gas protection welding 444
4 18 Angle grinder -VAS 5174- 444
4 19 Angle grinder -VAS 5175- 445
4 20 Wire brush -VAS 5182- 445
5 Body bonding 446
5 1 Transporter 1991 → 446
5 1 1 Separation process: 446
5 1 2 Bonding process: 446
5 2 Bonding types 446
5 2 1 Bonding-strong 446
5 2 2 Bonding-spot welding 447
5 3 Repair method for replacing the parts 447
5 3 1 Spot welding and bonding 447
5 3 2 Plug welding and bonding (if spot welding is impossible) 447
5 3 3 Welding fume ventilator 448
5 3 4 Preparations 448
5 3 5 Trimming 448
6 Corrosion protection measures 449
6 1 Corrosion protection 449
7 Waste disposal instructions 450
7 1 Waste disposal 450
7 2 Air pressure tappet exhaust 450
7 3 Airbag 451
7 3 1 Waste disposal 451
8 Contact corrosion protection 452
8 1 Connection of aluminum alloy/magnesium alloy with steel 452
9 Steel plate repair 453
9 1 High-strength body plate 453
9 2 Galvanized body parts 453
9 2 1 Preparations 453
9 2 2 Part cutting 454
9 2 3 Connection process 454
9 3 Welding on the galvanized body steel plate 454
9 3 1 Inert gas protection plug welding SG of the galvanized steelplate 454
9 3 2 Resistance pressure spot welding RP of the galvanized steelplate 455
9 3 3 Welding transformer 455
9 3 4 Welding clamp 455
9 4 Tearing test 455
10 Aluminum repair 456
10 1 Painting 456
10 2 Surface treatment 456
10 3 Leveling 457
10 4 Temperature control for heating 457
11 Plastic repair method 458
11 1 Material 458
11 2 Repairing the pit 459
11 3 Repairing the scratch 460
11 4 Repair the crack 462
11 5 Repairing the small hole (the diameter is more than 30 mm) 463
11 6 Plastic repair (glass fibre material) 464
11 7 Repair process 465
11 7 1 Repairing the breakage position 465
11 7 2 Repairing the surface damage 467
12 Glass repair 468
12 1 Repairing the windshield 468
12 1 1 Premises 468
12 1 2 Required special tools, operating equipment, testing instrumentsand auxiliary tools 469
12 1 3 Repair description 470
D4B80609EAF Air conditioning systems with refrigerant R1234yf – General information 474
00 – Technical data 480
1 Safety information 480
1 1 Safety precautions when working on air conditioning systems 480
1 2 Safety precautions when handling refrigerants 481
1 3 Safety measures when working on vehicles with a start/stop system 481
1 4 Safety precautions when using air conditioner service stations 481
1 5 Safety measures for working on vehicles with high-voltage system 482
1 6 Safety precautions when working in the vicinity of high-voltage components 483
1 7 Safety precautions when working on pressure vessels 483
2 Laws and regulations 484
2 1 Legal regulations and standards 484
2 2 Charging refrigerant circuit with different refrigerants 485
2 3 Occupational health and safety 486
3 Repair notes 487
3 1 Rules for cleanliness 487
3 2 Refrigerant circuit seals 487
3 3 Refrigerant and refrigerant oil 488
3 3 1 Important repair notes for refrigerant and refrigerant oil 488
3 3 2 Refrigerant oil 489
3 4 Handling pressure vessels 490
3 5 Handling refrigerants 491
4 Identification 493
4 1 Notice for refrigerant circuit 493
5 Technical data 494
5 1 Refrigerant capacity 494
5 2 Refrigerant oil capacities 494
5 3 Safety data sheets 494
6 Basic technical and physical properties 495
6 1 Basics of air conditioning technology 495
6 1 1 Physical properties of air conditioning system 495
6 1 2 Pressure and boiling point of refrigerant 496
6 1 3 Vapour pressure table for refrigerant 497
6 2 Physical properties 499
6 2 1 Refrigerant R1234yf 499
6 2 2 Potential risks with refrigerant R1234yf 499
6 2 3 Physical and chemical properties of refrigerant R1234yf 500
6 2 4 Critical point 500
6 2 5 Environmental aspects of refrigerant R1234yf 501
6 2 6 Trade names and designations of refrigerant R1234yf 501
6 2 7 Colour and odour of R1234yf refrigerant 502
6 2 8 Vapour pressure of R1234yf refrigerant 502
6 2 9 Physical properties of R1234yf refrigerant 502
6 2 10 How R1234yf refrigerant reacts to metals and plastics 502
6 2 11 Critical temperature / critical pressure of R1234yf refrigerant 503
6 2 12 Water content of R1234yf refrigerant 503
6 2 13 Flammability / decomposition of R1234yf refrigerant 503
6 2 14 Charge factor of refrigerant R1234yf 503
6 2 15 Evidence of leaks in a refrigerant circuit with R1234yf refrigerant 504
6 2 16 Analysis of refrigerant R1234yf 504
6 2 17 Returning contaminated R1234yf refrigerant for analysis, processing or disposal 505
6 3 Product characteristics 506
6 4 Function and role of air conditioning system 506
6 4 1 Principle of operation 506
6 4 2 Comfort 507
6 4 3 Environmental aspects 507
6 5 Other reference material 508
87 – Air conditioning system 509
1 Refrigerant circuit 509
1 1 System overview – refrigerant circuit 509
1 1 1 System overview – refrigerant circuit with expansion valve and receiver 509
1 1 2 System overview – refrigerant circuit with restrictor and reservoir 511
1 1 3 System overview – refrigerant circuit with electrically driven air conditioner compressor (with and without battery cooling module) 512
1 2 General description – components of refrigerant circuit 515
1 2 1 Layout and function of refrigerant circuit 515
1 2 2 Mechanical air conditioner compressor 516
1 2 3 Electrical air conditioner compressor for hybrid vehicles 519
1 2 4 Condenser 522
1 2 5 evaporator 523
1 2 6 Reservoir 525
1 2 7 Heat exchanger for heat pump mode 525
1 2 8 Liquid receiver 526
1 2 9 Restrictor 526
1 2 10 Receiver 528
1 2 11 Expansion valve (with and without shut-off valve) 530
1 2 12 Refrigerant shut-off valves 532
1 2 13 Refrigerant line with internal heat exchanger 534
1 2 14 Quick release couplings of refrigerant lines 535
1 2 15 Seals 536
1 2 16 Pipes and hoses in refrigerant circuit 537
1 2 17 High-pressure safety valve 537
1 2 18 Non-return valves 539
1 2 19 Quick-release coupling connections in refrigerant circuit 540
1 2 20 Connections with valve for switches in refrigerant circuit 544
1 2 21 Pressure senders and switches in refrigerant circuit 545
1 2 22 Refrigerant pressure and temperature sender 546
1 2 23 Air conditioner compressor regulating valve -N280- 549
1 2 24 Refrigerant temperature sender 550
1 3 Possible complaints 551
1 3 1 Prerequisites for investigating a complaint 551
1 3 2 Possible complaints 551
1 3 3 Odours from heater and air conditioning unit 553
1 4 Investigating leaks 555
1 4 1 General information about investigating leaks in the refrigerant circuit 555
1 4 2 Searching for leaks in refrigerant circuits using an electronic leak detector 556
1 4 3 Searching for leaks with UV leak detection system 557
1 4 4 Detecting leaks in a vacuum test using air conditioner service station, or in a pressure test 563
1 4 5 Detecting leaks in a pressure test (with nitrogen or compressed air) 564
1 5 Renewing components 566
1 5 1 General information about renewing components 566
1 5 2 Renewing leaking or damaged components of empty refrigerant circuit (apart from air conditioner compressor and receiver) 567
1 5 3 Renewing leaking or damaged components of charged refrigerant circuit (apart from air conditioner compressor and receiver) 569
1 5 4 Renewing air conditioner compressor with no need to clean refrigerant circuit 570
1 5 5 Renewing air conditioner compressor due to leaks or internal damage 573
1 5 6 Renewing desiccant cartridge / receiver after cleaning refrigerant circuit 574
1 5 7 Renewing receiver with no need to clean refrigerant circuit 576
1 5 8 Renewing desiccant cartridge / desiccant bag with no need to clean refrigerant circuit 577
1 6 Cleaning refrigerant circuit 578
1 6 1 General information about cleaning refrigerant circuit 578
1 6 2 Preparations for cleaning refrigerant circuit (flushing with R1234yf refrigerant) 580
1 6 3 Refrigerant circuit cleaning procedure 584
1 6 4 Principle circuit diagrams for cleaning (flushing circuits) – refrigerant circuit with expansion valve and receiver 584
1 6 5 Principle circuit diagrams for cleaning (flushing circuits) – refrigerant circuit with restrictor and receiver (without high-voltage system) 589
1 6 6 Adapters for setting up flushing circuits 592
1 6 7 General information about blowing through with compressed air or nitrogen 605
1 6 8 Blowing through refrigerant circuit with compressed air or nitrogen 609
1 7 Checking pressures with pressure gauge 610
1 7 1 Display on pressure gauges 610
1 7 2 Pressure gauges enable the following test and measurement work 611
2 Working with air conditioner service station 614
2 1 Working with air conditioner service station 615
2 2 Connecting air conditioner service station to refrigerant circuit 617
2 3 Performing gas analysis of refrigerant 620
2 4 Purging refrigerant circuit 623
2 5 Evacuating refrigerant circuit 626
2 6 Charging refrigerant circuit 632
2 7 Bringing air conditioning system into service after charging 635
2 8 Switching off air conditioner service station and separating from refrigerant circuit 637
2 9 Charging refrigerant in reservoir 639
2 10 Emptying air conditioner service station 640
2 11 Cleaning electrical air conditioning compressor 640
2 12 Cleaning refrigerant circuit 643
2 13 Filling contaminated refrigerant in a recycling cylinder for analysis, processing or disposal 646
2 13 1 Filling contaminated refrigerant into recycling cylinder using extraction unit -VAS 581 011- 646
2 13 2 Filling contaminated refrigerant into recycling cylinder using extraction unit -VAS 581 007- 647
2 14 Checking pressures 651
2 14 1 General information on checking pressures in the refrigerant circuit 651
2 14 2 Pressures and temperatures in refrigerant circuit 653
2 14 3 Checking pressures in the refrigerant circuit with the ignition switched off 657
2 14 4 Checking pressures with air conditioning system switched on – vehicles with mechanical air conditioning compressor 664
2 14 5 Checking pressures with air conditioning system switched on – vehicles with electrical air conditioning compressor 686
3 Testing equipment and tools 739
3 1 Tools and materials available from distribution centre or importer 739
3 2 Tools and materials available commercially 739
D4D807A48A7 Vehicle specific paint information 741
54 – Vehicle-specific paintwork information 745
1 Safety information and repair notes 745
1 1 Safety information 745
1 2 Repair instructions 745
2 Explanation of symbols 746
2 1 Sanding 746
2 2 Seam sealing 746
2 3 Cavity sealing 748
3 Paintwork structure 749
3 1 Structure of factory finish, surfacer 749
3 2 Structure of factory finish, base coat 749
3 3 Structure of factory finish, clear coat 750
4 Areas exposed to stone chipping 752
4 1 Areas exposed to stone chipping – overview 752
5 Masked sectors 754
5 1 Masking areas, front body 754
5 2 Masking areas, rear body 754
6 Seam sealing 756
6 1 Seam seals, front body 756
6 2 Seam sealing: Front wheel housing 757
6 3 Seam seals, A-pillar 757
6 4 Seam seals, bonnet, inner side 758
6 5 Seam seals, roof 759
6 6 Seam seals, doors 760
6 7 Seam seals, rear wheel housing 761
6 8 Seam seals, underbody 762
6 9 Seam seals, rear cross panel 763
7 Underseal 764
7 1 Underseal, body – overview 764
7 2 Underseal, front body 764
7 3 Underseal, centre body 765
7 4 Underseal, rear body 766
8 Cavity sealing 768
8 1 Cavity sealing, body – overview 768
8 2 Cavity sealing, front body 768
8 3 Cavity sealing, rear body 769
8 4 Cavity sealing, doors 769
9 Paintwork repair 770
9 1 Paintwork repair, radar sensor cover 770
D4D807A125B 1 speed gearbox 0MH rear 771
00 – Technical data 775
1 Safety information and repair notes 775
1 1 Safety information 775
1 2 Repair instructions 775
2 Identification 776
2 1 Gearbox identification 776
3 Technical data 777
3 1 Allocation gearbox ? motor 777
3 2 Capacities 777
34 – Controls, housing 778
1 Safety information and repair notes 778
1 1 Safety information 778
1 2 Repair instructions 778
2 Removing and installing gearbox 779
2 1 Removing gearbox 779
2 2 Installing gearbox 779
3 Gearbox housing, clutch housing 780
3 1 Assembly overview – gearbox housing 780
3 2 Removing and installing cap 780
4 Gear oil 782
4 1 Checking gear oil level 782
39 – Final drive – differential 784
1 Safety information and repair notes 784
1 1 Safety information 784
1 2 Repair instructions 784
2 Seals 785
2 1 Assembly overview ? seals 785
2 2 Renewing left seal 785
2 3 Renewing right seal 786
D4D807ACE28 Communication 787
00 – Technical data 791
1 Electrical components 791
1 1 Access to diagnosis 791
2 Safety information and repair notes 792
2 1 Safety information 792
2 2 Repair instructions 792
91 – Communication 793
1 Safety information and repair notes 793
1 1 Safety information 793
1 2 Repair instructions 793
2 Fitting locations 794
2 1 Overview of fitting locations – components/control units, ID 4 794
2 1 1 Overview of fitting locations – components/control units in middle section of vehicle 794
2 1 2 Overview of fitting locations – components/control units in rear section of vehicle 796
2 2 Overview of fitting locations – components/control units, ID 5 798
2 2 1 Overview of fitting locations – components/control units in middle section of vehicle 798
2 2 2 Overview of fitting locations – components/control units in rear section of vehicle 800
3 Components/control units 802
3 1 Removing and installing control unit for front display and information control panel [J685] 802
3 2 Control unit 1 for information electronics [J794] 802
3 2 1 Removing and installing control unit 1 for information electronics [J794] 802
3 2 2 Removing and installing bracket for control unit 1 for information electronics [J794] 803
3 3 Removing and installing front treble loudspeakers [R20]/[R22] 805
3 4 Removing and installing bass loudspeaker 805
3 5 Removing and installing subwoofer [R211] 806
3 6 Removing and installing digital sound package control unit [J525] 806
3 7 Removing and installing aerial module 807
3 8 Removing and installing frequency modulation (FM) frequency filters [R178]/[R179] 808
3 9 Removing and installing roof aerial [RX5] 809
3 10 Removing and installing LTE aerial 810
3 11 Removing and installing internet access control unit [J666] 810
3 12 Removing and installing data transmission aerial [R180] 811
3 13 Removing and installing aerial amplifier for mobile telephone [R86] 812
3 14 Removing and installing charging unit 1 for mobile devices [J1146] 812
3 15 Removing and installing multifunction buttons [E440]/[E441] 813
3 16 Removing and installing control unit for steering wheel contact detection [J1158] 816
3 17 Removing and installing USB connection 1 [U41] 816
3 18 Removing and installing USB charging socket 1 [U37] 817
3 19 Removing and installing emergency call module control unit and communication unit [J949], rear bench seat 818
3 20 Removing and installing loudspeaker for emergency call module [R335] 819
3 21 Removing and installing emergency battery, telematics [A16] 820
4 Multifunction steering wheel 822
4 1 Assembly overview – multifunction steering wheel 822
D4D807B3D51 Electric rear wheel drive EIP220 and all wheel drive EIA200 EIP220 823
00 – Technical data 829
1 Safety information and repair notes 829
1 1 Safety information 829
1 2 Repair instructions 829
2 Identification 830
2 1 Motor designation 830
2 2 Motor data 831
2 2 1 Motor data EBJA 831
2 2 2 Motor data EBJC 831
2 2 3 Motor data EBJD 832
2 2 4 Motor data EBRA 832
3 Electrical components 833
3 1 Access to diagnoses 833
4 Hazard classification of high-voltage system 835
4 1 Classification of dangers of the high-voltage system 835
10 – Removing and installing engine 844
1 Safety information and repair notes 844
1 1 Safety information 844
1 2 Repair instructions 844
2 Removing and installing front motor 845
2 1 Assembly overview – front motor 845
2 1 1 Assembly overview – front motor, left-hand drive vehicles 845
2 1 2 Assembly overview – front motor, right-hand drive vehicles 848
2 2 Removing front motor 851
2 2 1 Removing front motor, left-hand drive vehicles 851
2 2 2 Removing front motor, right-hand drive vehicles 852
2 3 Securing motor to engine and gearbox support, front motor 854
2 4 Installing front motor 856
2 4 1 Installing front motor, left-hand drive vehicles 856
2 4 2 Installing front motor, right-hand drive vehicles 858
3 Removing and installing rear motor 861
3 1 Assembly overview – rear motor 861
3 2 Removing rear motor 863
3 3 Securing motor to engine and gearbox support, rear motor 868
3 4 Installing rear motor 871
4 Front assembly mountings 875
4 1 Removing and installing motor mountings 875
4 2 Removing and installing gearbox mountings 875
5 Rear assembly mountings 876
5 1 Removing and installing assembly mountings 876
19 – Cooling 877
1 Safety information and repair notes 877
1 1 Safety information 877
1 2 Repair instructions 877
2 Cooling system/coolant 878
2 1 Connection diagram – coolant hoses, refrigerant R744 878
2 1 1 Connection diagram – coolant hoses, rear-wheel drive 878
2 1 2 Connection diagram – coolant hoses, four-wheel drive 878
2 2 Connection diagram – coolant hoses, refrigerant R1234yf 879
2 2 1 Connection diagram – coolant hoses, rear-wheel drive 879
2 2 2 Connection diagram – coolant hoses, four-wheel drive 880
2 3 Overview of fitting locations – cooling system, rear-wheel drive 881
2 3 1 Overview of fitting locations – cooling system 881
2 4 Overview of fitting locations – cooling system, all-wheel drive 883
2 4 1 Overview of fitting locations – cooling system 883
2 5 Assembly overview – cooling system, rear-wheel drive 885
2 5 1 Assembly overview – cooling system 885
2 6 Assembly overview – cooling system, all-wheel drive 890
2 6 1 Assembly overview – cooling system 890
2 7 Checking cooling system for leaks 895
2 8 Removing and installing coolant expansion tank 898
2 9 Checking filling quality 899
2 10 Draining coolant 901
2 10 1 Draining coolant 901
2 10 2 Draining coolant with cooling system service unit VAS 531 011 903
2 11 Filling cooling system 905
2 11 1 Filling cooling system with cooling system charge unit VAS 6096 905
2 11 2 Filling cooling system with cooling system service unit VAS 531 011 912
3 Coolant pump/coolant regulation 914
3 1 Assembly overview – electric coolant pump 914
3 2 Assembly overview – coolant valves 914
3 3 Exploded view – coolant temperature senders 915
3 4 Removing and installing coolant pump for high-voltage battery [V590], rear-wheel drive 917
3 4 1 Removing and installing coolant pump for high-voltage battery V590 917
3 5 Removing and installing coolant pump for high-voltage battery [V590], all-wheel drive 919
3 5 1 Removing and installing coolant pump for high-voltage battery V590 919
3 6 Removing and installing coolant pump for low-temperature circuit V468 920
3 7 Removing and installing mixing valve for high-voltage battery pre-heating [V683] 921
3 8 Removing and installing mixing valve 2 for high-voltage battery [V696] pre-heating, heat pump 922
3 8 1 Removing and installing mixing valve 2 for high-voltage battery pre-heating V696 922
3 9 Removing and installing temperature sensor [G18] 924
3 10 Removing and installing coolant temperature sender 1 for high-voltage battery G898 925
3 11 Removing and installing coolant temperature sender 2 for high-voltage battery G899 926
4 Radiator, radiator fan 928
4 1 Assembly overview – radiator/radiator fan 928
4 2 Assembly overview – radiator cowl and radiator fan 928
4 3 Removing and installing radiator module 929
4 4 Dismantling and assembling radiator module 931
4 5 Removing and installing radiator cowl with radiator fan 935
4 6 Removing and installing radiator fan [VX57] 936
4 7 Removing and installing control motor for radiator roller blind [V711], ID 3 937
4 7 1 Removing and installing control motor for radiator roller blind [V711] 937
4 8 Removing and installing control motor for radiator roller blind [V711], ID 4 938
4 8 1 Removing and installing control motor for radiator roller blind [V711] 938
93 – Electric drive systems 940
1 Safety information and repair notes 940
1 1 Safety information 940
1 2 Repair instructions 940
2 High-voltage components 941
2 1 Overview of fitting locations – high-voltage components, all-wheel drive 941
2 1 1 Overview of fitting locations – high-voltage components 941
2 2 Overview of fitting locations – high-voltage components, rear-wheel drive 943
2 2 1 Overview of fitting locations – high-voltage components 943
3 Warning stickers 946
3 1 Checking warning stickers 946
3 1 1 Checking warning stickers 946
3 2 Checking warning stickers 951
3 2 1 Checking warning stickers 951
4 High-voltage battery unit 957
4 1 Assembly overview – high-voltage battery, installed, 48, 55, 62 kWh 957
4 1 1 Assembly overview – high-voltage battery, installed 957
4 2 Assembly overview – high-voltage battery, installed, 82 kWh 958
4 2 1 Assembly overview – high-voltage battery, installed 958
4 3 Visual inspection of high-voltage battery 1 [AX2] 960
4 4 Diagnosis of high-voltage battery 1 [AX2] 960
4 5 Checking high-voltage battery for leaks 960
4 6 Leakage test of high-voltage battery 1 [AX2] 961
4 7 Removing and installing high-voltage battery 1 [AX2], 48, 55, 62 kWh 962
4 7 1 Removing and installing high-voltage battery 1 [AX2] 962
4 8 Removing and installing high-voltage battery 1 [AX2], 82 kWh 972
4 8 1 Removing and installing high-voltage battery 1 [AX2] 972
4 9 Raising high-voltage battery 1 [AX2] 982
4 10 Opening high-voltage battery 1 AX2 984
4 11 Sealing high-voltage battery 1 [AX2], 48, 55, 62 kWh 985
4 11 1 Sealing high-voltage battery 1 [AX2] 985
4 12 Sealing high-voltage battery 1 [AX2], 82 kWh 988
4 12 1 Sealing high-voltage battery 1 [AX2] 988
4 13 Voltage and insulation measurement, 48, 55, 62 kWh 990
4 13 1 Voltage and insulation measurement 990
4 14 Voltage and insulation measurement, 82 kWh 993
4 14 1 Voltage and insulation measurement 993
4 15 Opening electrical circuit, 48, 55 kWh 995
4 15 1 Interrupting electrical circuit 995
4 16 Opening electrical circuit, 62 kWh 998
4 16 1 Opening electrical circuit 998
4 17 Opening electrical circuit, 82 kWh 1001
4 17 1 Interrupting electrical circuit 1001
4 18 Removing and installing battery regulation control unit [J840] 1004
4 19 Charging and discharging battery modules 1005
4 20 Checking whether upper part of battery housing can be reused 1006
4 21 Renewing lower part of battery housing 1008
4 22 Renewing high-voltage battery 1 [AX2] 1010
5 High-voltage battery components 1012
5 1 Overview of fitting locations – battery modules, 48, 55 kWh 1012
5 1 1 Overview of fitting locations – battery modules 1012
5 2 Overview of fitting locations – battery modules, 62 kWh 1013
5 2 1 Overview of fitting locations – battery modules 1013
5 3 Overview of fitting locations – battery modules, 82 kWh 1015
5 3 1 Overview of fitting locations – battery modules 1015
5 4 Overview of fitting locations – battery connectors 1017
5 5 Assembly overview – high-voltage battery, removed, 48, 55, 62 kWh 1017
5 5 1 Assembly overview – high-voltage battery, removed 1017
5 6 Assembly overview – high-voltage battery, removed, 82 kWh 1020
5 6 1 Assembly overview – high-voltage battery, removed 1020
5 7 Assembly overview – high-voltage battery, battery modules 1023
5 8 Assembly overview – switching unit for high-voltage battery, 48, 55, 62 kWh 1024
5 8 1 Assembly overview – switching unit for high-voltage battery 1024
5 9 Assembly overview – switching unit for high-voltage battery, 82 kWh 1025
5 9 1 Assembly overview – switching unit for high-voltage battery 1025
5 10 Assembly overview – high-voltage battery, connecting element, 48, 55, 62 kWh 1026
5 10 1 Assembly overview – high-voltage battery, connector strip 1026
5 11 Assembly overview – high-voltage battery, connecting element, 82 kWh 1028
5 11 1 Assembly overview – high-voltage battery, connector strip 1028
5 12 Removing battery module 1029
5 13 Installing battery module 1033
5 14 Removing and installing battery modules control unit 1036
5 15 Removing and installing connecting element, 48, 55 kWh 1038
5 15 1 Removing and installing connector strip 1038
5 16 Removing and installing connecting element, 62 kWh 1040
5 16 1 Removing and installing connector strip 1040
5 17 Removing and installing connecting element, 82 kWh 1042
5 17 1 Removing and installing connector strip 1042
5 18 Removing and installing switching unit for high-voltage battery, negative terminal [SX7], 48, 55, 62 kWh 1045
5 18 1 Removing and installing switching unit for high-voltage battery, negative terminal SX7 1045
5 19 Removing and installing switching unit for high-voltage battery, negative terminal [SX7], 82 kWh 1047
5 19 1 Removing and installing switching unit for high-voltage battery, negative terminal SX7 1047
5 20 Removing and installing switching unit for high-voltage battery, positive terminal [SX8], 48, 55, 62 kWh 1049
5 20 1 Removing and installing switching unit for high-voltage battery, positive terminal SX8 1049
5 21 Removing and installing switching unit for high-voltage battery, positive terminal [SX8], 82 kWh 1051
5 21 1 Removing and installing switching unit for high-voltage battery, positive terminal SX8 1051
6 Power and control electronics for electric drive 1053
6 1 Assembly overview – power and control electronics for electric drive, rear-wheel drive 1053
6 1 1 Assembly overview – power and control electronics for electric drive [JX1] 1053
6 2 Assembly overview – power and control electronics for electric drive, all-wheel drive 1053
6 2 1 Assembly overview – power and control electronics 2 for electric drive [JX4] 1053
6 2 2 Assembly overview – power and control electronics for electric drive [JX1] 1053
6 3 Removing and installing power and control electronics for electric drive, rear-wheel drive 1053
6 3 1 Removing and installing power and control electronics for electric drive [JX1] 1053
6 4 Removing and installing power and control electronics for electric drive, all-wheel drive 1065
6 4 1 Removing and installing power and control electronics for electric drive [JX1] 1065
6 4 2 Removing and installing power and control electronics 2 for electric drive [JX4] 1075
7 Electric drive motor 1080
7 1 Calibrating three-phase current drive [VX54- 1080
7 2 Leak test for rear electric drive motor 1080
7 3 Assembly overview – electric drive motor 1089
7 3 1 Assembly overview – electric drive motor, rear motor 1089
7 3 2 Assembly overview – electric drive motor, front motor 1091
7 4 Removing and installing drive motor rotor position sender, rear-wheel drive 1094
7 4 1 Removing and installing drive motor rotor position sender 1 [G713] 1094
7 5 Removing and installing drive motor rotor position sender, all-wheel drive 1095
7 5 1 Removing and installing drive motor rotor position sender 1 [G713] 1095
7 5 2 Removing and installing rotor position sender 1 for drive motor 2 [G1147] 1097
8 Motor control unit 1101
8 1 Assembly overview – motor control unit 1101
8 2 Removing and installing motor control unit [J623] 1101
8 3 Removing and installing bracket for motor control unit [J623] 1102
9 De-energising high-voltage system 1103
9 1 De-energising high-voltage system 1103
10 Re-energise high-voltage system 1104
10 1 Re-energising high-voltage system 1104
11 Potential equalisation lines 1105
11 1 Overview of fitting locations – potential equalisation lines, all-wheel drive 1105
11 1 1 Overview of fitting locations – potential equalisation lines 1105
11 2 Overview of fitting locations – potential equalisation lines, rear-wheel drive 1106
11 2 1 Overview of fitting locations – potential equalisation lines 1106
12 Charging socket 1107
12 1 Assembly overview – charging socket 1107
12 2 Removing and installing high-voltage battery charging socket 1 [UX4] 1107
12 3 Removing and installing actuator for high-voltage charging socket lock 1 [F498] 1110
13 Charging unit for high-voltage battery 1112
13 1 Assembly overview – charging unit for high-voltage battery, rear-wheel drive 1112
13 1 1 Assembly overview – charging unit for high-voltage battery 1112
13 2 Assembly overview – charging unit for high-voltage battery, all-wheel drive 1113
13 2 1 Assembly overview – charging unit for high-voltage battery 1113
13 3 Removing and installing charging unit 1 for high-voltage battery [AX4], rear-wheel drive 1115
13 3 1 Removing and installing charging unit 1 for high-voltage battery [AX4] 1115
13 4 Removing and installing charging unit 1 for high-voltage battery [AX4], all-wheel drive 1119
13 4 1 Removing and installing charging unit 1 for high-voltage battery [AX4] 1119
14 Vehicle noise/engine sound 1123
14 1 Overview of fitting locations – driving sound/motor sound 1123
14 2 Removing and installing engine sound generator module 1 [RX21] 1123
14 3 Removing and installing engine sound generator module 2 [RX22] 1124
14 3 1 Removing and installing engine sound generator module 2 [RX22] 1124
15 Accelerator pedal 1126
15 1 Assembly overview – accelerator module 1126
15 2 Removing and installing accelerator pedal module [GX2] 1126
16 Voltage converter 1128
16 1 Assembly overview – voltage converter, rear-wheel drive 1128
16 1 1 Assembly overview – voltage converter 1128
16 2 Assembly overview – voltage converter, all-wheel drive 1128
16 2 1 Assembly overview – voltage converter 1128
16 3 Removing and installing voltage converter, rear-wheel drive 1129
16 3 1 Removing and installing voltage converter 1129
16 4 Removing and installing voltage converter, all-wheel drive 1132
16 4 1 Removing and installing voltage converter 1132
17 High-voltage cables 1134
17 1 Unplugging high-voltage connectors 1134
D4D807B46F5 General body repairs interior 1135
00 – Technical data 1143
1 Electrical components 1143
1 1 Access to diagnoses 1143
68 – Interior equipment 1144
1 Safety information and repair notes 1144
1 1 Safety information 1144
1 2 Repair instructions 1144
2 Compartments/covers 1145
2 1 Overview of fitting locations – storage compartments/covers/trim panels 1145
2 2 Assembly overview ? dash panel cover on driver side 1147
2 2 1 Assembly overview ? dash panel cover on driver side, left-hand drive vehicles 1147
2 2 2 Assembly overview ? dash panel cover on driver side, right-hand drive vehicles 1147
2 3 Assembly overview – dash panel cover (passenger side) 1148
2 4 Assembly overview – steering column trim 1149
2 5 Assembly overview – glove compartment 1150
2 6 Removing and installing dash panel cover on driver side 1151
2 6 1 Removing and installing dash panel cover on driver side, left-hand drive vehicles 1151
2 6 2 Removing and installing dash panel cover on driver side, right-hand drive vehicles 1152
2 7 Removing and installing gap cover for dash panel insert 1153
2 8 Removing and installing upper steering column trim 1153
2 9 Removing and installing lower steering column trim 1154
2 10 Removing and installing glove compartment opener 1154
2 11 Removing and installing glove compartment with dash panel trim 1155
2 12 Removing and installing glove compartment cover 1156
2 12 1 Removing and installing glove compartment cover 1156
2 12 2 Removing and installing glove compartment cover 1156
2 13 Removing and installing restrictor for glove compartment 1157
2 14 Service position of glove compartment 1157
2 15 Removing and installing information electronics cover 1158
2 16 Removing and installing footwell cover on driver side 1158
3 Equipment 1160
3 1 Assembly overview – net partition 1160
3 2 Assembly overview ? sun visors 1160
3 3 Removing and installing net partition bracket 1161
3 3 1 Removing and installing upper net partition bracket 1161
3 3 2 Removing and installing lower net partition bracket 1162
3 4 Removing and installing sun visor 1162
3 5 Removing and installing sun visor centre mount 1164
3 6 Removing and installing roof grab handle 1164
4 Centre console 1167
4 1 Assembly overview – centre console 1167
4 2 Removing and installing rear centre console trim 1168
4 3 Removing and installing centre console cover 1168
4 4 Removing and installing centre console insert 1169
4 5 Removing and installing centre console 1169
4 6 Removing and installing cup holder 1170
4 7 Removing and installing rear centre console storage compartment 1170
4 8 Removing and installing centre console bracket 1171
4 9 Removing and installing front centre console trim 1172
4 10 Removing and installing centre console side trim 1172
4 11 Removing and installing rear centre console vent 1173
5 Front centre armrest 1174
5 1 Assembly overview ? front centre armrest 1174
5 2 Removing and installing front centre armrest 1174
6 Interior mirror 1176
6 1 Assembly overview – interior mirror 1176
6 2 Removing and installing interior mirror 1176
6 3 Bonding retaining plate for interior mirror 1178
69 – Passenger protection 1180
1 Safety information and repair notes 1180
1 1 Safety information 1180
1 2 Repair instructions 1180
2 Seat belts 1181
2 1 Overview of fitting locations – seat belts and anchorage points 1181
2 2 Assembly overview ? front three-point seat belt 1183
2 3 Assembly overview ? rear outer three-point seat belt 1185
2 4 Assembly overview – rear centre three-point seat belt 1185
2 5 Assembly overview ? front belt buckle 1186
2 6 Assembly overview – rear belt buckle 1187
2 7 Removing and installing front three-point seat belt [NX10]/[NX11] 1188
2 8 Removing and installing rear three-point seat belt 1191
2 8 1 Removing and installing rear outer three-point seat belt 1191
2 8 2 Removing and installing rear centre three-point seat belt 1192
2 9 Removing and installing rear belt guide 1193
2 10 Removing and installing front belt guide 1193
2 11 Removing and installing front belt end fitting 1194
2 12 Removing and installing rear outer belt end fitting 1196
2 13 Removing and installing belt height adjuster 1197
2 14 Removing and installing front belt buckle 1198
2 15 Removing and installing rear belt buckle 1199
2 15 1 Removing and installing rear right belt buckle 1199
2 15 2 Removing and installing rear centre belt buckle 1199
3 Child seat anchors 1201
3 1 Assembly overview ? front child seat anchors 1201
3 2 Assembly overview – rear child seat anchors 1201
3 3 Removing and installing front child seat anchors 1202
4 Airbag system 1204
4 1 Overview of fitting locations – airbag system 1204
5 Airbag control unit 1207
5 1 Assembly overview ? airbag control unit 1207
5 2 Removing and installing airbag control unit [J234] 1207
5 2 1 Removing and installing airbag control unit [J234], left-hand drive vehicles 1207
5 2 2 Removing and installing airbag control unit J234, right-hand drive vehicles 1209
6 Front airbag, driver side 1211
6 1 Assembly overview – front airbag, driver side 1211
6 2 Removing and installing airbag unit with airbag igniter on driver side [N95] 1211
6 3 Renewing connector on airbag 1214
7 Front passenger airbag 1216
7 1 Assembly overview – front passenger airbag 1216
7 2 Removing and installing front passenger airbag unit with igniter 1217
7 3 Removing and installing key-operated switch to deactivate airbag on front passenger side [E224] 1219
8 Side airbags 1221
8 1 Assembly overview ? front side airbag, outer side 1221
8 2 Assembly overview – front side airbag, inner side 1221
8 3 Removing and installing front outer side airbag 1222
8 4 Removing and installing front inner side airbag 1224
9 Curtain airbags 1227
9 1 Assembly overview – curtain airbag 1227
9 1 1 Assembly overview ? curtain airbag 1227
9 1 2 Assembly overview – curtain airbag, NAR 1227
9 2 Removing and installing curtain airbag with igniter 1228
10 Airbag crash sensors 1233
10 1 Assembly overview – crash sensors for airbags 1233
10 2 Removing and installing crash sensor for front airbag [G283]/[G284] 1235
10 3 Removing and installing front side airbag crash sensor [G179/G180] 1236
10 4 Removing and installing rear side airbag crash sensor [G256/G257] 1238
10 5 Removing and installing crash sensor for side airbag in B-pillar [G1101/G1102] 1239
11 Seat belt verification 1242
11 1 Assembly overview – seat occupied sensor 1242
11 1 1 Assembly overview – seat occupied sensor 1242
11 1 2 Assembly overview – seat occupied sensor, NAR 1242
11 2 Removing and installing front seat occupied sensor [G1067]/[G128] 1243
11 3 Removing and installing rear seat occupied sensor [G177/G178/G1010] 1244
12 Seat occupied recognition 1246
12 1 Overview of fitting locations – seat occupied recognition 1246
12 2 Removing and installing seat occupied recognition control unit [J706] 1246
70 – Trim, insulation 1248
1 Safety information and repair notes 1248
1 1 Safety information 1248
1 2 Repair instructions 1248
2 Front door trims 1249
2 1 Assembly overview – front door trim 1249
2 2 Removing and installing front door trim 1249
2 3 Removing and installing button trim 1252
3 Rear door trims 1254
3 1 Assembly overview – rear door trim 1254
3 2 Removing and installing button trim 1254
3 3 Removing and installing rear door trim 1255
4 Dash panel 1258
4 1 Assembly overview – dash panel 1258
4 2 Removing and installing dash panel end cover 1260
4 3 Removing and installing dash panel trim 1260
4 3 1 Removing and installing dash panel trim on driver side 1260
4 3 2 Removing and installing dash panel trim on front passenger side 1261
4 4 Removing and installing loudspeaker trim 1262
4 5 Removing and installing dash panel 1262
4 6 Removing and installing side defroster vent 1264
4 7 Removing and installing centre vent 1265
4 8 Removing and installing cover for dash panel/head-up display 1265
4 9 Removing and installing tunnel support cover 1266
5 Central tube for dash panel 1267
5 1 Assembly overview ? central tube for dash panel 1267
5 2 Assembly overview ? impact damper and glove compartment bracket 1267
5 3 Removing and installing dash panel cross member 1268
5 4 Removing and installing crash bar 1271
5 5 Removing and installing impact absorber 1272
5 5 1 Removing and installing impact damper on front passenger side 1272
5 5 2 Removing and installing left impact damper on driver side 1273
5 5 3 Removing and installing right impact damper on driver side 1274
6 Interior trims 1275
6 1 Overview of fitting locations – interior trims 1275
6 2 Assembly overview – sill panel moulding 1276
6 3 Assembly overview – A-pillar trim 1276
6 4 Assembly overview – B-pillar trim 1277
6 5 Assembly overview ? C-pillar trim 1278
6 6 Assembly overview – foot rest and floor covering 1279
6 7 Removing and installing front sill panel moulding 1280
6 8 Removing and installing rear sill panel moulding 1281
6 9 Removing and installing upper A-pillar trim 1282
6 10 Removing and installing lower A-pillar trim 1283
6 11 Removing and installing A-pillar gap cover 1284
6 12 Removing and installing upper B-pillar trim 1285
6 13 Removing and installing lower B-pillar trim 1286
6 14 Removing and installing C-pillar trim 1287
6 15 Removing and installing floor covering 1288
6 16 Removing and installing foot rest 1289
7 Luggage compartment trims 1290
7 1 Overview of fitting locations – luggage compartment trims 1290
7 2 Assembly overview ? luggage compartment side trim 1291
7 3 Assembly overview – luggage compartment floor 1291
7 4 Assembly overview ? lower rear lid trim 1292
7 5 Assembly overview ? upper rear lid trim 1293
7 6 Removing and installing lower rear lid trim 1294
7 7 Removing and installing upper rear lid trim 1296
7 8 Removing and installing luggage compartment side trim 1296
7 9 Removing and installing lock carrier trim 1297
7 10 Removing and installing support for luggage compartment floor 1298
7 11 Removing and installing side rear lid trim 1299
8 Roof trims 1300
8 1 Assembly overview ? moulded headliner 1300
8 2 Removing and installing moulded headliner 1300
8 3 Installing roof reinforcement to body 1303
72 – Seat frames 1306
1 Safety information and repair notes 1306
1 1 Safety information 1306
1 2 Repair instructions 1306
2 Overview of seat variants 1307
2 1 Overview of fitting locations – seat variants 1307
3 Front seats 1308
3 1 Overview of fitting locations ? electrical and electronic components 1308
3 1 1 Overview of fitting locations – electrical and electronic components 1308
3 1 2 Overview of fitting locations – electrical and electronic components, NAR 1310
3 2 Assembly overview ? front seat 1312
3 2 1 Assembly overview – front seat, manually adjustable 1312
3 2 2 Assembly overview – front seat, electric adjustment 1313
3 2 3 Assembly overview – front seat, Top-Sport 1315
3 3 Assembly overview – front backrest 1317
3 3 1 Assembly overview – front backrest 1317
3 3 2 Assembly overview – front backrest, Top-Sport 1318
3 4 Assembly overview – head restraint 1320
3 5 Assembly overview ? seat pan 1321
3 5 1 Assembly overview – seat pan, manual adjustment 1321
3 5 2 Assembly overview – seat pan, electric adjustment 1322
3 5 3 Assembly overview ? seat pan, fixed seat 1324
3 5 4 Assembly overview – seat pan, NAR 1325
3 6 Assembly overview ? seat height adjustment 1327
3 6 1 Assembly overview – seat height adjustment, manual 1327
3 6 2 Assembly overview ? seat height adjustment, electrical 1328
3 7 Assembly overview ? lumbar support 1329
3 8 Assembly overview ? seat rake adjustment 1330
3 9 Assembly overview ? seat depth adjustment 1331
3 10 Removing and installing front seat 1332
3 11 Removing and installing trim for backrest with integrated head restraint 1335
3 12 Removing and installing seat longitudinal adjustment handle 1336
3 13 Removing and installing seat height adjustment handle 1336
3 14 Removing and installing seat height adjuster 1337
3 14 1 Removing and installing seat height adjustment unit, manually adjustable 1337
3 14 2 Removing and installing seat height adjustment unit, electrically adjustable 1338
3 15 Removing and installing seat rake adjustment motor [V243]/[V244] 1339
3 16 Removing and installing front backrest 1340
3 17 Removing and installing head restraint 1341
3 17 1 Removing and installing head restraint 1341
3 17 2 Removing and installing integrated head restraint 1342
3 18 Removing and installing head restraint guide 1343
3 18 1 Removing and installing head restraint guide 1343
3 18 2 Removing and installing head restraint guide, integrated head restraint 1343
3 19 Removing and installing lumbar support adjustment switch [E176]/[E177] 1344
3 20 Removing and installing backrest adjuster 1345
3 21 Securing front seat to seat repair stand 1346
3 22 Removing and installing lumbar support 1346
3 23 Removing and installing seat adjustment operating unit [E470]/[E471] 1347
3 24 Removing and installing bracket for seat trim 1348
3 25 Removing and installing inner seat trim 1349
3 26 Removing and installing outer seat trim 1350
3 26 1 Removing and installing outer seat trim 1350
3 26 2 Removing and installing outer seat trim, front passenger seat without height adjustment 1351
3 27 Removing and installing seat longitudinal adjustment motor [V28]/[V31] 1352
3 28 Removing and installing seat depth adjuster 1353
3 29 Removing and installing seat adjustment control unit 1355
3 30 Removing and installing operating unit for memory settings [E464]/[E465] 1356
3 31 Removing and installing wiring harness for seat frame 1357
4 Rear seats 1359
4 1 Assembly overview – bench seat/individual seats 1359
4 2 Assembly overview ? rear seat backrest 1360
4 3 Assembly overview ? locking mechanism 1362
4 4 Assembly overview – centre armrest 1362
4 5 Removing and installing bench seat/individual seats 1363
4 6 Removing and installing seat pan 1365
4 7 Removing and installing head restraint 1366
4 8 Removing and installing head restraint guide 1367
4 9 Removing and installing rear seat backrest 1367
4 10 Removing and installing back panel trim 1369
4 11 Removing and installing trim for locking mechanism 1370
4 12 Removing and installing locking mechanism for rear seat backrest 1371
4 13 Removing and installing trim frame for load-through hatch 1372
4 14 Removing and installing flap for load-through hatch 1373
4 15 Removing and installing centre armrest 1374
74 – Seat – padding, covers 1376
1 Safety information and repair notes 1376
1 1 Repair instructions 1376
1 2 Safety information 1376
2 Front seat covers and padding 1377
2 1 Assembly overview ? seat pan cover and padding 1377
2 2 Assembly overview ? backrest cover and padding 1377
2 3 Assembly overview ? seat heating element 1378
2 4 Assembly overview ? backrest heating element 1379
2 5 Removing and installing seat pan cover and padding 1380
2 6 Removing and installing backrest cover and padding 1381
2 7 Separating seat pan cover from seat pan padding 1382
2 8 Separating backrest cover from backrest padding 1384
2 9 Removing and installing seat heating element [ZX11]/[ZX13] 1386
2 10 Removing and installing backrest heating element [Z116]/[Z117] 1387
3 Rear seat covers and padding 1389
3 1 Assembly overview – rear bench seat cover and padding 1389
3 2 Assembly overview ? rear seat backrest cover and padding 1389
3 3 Removing and installing cover and padding of rear bench seat 1390
3 4 Removing and installing cover and padding of rear seat backrest 1391
3 5 Removing and installing intermediate padding, backrest with load-through hatch 1394
3 6 Separating rear bench seat cover from padding 1394
3 7 Separating rear seat backrest cover from padding 1395
D4D807BC2FF Safety information and repair notes 1397
00 – Technical data 1401
1 Safety information 1401
1 1 General safety information 1401
1 2 Safety measures for working on vehicles with high-voltage system 1401
1 3 Safety precautions when working on the cooling system 1402
1 4 Safety precautions when working on air conditioning systems 1403
1 5 Safety measures during road test with testing and measuring instruments 1403
1 6 Safety precautions when working on passenger protection systems 1404
1 7 Safety precautions when working with chemical substances 1405
1 8 Safety precautions when working with compressed gas cylinders 1405
1 9 Safety precautions when working with batteries 1405
2 Repair notes 1406
2 1 Laws, specifications, guidelines and risk assessments 1406
2 2 Notes on the application of the workshop manual 1406
2 3 Spare parts, servicing materials and consumables 1406
2 4 Transport and storage 1408
2 5 Qualification 1409
2 6 Environmental protection 1409
2 7 Rules for cleanliness 1409
2 8 Identification labels 1409
2 9 Bolts and nuts 1410
2 10 Using power tools 1410
2 11 Contact corrosion 1411
2 12 Gaskets and seals 1411
2 13 Bonding surfaces 1412
2 14 Unplugging electrical connectors 1412
2 15 Routing and attachment of lines 1412
2 16 Retaining rings 1413
2 17 Working on refrigerant circuit 1413
2 18 Work on seat occupied recognition for front passenger airbag deactivation 1413
2 19 Battery 1414
2 20 Assessing accident vehicles 1414
2 20 1 Assessing accident vehicles, basic information 1414
2 20 2 Assessing accident vehicles, running gear 1414
2 20 3 Assessing accident vehicles, passenger protection systems 1415
D4D807CEE5B Wheels and Tyres Guide 1419
44 – Wheels, tyres, vehicle geometry 1423
1 General information 1423
2 Wheels, tyres 1424
2 1 Tightening torque for wheel bolts 1424
3 Wheel and tyre combinations 1425
3 1 Determining the correct wheel and tyre combinations according to WLTP 1425
3 2 Breakdown of version key (D2) 1427
3 2 1 Version key (D2) type approval no (K): e1*2018/858*00004*00 and e1*2018/858*00004*01 1427
3 2 2 Version key (D2) type approval no (K): e1*2018/858*00004*02 1427
3 2 3 Version key (D2) type approval no (K): e1*2018/858*00004*03 and e1*2018/858*00004*04 1427
3 2 4 Version key (D2) type approval no (K): e1*2018/858*00004*05 1428
3 2 5 Version code (D2) type approval number (K): e1*2018/858*00004*06 to e1*2018/858*00004*08 1428
3 2 6 Version code (D2) type approval number (K): e1*2018/858*00004*09 to e1*2018/858*00004*11 1429
3 3 Possible wheel and tyre combinations 1429
3 3 1 Type approval number (K): e1*2018/858*00004*00 and e1*2018/858*00004*01 1429
3 3 2 Type approval number (K): e1*2018/858*00004*02 1430
3 3 3 Type approval number (K): e1*2018/858*00004*03 1431
3 3 4 Type approval number (K): e1*2018/858*00004*04 and e1*2018/858*00004*05 1433
3 3 5 Type approval number (K): e1*2018/858*00004*06 1434
3 3 6 Type approval number (K): e1*2018/858*00004*07 and e1*2018/858*00004*08 1436
3 3 7 Type approval number (K): e1*2018/858*00004*09 to e1*2018/858*00004*11 1438
3 4 Wheel assignment 1440
3 4 1 8 J x 18 offset 45 1440
3 4 2 8 J x 19 offset 45 1441
3 4 3 8 J x 20 offset 45 1442
3 4 4 9 J x 20 offset 42 1443
3 4 5 8 5 J x 21 offset 40 1444
3 4 6 9 J x 21 offset 42 1445
3 5 Temporary spare wheel 1445
D4D807E4F94 Electrical system 1446
00 – Technical data 1452
1 Safety and repair instructions 1452
1 1 Safety information 1452
1 2 Repair instructions 1452
2 Electrical components 1453
2 1 Access to diagnoses 1453
27 – Starter, current supply, CCS 1454
1 Safety information and repair notes 1454
1 1 Safety information 1454
1 2 Repair instructions 1454
2 Battery 1455
2 1 Assembly overview – battery 1455
2 2 Removing and installing battery A 1455
2 3 Disconnecting and connecting battery 1460
2 4 Removing and installing battery tray 1463
2 5 Removing and installing earth wire with battery monitor control unit [J367] 1463
2 6 Commissioning battery monitor control unit [J367] 1464
90 – Gauges, instruments 1465
1 Safety information and repair notes 1465
1 1 Safety information 1465
1 2 Repair instructions 1465
2 Dash panel insert 1466
2 1 Assembly overview ? control unit with display unit for driver information system 1466
2 2 Assembly overview – head-up display 1466
2 3 Removing and installing control unit with display unit for driver information system [J1254] 1467
2 4 Removing and installing control unit for head-up display [J898] 1468
2 5 Calibrating control unit for head-up display [J898] 1470
2 5 1 Calibrating control unit for head-up display [J898], left-hand drive vehicles 1470
2 5 2 Calibrating control unit for head-up display [J898], right-hand drive vehicles 1472
3 Horn 1474
3 1 Assembly overview – horn 1474
3 2 Removing and installing horn or dual tone horn [H1] 1474
92 – Windscreen wash/wipe system 1476
1 Safety information and repair notes 1476
1 1 Safety information 1476
1 2 Repair instructions 1476
2 Windscreen wiper system 1477
2 1 Assembly overview – windscreen wiper system 1477
2 2 Moving wipers to service position 1478
2 3 Removing and installing wiper blade 1478
2 4 Removing and installing wiper arms 1479
2 5 Adjusting wiper arms 1481
2 6 Removing and installing wiper motor V 1483
2 7 Removing and installing rain and light sensor G397 1484
3 Windscreen washer system 1488
3 1 Assembly overview – windscreen washer system 1488
3 2 Removing and installing washer fluid reservoir 1489
3 3 Removing and installing washer pump [V59] 1490
3 4 Removing and installing washer jets 1491
4 Rear window wiper system ID4 1493
4 1 Assembly overview ? rear window wiper system 1493
4 2 Removing and installing wiper blade 1493
4 3 Removing and installing wiper arm 1494
4 4 Adjusting wiper arm 1495
4 5 Removing and installing rear window wiper motor [V12] 1496
5 Rear window washer system 1497
5 1 Assembly overview – rear window washer system 1497
5 2 Removing and installing spray jet 1497
5 2 1 Removing and installing spray jet, rear window washer system 1497
5 2 2 Removing and installing spray jet, reversing camera 1498
94 – Lights, bulbs, switches – exterior 1500
1 Safety information and repair notes 1500
1 1 Safety information 1500
1 2 Repair instructions 1500
2 Headlights 1501
2 1 Assembly overview – headlight, ECO 1501
2 1 1 Assembly overview – headlight 1501
2 2 Assembly overview – headlight, Performance 1503
2 2 1 Assembly overview – headlight 1503
2 3 Assembly overview ? LED module for daytime running light 1505
2 4 Removing and installing headlight 1506
2 5 Removing and installing front turn signal bulb [M5]/[M7], ECO headlights 1507
2 5 1 Removing and installing front turn signal bulb [M5]/[M7] 1507
2 6 Removing and installing front turn signal bulb [M5]/[M7], Performance headlights 1508
2 6 1 Removing and installing front turn signal bulb [M5]/[M7] 1508
2 7 Installing repair kit for headlight housing 1508
2 8 Removing and installing headlight range control motor [V48]/[V49], ECO headlights 1509
2 8 1 Removing and installing headlight range control motor [V48]/[V49] 1509
2 9 Removing and installing headlight range control motor [V48]/[V49], Performance headlights 1511
2 9 1 Removing and installing headlight range control motor [V48]/[V49] 1511
2 10 Removing and installing LED module for daytime running light and side light [L176]/[L177] 1513
2 11 Removing and installing bulb for VARILIS headlight [L207]/[L208] 1514
2 12 Removing and installing headlight fan [V407]/[V408] 1517
2 13 Removing and installing output module 1 for LED headlight [A27]/[A31] 1518
2 14 Removing and installing light conductor for contour lighting in radiator grille [L362]/[L363] 1519
2 15 Removing and installing LED module for daytime running lights [L377]/[L378] 1520
3 Lights in exterior mirror 1522
3 1 Removing and installing turn signal repeater bulb [L131]/[L132] 1522
3 2 Removing and installing entry light in exterior mirror [W52]/[W53] 1522
4 Tail lights 1524
4 1 Removing and installing centre rear tail light cluster [MX13] 1524
4 2 Removing and installing tail light cluster [MX3]/[MX4] 1525
4 3 Removing and installing rear fog light [X3] 1525
5 High-level brake light 1527
5 1 High-level brake light ID4 1527
5 1 1 Removing and installing high-level brake light 1527
5 2 High-level brake light ID5 1527
5 2 1 Assembly overview – high-level brake light 1527
5 2 2 Removing and installing high-level brake light bulb [M25] 1528
6 Number plate light 1530
6 1 Removing and installing number plate light [X4]/[X5] 1530
7 LED module for charging socket 1531
7 1 Removing and installing LED module for charging socket 1 [L263] 1531
8 Entry and start authorisation system 1532
8 1 Overview of fitting locations – entry and start authorisation system 1532
8 1 1 Overview of fitting locations – entry and start authorisation system, left-hand drive vehicles 1532
8 1 2 Overview of fitting locations – entry and start authorisation system, right-hand drive vehicles 1534
8 2 Overview of fitting locations – keyless entry system 1535
8 2 1 Overview of fitting locations – keyless entry system, left-hand drive vehicles 1535
8 2 2 Overview of fitting locations – keyless entry system, right-hand drive vehicles 1536
8 3 Removing and installing entry and start authorisation control unit [J518] 1537
8 3 1 Removing and installing entry and start authorisation control unit [J518], left-hand drive vehicles 1537
8 3 2 Removing and installing entry and start authorisation control unit [J518], right-hand drive vehicles 1538
8 4 Removing and installing entry and start authorisation aerials 1539
8 5 Removing and installing interior aerial 1 for entry and start system [R138] 1540
8 6 Removing and installing luggage compartment aerial for entry and start system [R137] 1541
8 7 Removing and installing front control unit for break-in protection 1541
8 8 Removing and installing rear control unit for break-in protection 1542
8 9 Removing and installing control unit for mobile-controlled entry and start authorisation system [J1308] ID4 1543
8 9 1 Removing and installing control unit for mobile-controlled entry and start authorisation system [J1308] 1543
8 10 Removing and installing aerial 1 for mobile-controlled entry and start authorisation system [R415] ID4 1544
8 10 1 Removing and installing aerial 1 for mobile-controlled entry and start authorisation system [R415] 1544
8 11 Removing and installing aerial 2 for mobile-controlled entry and start authorisation system [R416] ID4 1545
8 11 1 Removing and installing aerial 2 for mobile-controlled entry and start authorisation system [R416] 1545
9 Steering column switch module 1546
9 1 Assembly overview – steering column switch module 1546
9 2 Removing and installing steering column electronics control unit [J527] 1547
10 Towing bracket 1549
10 1 Removing and installing trailer socket [U10] 1549
96 – Lights, bulbs, switches – interior 1550
1 Safety information and repair notes 1550
1 1 Safety information 1550
1 2 Repair instructions 1550
2 Lights 1551
2 1 Overview of fitting locations – lights in dash panel 1551
2 2 Overview of fitting locations – lights in front doors 1551
2 3 Overview of fitting locations – footwell lights 1552
2 4 Overview of fitting locations ? lights in centre console 1553
2 5 Overview of fitting locations – lights in luggage compartment 1554
2 6 Overview of fitting locations ? lights in roof trim 1555
2 6 1 Overview of fitting locations – lights in roof trim 1555
2 6 2 Overview of fitting locations – lights in roof trim, with panoramic sliding sunroof 1556
2 7 Removing and installing footwell/luggage compartment light 1557
2 8 Removing and installing central locking SAFELOCK function warning lamp [K133] 1558
2 9 Removing and installing rear illuminated vanity mirror [W49]/[W50] 1558
2 10 Removing and installing dynamic light strip 1 for information in dash panel [L385] 1559
2 11 Removing and installing light 1 for front centre console background lighting [L193] 1560
3 Controls 1562
3 1 Overview of fitting locations – controls in dash panel 1562
3 2 Overview of fitting locations – controls in front doors 1563
3 3 Overview of fitting locations – controls in rear doors 1564
3 4 Overview of fitting locations – controls in luggage compartment 1564
3 5 Overview of fitting locations ? controls in roof trim 1565
3 5 1 Overview of fitting locations – controls in roof trim 1565
3 5 2 Overview of fitting locations – controls in roof trim, with panoramic sliding sunroof 1566
3 6 Removing and installing operating unit for lighting [EX59] 1567
3 7 Removing and installing centre switch module in dash panel [EX22] 1568
3 8 Removing and installing operating unit for window regulator in driver door [EX36] 1568
3 9 Removing and installing window regulator switch/door operating unit 1569
3 10 Removing and installing rear lid remote release button [E233] 1570
3 11 Removing and installing starter button [E378] 1571
3 12 Removing and installing towing bracket release button [E754] 1571
3 13 Removing and installing rear lid closure button 1572
3 14 Removing and installing rear lid warning buzzer [H32] 1573
3 15 Removing and installing front roof module [WX3] 1573
3 16 Removing and installing rear interior light/reading light 1574
3 16 1 Removing and installing rear interior light [WX2] 1574
3 16 2 Removing and installing rear interior light [W47]/[W48] 1574
4 Anti-theft alarm system 1576
4 1 Assembly overview – interior monitor 1576
4 1 1 Assembly overview – interior monitoring, left-hand drive vehicles 1576
4 1 2 Assembly overview – interior monitoring, RHD vehicles 1576
4 2 Removing and installing alarm horn [H12] 1577
4 3 Removing and installing anti-theft alarm sensor [G578] 1578
5 Cigarette lighter, socket 1580
5 1 Removing and installing 12 V socket [U5/U19] 1580
97 – Wiring 1581
1 Safety information and repair notes 1581
1 1 Safety information 1581
1 2 Repair instructions 1581
2 Relay carriers, fuse holders, electronics boxes 1582
2 1 Overview of fitting locations – relay carriers, fuse carriers 1582
2 2 Assembly overview ? relay carriers, fuse holders, electronics boxes 1582
2 2 1 Assembly overview – fuse holder A 1582
2 2 2 Assembly overview ? fuse holder B 1583
2 3 Removing and installing electronics box 1584
2 4 Removing and installing fuse holder A [SA] 1585
2 5 Removing and installing fuse holder B [SB] 1587
2 6 Removing and installing fuse holder C [SC] 1589
2 6 1 Removing and installing fuse holder C [SC] 1589
2 6 2 Removing and installing bracket for fuse holder C [SC], left-hand drive vehicles 1590
2 6 3 Removing and installing bracket for fuse holder C [SC], right-hand drive vehicles 1590
3 Control units 1592
3 1 Overview of fitting locations – control units 1592
3 1 1 Overview of fitting locations – control units, left-hand drive vehicles 1592
3 1 2 Overview of fitting locations – control units, right-hand drive vehicles 1592
3 2 Removing and installing onboard supply control unit [J519] 1593
3 2 1 Removing and installing onboard supply control unit [J519], left-hand drive vehicles 1593
3 2 2 Removing and installing onboard supply control unit [J519], right-hand drive vehicles 1594
3 3 Removing and installing bracket for onboard supply control unit [J519] 1595
3 3 1 Removing and installing bracket for onboard supply control unit [J519], left-hand drive vehicles 1595
3 3 2 Removing and installing bracket for onboard supply control unit [J519], right-hand drive vehicles 1596
3 4 Removing and installing data bus diagnostic interface [J533] 1598
3 5 Removing and installing fan for control unit [V274] 1598
D4D807E4FAD Running gear axles steering 1600
00 – Technical data 1606
1 Safety information and repair notes 1606
1 1 Safety information 1606
1 2 Repair instructions 1606
2 Electrical components 1607
2 1 Starting diagnosis 1607
3 Technical data 1609
3 1 Test and adjustment values 1609
40 – Front suspension 1610
1 Safety information and repair notes 1610
1 1 Safety information 1610
1 2 Repair instructions 1610
2 Front axle 1611
2 1 Overview of fitting locations – front axle, rear-wheel drive 1611
2 1 1 Overview of fitting locations – front axle 1611
2 2 Overview of fitting locations – front axle, all-wheel drive 1612
2 2 1 Overview of fitting locations – front axle 1612
3 Subframe 1613
3 1 Assembly overview – subframe 1613
3 1 1 Assembly overview – subframe 1613
3 2 Removing and installing subframe with steering rack 1615
3 2 1 Removing and installing subframe 1615
3 3 Removing and installing subframe with steering rack and motor 1620
3 3 1 Removing and installing subframe 1620
3 4 Servicing threads in longitudinal member 1631
3 5 Fixing subframe in position 1631
3 6 Taking up weight of subframe using scissor-type assembly platform 1635
3 7 Preparing scissor-type assembly platform 1636
3 8 Supporting components in vehicle front end 1638
3 9 Renewing front motor mounting, all-wheel drive 1643
3 9 1 Renewing front motor mounting 1643
4 Suspension strut, upper suspension link 1645
4 1 Assembly overview – suspension strut 1645
4 2 Removing and installing suspension strut 1647
4 3 Removing and installing spring 1655
5 Lower suspension link, swivel joint 1661
5 1 Assembly overview – suspension link, swivel joint 1661
5 2 Removing and installing suspension link 1663
5 3 Removing and installing swivel joint 1664
5 4 Removing and installing stone deflector for suspension link 1666
5 5 Renewing front suspension link bush 1667
5 6 Renewing suspension link bush, rear 1671
6 Wheel bearing 1674
6 1 Assembly overview – wheel bearing assembly, rear-wheel drive 1674
6 1 1 Assembly overview – wheel bearing 1674
6 2 Assembly overview – wheel bearing, all-wheel drive 1674
6 2 1 Assembly overview – wheel bearing 1674
6 3 Removing and installing wheel bearing housing 1675
6 4 Removing and installing wheel bearing unit 1679
6 5 Loosening and tightening threaded connections of wheel bearings 1681
7 Drive shaft 1684
7 1 Assembly overview – drive shaft 1684
7 2 Removing and installing drive shaft 1685
7 3 Loosening and tightening threaded connections of drive shaft 1690
7 4 Dismantling and assembling drive shaft 1692
7 4 1 Removing and installing outer constant velocity joint 1692
7 4 2 Removing and installing triple roller joint 1694
7 5 Tensioning clamp for boot 1698
8 Anti-roll bar 1700
8 1 Assembly overview – anti-roll bar 1700
8 2 Removing and installing anti-roll bar 1700
8 3 Removing and installing coupling rod 1702
42 – Rear suspension 1704
1 Safety information and repair notes 1704
1 1 Safety information 1704
1 2 Repair instructions 1704
2 Rear axle 1705
2 1 Overview of fitting locations – rear axle 1705
2 2 Removing and installing rear axle 1707
2 3 Lowering rear axle 1711
2 3 1 Lowering rear axle, front section 1711
2 3 2 Lowering rear axle, rear section 1715
2 4 Securing vehicle to support arms of lifting platform 1717
3 Subframe 1719
3 1 Assembly overview – subframe mountings 1719
3 2 Assembly overview – subframe 1719
3 3 Fixing subframe in position 1720
3 4 Preparing scissor-type assembly platform 1723
3 5 Taking up weight of subframe using scissor-type assembly platform 1725
3 6 Renewing gearbox mounting 1727
3 7 Renewing motor mountings 1734
3 8 Renewing front subframe mountings 1741
3 9 Renewing rear subframe mountings 1748
4 Anti-roll bar 1755
4 1 Assembly overview – anti-roll bar 1755
4 2 Removing and installing anti-roll bar 1757
4 3 Removing and installing coupling rod 1758
5 Suspension link, track rod 1761
5 1 Assembly overview ? suspension link 1761
5 1 1 Assembly overview – upper suspension link 1761
5 1 2 Assembly overview – lower suspension link 1761
5 2 Removing and installing track rod 1762
5 3 Assembly overview – track rod 1764
5 4 Removing and installing stone deflector for spring control arm 1765
5 5 Assembly overview – spring control arm 1766
5 6 Removing and installing spring control arm 1767
5 7 Removing and installing lower suspension link 1770
5 8 Removing and installing upper rear suspension link 1772
5 9 Removing and installing upper front suspension link 1773
6 Suspension strut, shock absorber, spring 1775
6 1 Exploded view – shock absorber 1775
6 2 Assembly overview – spring 1775
6 3 Removing and installing shock absorber 1776
6 4 Renewing shock absorber 1778
6 5 Removing and installing spring 1781
6 6 Renewing spring 1790
7 Wheel bearing assembly, trailing arm 1798
7 1 Assembly overview – wheel bearing assembly 1798
7 2 Removing and installing wheel bearing housing 1798
7 3 Removing and installing wheel bearing unit 1801
7 4 Raising wheel bearing assembly to unladen position 1802
8 Drive shaft 1806
8 1 Assembly overview – drive shaft 1806
8 2 Removing and installing drive shaft 1807
8 3 Loosening and tightening threaded connections of drive shaft 1814
8 4 Dismantling and assembling drive shaft 1816
8 4 1 Removing and installing outer constant velocity joint 1816
8 4 2 Removing and installing triple roller joint 1818
8 5 Tensioning clamp for boot 1822
43 – Self-levelling suspension 1824
1 Safety information and repair notes 1824
1 1 Safety information 1824
1 2 Repair instructions 1824
2 Electronic damping control 1825
2 1 Overview of fitting locations – damping control 1825
2 2 Assembly overview – electronically controlled damping control unit 1827
2 3 Exploded view – damping control 1827
2 4 Removing and installing electronically controlled damping control unit [J250] 1828
2 5 Removing and installing front body acceleration senders [G341]/[G342] 1829
2 6 Removing and installing rear body acceleration sender [G343] 1830
3 Vehicle level sender 1832
3 1 Exploded view – front vehicle level senders 1832
3 2 Assembly overview – rear vehicle level senders 1832
3 3 Removing and installing front vehicle level senders [G78]/[G289] 1833
3 4 Removing and installing rear vehicle level senders [G76]/[G77] 1835
44 – Wheels, tyres, vehicle geometry 1837
1 Safety information and repair notes 1837
1 1 Safety information 1837
1 2 Repair instructions 1837
2 Wheel alignment 1838
2 1 Notes on wheel alignment 1838
2 2 Test requirements 1838
2 3 Specifications for wheel alignment 1838
2 4 Setting vehicle to initial position for wheel alignment 1840
2 5 When does wheel alignment have to be checked? 1840
2 6 Adjusting camber at front wheels 1841
2 7 Adjusting camber at rear wheels 1842
2 8 Adjusting toe setting at rear wheels 1843
2 9 Adjusting toe setting at front wheels 1844
2 10 Checking full steering lock 1844
2 11 Preparations for measurement 1845
3 Wheels, tyres 1846
3 1 Removing wheel 1846
3 2 Installing wheel 1846
48 – Steering 1848
1 Safety information and repair notes 1848
1 1 Safety information 1848
1 2 Repair instructions 1848
2 Steering wheel 1849
2 1 Assembly overview – steering wheel 1849
2 2 Removing and installing steering wheel 1849
3 Steering column 1851
3 1 Assembly overview – steering column 1851
3 1 1 Assembly overview – steering column, left-hand drive vehicles 1851
3 1 2 Assembly overview – steering column, right-hand drive 1853
3 2 Checking steering column for damage 1855
3 3 Removing and installing steering column 1855
3 4 Removing and installing intermediate steering shaft 1858
3 5 Removing and installing control unit for electronic steering column lock [J764] 1860
4 Steering rack 1864
4 1 Assembly overview ? steering rack 1864
4 1 1 Assembly overview – steering rack, left-hand drive 1864
4 1 2 Assembly overview – steering rack, right-hand drive 1864
4 2 Exploded view – track rods 1865
4 3 Removing and installing steering rack, rear-wheel drive 1867
4 3 1 Removing and installing steering rack, left-hand drive 1867
4 3 2 Removing and installing steering rack, right-hand drive vehicle 1869
4 4 Removing and installing steering rack, all-wheel drive 1871
4 4 1 Removing and installing steering rack 1871
4 5 Repairing steering rack 1873
4 6 Removing and installing boot 1873
4 7 Removing and installing track rod 1875
4 8 Removing and installing track rod ball joint 1877
D4D807E4FBC General body repairs exterior 1880
00 – Technical data 1890
1 Safety information and repair notes 1890
1 1 Safety information 1890
1 2 Repair instructions 1890
2 Electrical components 1891
2 1 Access to diagnoses 1891
3 Repair instructions 1892
3 1 General information for use of adhesives 1892
3 2 Bonding surfaces for self-adhesive components 1893
3 2 1 Specifications for installation of self-adhesive components 1893
50 – Body – front 1895
1 Safety information and repair notes 1895
1 1 Safety information 1895
1 2 Repair instructions 1895
2 Lock carrier 1896
2 1 Assembly overview – lock carrier 1896
2 2 Removing and installing lock carrier 1896
2 3 Removing and installing anti-vibration brace 1898
2 4 Removing and installing lock carrier support 1898
3 Wings 1900
3 1 Assembly overview ? wing 1900
3 2 Removing and installing wing 1900
3 3 Removing and installing end plate 1902
3 4 Removing and installing wing bracket 1903
3 5 Removing and installing wing bracket 1904
3 6 Removing and installing bracket for deformation element 1904
4 Bulkhead 1906
4 1 Assembly overview – bulkhead 1906
4 2 Assembly overview ? plenum chamber cover 1906
4 3 Removing and installing bulkhead 1907
4 4 Removing and installing plenum chamber cover 1909
55 – Bonnet, rear lid 1911
1 Safety information and repair notes 1911
1 1 Safety information 1911
1 2 Repair instructions 1911
2 Bonnet 1912
2 1 Assembly overview – bonnet 1912
2 2 Assembly overview – Bowden cable 1914
2 3 Removing and installing bonnet 1915
2 4 Adjusting bonnet 1915
2 5 Adjusting hinges 1916
2 6 Adjusting striker pin 1917
2 7 Adjusting adjusting buffers 1918
2 8 Adjusting bonnet lock 1919
2 9 Removing and installing bonnet lock 1920
2 10 Removing and installing bonnet lock operating lever 1921
2 11 Removing and installing striker pin 1922
2 12 Removing and installing hinge 1922
2 13 Removing and installing Bowden cable 1923
2 14 Removing and installing bonnet stay 1926
3 Rear lid 1927
3 1 Assembly overview – rear lid 1927
3 2 Assembly overview – electrically operated rear lid 1930
3 3 Removing and installing rear lid 1932
3 4 Adjusting rear lid 1933
3 5 Adjust adjustment buffer at bottom 1935
3 6 Adjusting adjusting buffer at side 1936
3 7 Adjusting striker pin 1937
3 8 Removing and installing power latching for rear lid [VX16] 1937
3 9 Removing and installing Bowden cable for power latching system 1938
3 10 Removing and installing rear lid handle [EX37] 1940
3 11 Removing and installing adapter for rear lid handle 1941
3 12 Removing and installing hinge 1942
3 13 Removing and installing adjusting buffer at bottom 1944
3 14 Removing and installing adjusting buffer at side 1944
3 15 Removing and installing stop for adjusting buffer 1945
3 16 Removing and installing striker pin 1945
3 17 Removing and installing rear lid seal 1946
3 17 1 Removing and installing rear lid seal 1946
3 17 2 Removing and installing rear lid seal at roof channel 1947
3 18 Removing and installing gas strut 1948
3 19 Removing and installing rear lid drive unit [VX69]/[VX77] 1949
3 20 Removing and installing rear lid power opening sender [G750]/[G760] 1950
3 21 Rear lid control unit [J605] 1952
3 21 1 Removing and installing rear lid control unit [J605] 1952
3 21 2 Removing and installing holder for rear lid control unit [J605] 1952
3 22 Rear lid lock unit [VX25] 1953
3 22 1 Removing and installing rear lid lock unit [VX25] 1953
3 22 2 Removing and installing rear lid lock unit [VX25] with power latching system 1954
3 23 Rear lid power opening control unit [J938] 1954
3 23 1 Removing and installing rear lid power opening control unit [J938] 1954
3 23 2 Removing and installing holder for rear lid power opening control unit [J938] 1955
3 24 Preparing gas strut for disposal 1956
3 25 Preparing rear lid drive unit [VX69]/rear lid drive unit 2 [VX77] for disposal 1957
3 26 Removing and installing ball stud 1957
4 Charging flap unit 1960
4 1 Assembly overview – charging flap unit 1960
4 2 Removing and installing charging flap unit 1960
4 3 Removing and installing charging flap 1962
4 4 Removing and installing LED module for charging socket 1 [L263] 1963
57 – Front doors, door components, central locking 1965
1 Safety information and repair notes 1965
1 1 Repair instructions 1965
1 2 Safety information 1965
2 Door 1966
2 1 Assembly overview – door 1966
2 2 Removing and installing inner door seal 1968
2 3 Removing and installing outer door seal 1970
2 4 Removing and installing door 1974
2 5 Adjusting door 1976
2 6 Adjusting striker pin 1978
2 7 Removing and installing door hinge 1979
2 8 Removing and installing door arrester 1980
3 Door components 1982
3 1 Assembly overview – door components 1982
3 2 Assembly overview – assembly carrier 1982
3 3 Assembly overview – door handle and door lock 1983
3 4 Removing and installing window regulator motor [V147]/[V148] 1985
3 5 Removing and installing striker pin 1986
3 6 Removing and installing exterior door handle [EX6]/[EX7] 1986
3 7 Dismantling and assembling exterior door handle [EX6]/[EX7] 1988
3 8 Removing and installing mounting bracket 1991
3 9 Removing and installing lock unit [VX21]/[VX22] 1992
3 10 Removing and installing assembly carrier 1993
3 11 Removing and installing window channel 1995
3 12 Removing and installing inner window slot seal 1996
3 13 Removing and installing window slot outer seal 1998
3 14 Removing and installing lock cylinder 1999
3 15 Removing and installing cap on door handle 2000
3 16 Removing and installing Bowden cable for exterior door handle 2001
3 17 Removing and installing Bowden cable for interior door handle 2001
4 Central locking 2003
4 1 Overview of fitting locations – central locking system 2003
4 2 Removing and installing door control unit [J386]/[J387] 2005
4 3 Removing and installing rear door control unit [J926]/[J927] 2006
4 4 Removing and installing ignition key battery 2007
4 5 Removing and installing actuator for high-voltage charging flap lock [F496] 2007
58 – Rear doors, door components 2009
1 Safety information and repair notes 2009
1 1 Safety information 2009
1 2 Repair instructions 2009
2 Door 2010
2 1 Assembly overview – door 2010
2 2 Removing and installing door 2012
2 3 Adjusting door 2014
2 4 Adjusting striker pin 2016
2 5 Removing and installing door hinge 2017
2 6 Removing and installing door arrester 2018
2 7 Removing and installing outer door seal 2019
2 8 Removing and installing inner door seal 2023
3 Door components 2025
3 1 Assembly overview – door components 2025
3 2 Assembly overview – assembly carrier 2025
3 3 Assembly overview – door handle and door lock 2026
3 4 Removing and installing rear window regulator motor [V471]/[V472] 2027
3 5 Removing and installing striker pin 2029
3 6 Removing and installing rear exterior door handle [EX8]/[EX9] 2029
3 7 Dismantling and assembling rear exterior door handle [EX8]/[EX9] 2031
3 8 Removing and installing mounting bracket 2034
3 9 Removing and installing rear door lock unit [VX83]/[VX84] 2035
3 10 Removing and installing assembly carrier 2036
3 11 Removing and installing window channel 2037
3 12 Removing and installing window slot outer seal 2039
3 13 Removing and installing inner window slot seal 2041
3 14 Removing and installing Bowden cable for exterior door handle 2042
3 15 Removing and installing Bowden cable for interior door handle 2043
60 – Sunroof 2044
1 Safety information and repair notes 2044
1 1 Safety information 2044
1 2 Repair instructions 2044
2 Sliding sunroof 2045
2 1 Assembly overview – glass panel 2045
2 2 Assembly overview – sun blind 2045
2 3 Removing and installing glass panel 2047
2 4 Removing and installing frame with sun blind 2053
2 5 Removing and installing sliding sunroof adjustment control unit [J245] 2053
2 6 Removing and installing sun blind 2054
2 7 Adapting sliding sunroof adjustment control unit [J245] 2056
2 8 Removing and installing sunroof roller blind motor [V260] 2056
2 9 Removing and installing sun blind cables 2057
2 10 Manual operation 2058
2 11 Minimum drying time for bonded glass panels 2058
2 12 Installations instructions for bonded glass panels 2059
2 12 1 Installation instructions for bonded windows and glass panels 2059
2 12 2 Materials for bonded glass panels 2060
3 Water drain hoses 2061
3 1 Assembly overview – water drain hoses 2061
3 2 Cleaning water drain hoses 2061
3 3 Removing and installing water drain hoses 2062
63 – Bumpers 2064
1 Safety information and repair notes 2064
1 1 Safety information 2064
1 2 Repair instructions 2064
2 Bumper, front 2065
2 1 Assembly overview – bumper cover 2065
2 2 Assembly overview – bumper carrier 2067
2 3 Assembly overview – add-on parts 2068
2 4 Removing and installing bumper cover 2070
2 5 Repairing bumper cover 2071
2 6 Moving bumper carrier to and back from service position 2072
2 7 Removing and installing bumper carrier 2073
2 8 Removing and installing radar sensor cover 2074
2 9 Removing and installing centre air intake grille 2076
2 10 Removing and installing trim for side air intake grille 2077
2 11 Removing and installing air duct 2077
2 12 Removing and installing closure section of bumper cover 2078
2 13 Removing and installing bottom end plate of bumper cover 2079
2 13 1 Removing and installing lower closure section of bumper cover 2079
2 14 Removing and installing bottom end plate of bumper cover, GTX 2079
2 14 1 Removing and installing bottom end plate of bumper cover 2079
2 15 Removing and installing reinforcement of bumper cover 2080
2 15 1 Removing and installing reinforcement of bumper cover 2080
2 16 Removing and installing reinforcement of bumper cover, GTX 2081
2 16 1 Removing and installing reinforcement of bumper cover 2081
2 17 Removing and installing front spoiler of bumper cover 2082
2 17 1 Removing and installing front spoiler of bumper cover 2082
2 18 Removing and installing front spoiler of bumper cover, GTX 2083
2 18 1 Removing and installing front spoiler of bumper cover 2083
2 19 Removing and installing spoiler strip 2084
2 20 Removing and installing cover section for bumper cover 2084
2 21 Removing and installing trim 2085
2 22 Removing and installing trim strip 2086
2 23 Installing holder for park assist steering sender 2086
2 24 Removing and installing towing eye cap 2089
2 25 Removing and installing side marker reflector 2089
2 26 Removing and installing number plate carrier, version 1 2091
2 26 1 Removing and installing number plate carrier 2091
2 27 Removing and installing number plate carrier, version 2 2092
2 27 1 Removing and installing number plate carrier 2092
3 Bumper, rear 2094
3 1 Assembly overview – bumper cover 2094
3 2 Assembly overview – bumper carrier 2094
3 3 Assembly overview – attachments 2095
3 4 Removing and installing bumper cover 2097
3 5 Repairing bumper cover 2100
3 6 Removing and installing bumper carrier 2100
3 7 Removing and installing base plate for bumper cover 2101
3 7 1 Removing and installing base plate for bumper cover 2101
3 8 Removing and installing base plate for bumper cover, GTX 2101
3 8 1 Removing and installing base plate for bumper cover 2101
3 9 Removing and installing top section of bumper cover 2102
3 10 Removing and installing bottom section of bumper cover 2103
3 11 Removing and installing bumper cover trim 2103
3 12 Installing holder for park assist steering sender 2104
3 13 Installing number plate 2106
3 14 Removing and installing towing eye cap 2107
3 14 1 Removing and installing towing eye cap, two-piece 2107
3 15 Removing and installing towing eye cap, GTX 2108
3 15 1 Removing and installing towing eye cap, one-piece 2108
3 16 Removing and installing forced ventilation for passenger compartment 2108
3 17 Checking forced ventilation for passenger compartment 2109
64 – Glazing 2110
1 Safety information and repair notes 2110
1 1 Safety information 2110
1 2 Repair instructions 2110
2 Repair notes 2111
2 1 Minimum drying times for bonded windows 2111
2 2 Repairing windows 2111
2 3 Installation instructions for bonded windows 2111
2 3 1 Installation instructions for bonded windows and glass panels 2111
2 3 2 Materials for bonded windows 2112
2 4 Preparing old undamaged windows for installing 2113
2 5 Preparing new windows for installing 2114
2 6 Preparing body flange for installing 2115
2 7 Removing broken window 2117
2 8 Cleaning off excess adhesive 2118
3 Windscreen 2119
3 1 Assembly overview – windscreen 2119
3 2 Removing and installing windscreen 2119
3 3 Removing broken windscreen 2125
4 Rear windscreen 2126
4 1 Assembly overview – rear window 2126
4 2 Removing and installing rear window 2126
4 3 Removing broken rear window 2129
5 Side windows 2130
5 1 Assembly overview – rear side windows 2130
5 2 Removing and installing rear side window 2130
5 3 Removing broken rear side window 2133
6 Door windows 2134
6 1 Assembly overview – front door window 2134
6 2 Assembly overview ? fixed front door window 2134
6 3 Assembly overview – rear door window 2135
6 4 Assembly overview – fixed rear door window 2136
6 5 Removing and installing front door window 2137
6 6 Removing and installing rear door window 2140
6 7 Removing and installing fixed front door window 2142
6 8 Removing and installing fixed rear door window 2143
66 – Exterior equipment 2146
1 Safety information and repair notes 2146
1 1 Safety information 2146
1 2 Repair instructions 2146
2 Spoiler 2147
2 1 Assembly overview – spoiler 2147
2 2 Removing and installing side spoiler 2147
2 3 Removing and installing spoiler trim 2149
2 4 Removing and installing spoiler trim carrier 2150
3 Mouldings, trims, extensions 2153
3 1 Assembly overview – covers 2153
3 2 Assembly overview – step moulding 2153
3 3 Assembly overview – side member trim 2154
3 4 Assembly overview – water deflector 2155
3 5 Assembly overview ? C-pillar trim 2156
3 6 Assembly overview – wheel arch trims 2157
3 7 Removing and installing step moulding 2159
3 8 Removing and installing side member trim 2160
3 9 Removing and installing water deflector 2162
3 10 Removing and installing retaining strip 2162
3 11 Removing and installing A-pillar trim 2163
3 12 Removing and installing B-pillar trim on door 2164
3 12 1 Removing and installing B-pillar trim on front door 2164
3 12 2 Removing and installing B-pillar trim on rear door 2166
3 13 Removing and installing C-pillar trim 2167
3 14 Removing and installing front wheel arch trim 2169
3 15 Removing and installing wing cover 2171
3 15 1 Removing and installing wing cover 2171
3 16 Removing and installing rear wheel cover 2172
3 17 Removing and installing trim cover for front door 2173
3 18 Removing and installing trim cover for rear door 2174
3 18 1 Removing and installing trim cover for rear door 2174
3 19 Removing and installing trim cover for rear door, GTX 2176
3 19 1 Removing and installing trim cover for rear door 2176
4 Underbody cladding 2178
4 1 Assembly overview – underbody cladding, 55, 62 kWh 2178
4 1 1 Assembly overview – underbody cladding 2178
4 2 Assembly overview – underbody cladding, 82 kWh 2180
4 2 1 Assembly overview – underbody cladding 2180
4 3 Assembly overview – underbody cladding, 82 kWh, GTX 2182
4 3 1 Assembly overview – underbody cladding 2182
4 4 Removing and installing high-voltage battery skid plate, 55, 62 kWh 2184
4 4 1 Removing and installing high-voltage battery skid plate 2184
4 5 Removing and installing high-voltage battery skid plate, 82 kWh 2186
4 5 1 Removing and installing high-voltage battery skid plate 2186
4 6 Removing and installing front underbody cladding 2187
4 7 Removing and installing side underbody cladding, 55 kWh, 62 kWh 2188
4 7 1 Removing and installing side underbody cladding 2188
4 8 Removing and installing side underbody cladding, 82 kWh 2189
4 8 1 Removing and installing side underbody cladding 2189
4 9 Removing and installing centre underbody cladding 2191
4 10 Removing and installing rear underbody cladding 2191
4 11 Removing and installing skid plate 2192
4 12 Removing and installing underbody towing eye 2193
4 13 Removing and installing power unit skid plate 2194
4 13 1 Removing and installing power unit skid plate 2194
4 14 Removing and installing power unit skid plate 2195
4 14 1 Removing and installing power unit skid plate 2195
4 15 Removing and installing underbody cladding, rear centre 2195
4 15 1 Removing and installing rear centre underbody cladding 2195
5 Roof moulding and roof railing 2197
5 1 Assembly overview ? roof railing 2197
5 2 Assembly overview ? roof trim strip 2197
5 3 Removing and installing roof railing 2198
5 4 Removing and installing roof trim strip 2199
6 Exterior mirror 2201
6 1 Assembly overview – exterior mirror 2201
6 2 Removing and installing exterior mirror [VX4]/[VX5] 2203
6 3 Removing and installing mirror glass 2204
6 4 Removing and installing mirror adjustment unit 2206
6 5 Removing and installing upper mirror cover 2206
6 6 Removing and installing lower mirror cover 2207
6 7 Removing and installing mirror frame 2208
7 Wheel housing liner 2210
7 1 Assembly overview – front wheel housing liner 2210
7 2 Assembly overview – rear wheel housing liner 2210
7 3 Removing and installing front wheel housing liner 2211
7 4 Removing and installing rear wheel housing liner 2213
7 5 Removing and installing side member trim 2214
8 Lettering and emblems 2215
8 1 Assembly overview – lettering and badges 2215
8 2 Removing and installing front badge 2215
8 3 Removing and installing badge at rear 2216
8 4 Removing and installing lettering at rear 2217
8 5 Renewing lettering and badges on sides 2218
9 Towing bracket 2220
9 1 Removing and installing trailer detector control unit [J345] 2220
9 2 Hinged towing bracket [VX15] 2220
9 2 1 Assembly overview – towing bracket 2220
9 2 2 Removing and installing hinged tow attachment ball head motor [V317] 2221
9 2 3 Removing and installing hinged towing bracket [VX15] 2222
9 3 Towing bracket with mounting for trailer coupling ball head 2223
9 3 1 Assembly overview – towing bracket 2223
9 3 2 Removing and installing towing bracket 2224
D4D807E4FD8 Heating air conditioning system 2226
00 – Technical data 2232
1 Safety and repair instructions 2232
1 1 Safety information 2232
1 2 Repair instructions 2232
2 General notes, R134a/R1234yf 2233
2 1 Type plates 2233
3 General notes, R744 2234
3 1 Type plates 2234
4 Technical data, R134a/1234yf 2235
4 1 Capacities for refrigerant R134a 2235
4 1 1 Refrigerant capacities 2235
4 2 Refrigerant capacities, R1234yf 2235
4 2 1 Refrigerant capacity 2235
4 3 Capacities for refrigerant oil R134a 2235
4 3 1 Refrigerant oil capacities 2235
4 4 Refrigerant oil capacities, R1234yf 2235
4 4 1 Refrigerant oil capacities 2235
4 5 Oil distribution 2235
4 6 Refrigerant oil capacities after renewal of components 2236
5 Technical data, R744 2237
5 1 Refrigerant capacity 2237
5 2 Refrigerant oil capacities 2237
5 3 Oil distribution 2237
6 Electrical components 2238
6 1 Access to diagnoses 2238
87 – Air conditioning system 2240
1 Safety information and repair notes 2240
1 1 Safety information 2240
1 2 Repair instructions 2240
2 Overview of fitting locations – air conditioning system, R134a/R1234yf 2241
2 1 Overview of fitting locations – components not located in passenger compartment 2241
2 2 Overview of fitting locations – components located in front section of passenger compartment 2243
3 Overview of fitting locations – air conditioning system, R744 2246
3 1 Overview of fitting locations – components not located in passenger compartment 2246
3 2 Overview of fitting locations – components located in front section of passenger compartment 2248
4 Refrigerant circuit, R134a/R1234yf 2251
4 1 System overview – refrigerant circuit 2251
4 2 Assembly overview – refrigerant lines 2253
4 3 Assembly overview – heat exchanger for high-voltage battery 2255
4 4 Exploded view – condenser 2256
4 5 Removing and installing refrigerant pressure and temperature sender [G395] 2257
4 6 Removing and installing pressure sender for refrigerant circuit G805 2258
4 7 Removing and installing expansion valve 2259
4 8 Detaching and attaching refrigerant line at expansion valve 2260
4 9 Removing and installing condenser 2261
4 10 Removing and installing desiccant bag 2261
4 11 Removing and installing evacuating and charging valve (low-pressure and high-pressure sides) 2263
4 12 Removing and installing refrigerant expansion valve 1 N636 2264
4 13 Removing and installing heat exchanger for high-voltage battery 2266
4 14 Removing and installing refrigerant shut-off valve for heater and air conditioning unit [N541] 2269
4 14 1 Removing and installing refrigerant shut-off valve for heater and air conditioner unit [N541], left-hand drive vehicles 2269
4 14 2 Removing and installing refrigerant shut-off valve for heater and air conditioning unit N541 – right-hand drive vehicles 2271
4 15 Removing and installing refrigerant line, R134a/R1234yf 2273
4 15 1 Removing and installing refrigerant line from condenser to expansion valve 2273
4 15 2 Removing and installing refrigerant line from air conditioner compressor to expansion valve 2275
4 15 3 Removing and installing refrigerant line from condenser to air conditioner compressor [VX81] 2277
4 15 4 Removing and installing refrigerant line from heat exchanger for high-voltage battery to high-pressure line 2278
4 15 5 Removing and installing refrigerant line from heat exchanger for high-voltage battery to low-pressure line 2279
4 16 Detaching and attaching refrigerant lines at condenser 2280
4 17 Cleaning refrigerant circuit 2281
5 Refrigerant circuit, R744 2285
5 1 System overview – refrigerant circuit 2285
5 2 Assembly overview – refrigerant lines 2287
5 3 Removing and installing refrigerant pressure and temperature sender G395 2289
5 4 Removing and installing gas cooler 2291
5 5 Removing and installing dryer 2291
5 6 Removing and installing evacuating and charging valve (low-pressure and high-pressure sides) 2293
5 7 Removing and installing refrigerant pressure and temperature sender 2 [G826] 2294
5 8 Removing and installing refrigerant pressure and temperature sender 3 G827 2296
5 9 Removing and installing refrigerant pressure and temperature sender 4 G828 2297
5 10 Removing and installing refrigerant pressure and temperature sender 5 [G829] 2299
5 11 Removing and installing pressure limiting valve 2300
5 12 Removing and installing heat exchanger for high-voltage battery 2301
5 13 Removing and installing heat condenser 2303
5 14 Removing and installing refrigerant line 2303
5 14 1 Removing and installing refrigerant line between air conditioner compressor and dryer 2303
5 14 2 Removing and installing refrigerant line between air conditioner compressor and valve block N641/N640 2305
5 14 3 Removing and installing refrigerant line between dryer and gas cooler 2306
5 14 4 Removing and installing refrigerant line between gas cooler and refrigerant shut-off valve 2 [N640] 2308
5 14 5 Removing and installing refrigerant line between refrigerant shut-off valve 3 N641 and heat condenser 2309
5 14 6 Removing and installing refrigerant line between expansion valve N638/N637 and evaporator 2310
5 14 7 Removing and installing refrigerant line between heat pump valve unit and evaporator 2312
5 14 8 Removing and installing refrigerant line between expansion valve N636/N696 and heat condenser 2313
5 15 Disconnecting and connecting refrigerant lines on gas cooler 2314
5 16 Cleaning refrigerant circuit 2315
6 Valve unit of heat pump, R744 2319
6 1 Assembly overview – heat pump valve unit 2319
6 2 Removing and installing valve unit of heat pump 2323
6 3 Removing and installing refrigerant expansion valve 1 [N636] 2326
6 4 Removing and installing refrigerant expansion valve 2 N637 2328
6 5 Removing and installing refrigerant expansion valve 3 N638 2329
6 6 Removing and installing refrigerant shut-off valve 1 N696 2329
6 7 Removing and installing refrigerant shut-off valve 2 N640 2329
6 8 Removing and installing refrigerant shut-off valve 3 N641 2331
6 9 Removing and installing refrigerant shut-off valve 4 N642 2331
6 10 Removing and installing refrigerant shut-off valve 5 N643 2332
7 Air conditioner compressor, R134a/R1234yf 2333
7 1 Exploded view – air conditioner compressor 2333
7 2 Detaching and attaching refrigerant lines at air conditioner compressor 2333
7 3 Removing and installing air conditioner compressor [VX81] 2334
7 4 Detaching/attaching air conditioner compressor [VX81] from/to bracket 2337
8 Air conditioner compressor, R744 2339
8 1 Exploded view – air conditioner compressor 2339
8 2 Detaching and attaching refrigerant lines at air conditioner compressor 2339
8 3 Removing and installing air conditioner compressor [VX81] 2341
8 4 Detaching/attaching air conditioner compressor [VX81] from/to bracket 2344
9 Control motors 2345
9 1 Overview of fitting locations – control motors (front) 2345
9 2 Assembly overview – control motors, PR numbers KC0, KH4 2347
9 2 1 Exploded view – control motors (front) 2347
9 3 Assembly overview – control motors, PR number KH7 2349
9 3 1 Exploded view – control motors (front) 2349
9 4 Removing and installing control motor for front left temperature flap [VX34] 2352
9 4 1 Removing and installing control motor for front left temperature flap [VX34], LHD vehicles 2352
9 4 2 Removing and installing control motor for front left temperature flap [VX34], right-hand drive vehicles 2353
9 5 Removing and installing control motor for front right temperature flap [VX35] 2355
9 5 1 Removing and installing control motor for front right temperature flap [VX35], left-hand drive vehicles 2355
9 5 2 Removing and installing control motor for front right temperature flap [VX35], right-hand drive vehicles 2356
9 6 Removing and installing control motor for defroster flap VX47 2357
9 7 Removing and installing control motor for front left air distribution flap [VX93] 2358
9 7 1 Removing and installing control motor for front left air distribution flap [VX93], left-hand drive vehicles 2358
9 7 2 Removing and installing control motor for front left air distribution flap [VX93], right-hand drive vehicles 2359
9 8 Removing and installing control motor for front right air distribution flap [VX94] 2361
9 8 1 Removing and installing control motor for front right air distribution flap [VX94], left-hand drive vehicles 2361
9 8 2 Removing and installing control motor for front right air distribution flap [VX94], right-hand drive vehicles 2362
9 9 Removing and installing control motor for rear temperature flap [VX95] 2363
9 10 Removing and installing control motor for fresh air and air recirculation flap [VX96] 2364
9 11 Removing and installing actuator for left air distribution flap 2366
9 12 Removing and installing right air distribution flap actuator 2366
10 Front heater and air conditioning unit, R134a/R1234yf 2368
10 1 Exploded view – heater and air conditioning unit 2368
10 2 Assembly overview – evaporator housing 2368
10 3 Assembly overview – air intake box of heater and air conditioning unit 2369
10 4 Removing and installing heater and air conditioning unit 2371
10 5 Removing and installing evaporator 2374
10 6 Dismantling and assembling heater and air conditioning unit 2375
10 7 Removing and installing dust and pollen filter 2375
10 8 Removing and installing fresh air blower control unit [J126] 2376
10 9 Removing and installing evaporator temperature sensor [G308] 2378
10 10 Removing and installing condensation drain 2378
10 11 Checking condensation drain 2379
10 12 Removing and installing air intake box of heater and air conditioning unit 2380
10 13 Removing and installing air intake cowling 2382
10 14 Removing and installing high voltage heater (PTC) [ZX17] 2384
11 Front heater and air conditioning unit, R744 2388
11 1 Exploded view – heater and air conditioning unit 2388
11 2 Assembly overview – evaporator housing 2388
11 3 Assembly overview – air intake box of heater and air conditioning unit 2389
11 4 Removing and installing heater and air conditioning unit 2391
11 5 Removing and installing evaporator 2395
11 6 Dismantling and assembling heater and air conditioning unit 2395
11 7 Removing and installing dust and pollen filter 2395
11 8 Removing and installing fresh air blower control unit [J126] 2396
11 9 Removing and installing evaporator temperature sensor [G308] 2397
11 10 Removing and installing condensation drain 2397
11 11 Checking condensation drain 2398
11 12 Removing and installing air intake box of heater and air conditioning unit 2399
11 13 Removing and installing air intake cowling 2401
11 14 Removing and installing high voltage heater (PTC) [ZX17] 2403
12 Air duct 2407
12 1 Assembly overview – air duct and air distribution in passenger compartment 2407
12 2 Removing and installing driver side footwell vents 2409
12 2 1 Removing and installing driver side footwell vents, left-hand drive vehicles 2409
12 2 2 Removing and installing driver side footwell vents, right-hand drive vehicles 2409
12 3 Removing and installing front passenger side footwell vents 2410
12 3 1 Removing and installing footwell vent (front passenger side) – left-hand drive vehicles 2410
12 3 2 Removing and installing footwell vent (front passenger side) – right-hand drive vehicles 2410
12 4 Removing and installing rear footwell vent 2411
12 5 Removing and installing fresh air intake 2411
12 6 Removing and installing air duct for defroster vent 2412
12 7 Removing and installing air duct for centre dash panel vent 2412
12 8 Removing and installing air duct for rear centre console vent 2412
12 9 Removing and installing front air duct for dash panel 2413
13 Coolant circuit 2414
13 1 Assembly overview – high-voltage heater (PTC), rear-wheel drive 2414
13 1 1 Exploded view – high-voltage heater (PTC) 2414
13 2 Assembly overview – high-voltage heater (PTC), all-wheel drive 2414
13 2 1 Exploded view – high-voltage heater (PTC) 2414
13 3 Removing and installing PTC heater element 3 [Z132], rear-wheel drive 2415
13 3 1 Removing and installing PTC heater element 3 [Z132] 2415
13 4 Removing and installing PTC heater element 3 [Z132], all-wheel drive 2418
13 4 1 Removing and installing PTC heater element 3 [Z132] 2418
14 Operating and display unit 2422
14 1 Overview of fitting locations – operating and display unit 2422
14 2 Removing and installing display unit for front information display and operating unit control unit [J685] 2422
14 3 Removing and installing operating and display unit for rear air conditioning system [E265] 2422
15 Other controlling and regulating components 2423
15 1 Removing and installing external air quality and air humidity sensor G935 2423
15 2 Removing and installing ambient temperature sensor G17 2423
15 3 Removing and installing humidity sender for air conditioning system [G260] 2424
15 4 Removing and installing left vent temperature sender [G150[ 2424
15 4 1 Removing and installing left vent temperature sender [G150], left-hand drive vehicles 2424
15 4 2 Removing and installing left vent temperature sender [G150], right-hand drive vehicles 2424
15 5 Removing and installing right vent temperature sender [G151] 2425
15 5 1 Removing and installing right vent temperature sender [G151], left-hand drive vehicles 2425
15 5 2 Removing and installing right vent temperature sender [G151], right-hand drive vehicles 2425
15 6 Removing and installing left footwell vent temperature sender [G261] 2426
15 7 Removing and installing right footwell vent temperature sender [G262] 2427
15 8 Removing and installing sensor for interior carbon dioxide concentration [G929] 2427
15 9 Removing and installing heater and air conditioning system control unit [J979] 2428
15 10 Removing and installing vehicle interior temperature sensor [G1090] 2429
15 11 Removing and installing rear vent temperature sender [G174] 2429
D4D809D5F1A Electrical system General information 2430
27 – Starter, current supply, CCS 2434
1 Battery 2434
1 1 Checking battery 2434
1 1 1 Checking battery, 12 V 2434
1 1 2 Checking open-circuit voltage 2435
1 2 Charging battery 2436
1 2 1 Charging battery 2436
1 2 2 Service charging 2436
1 2 3 Totally discharged batteries 2437
92 – Windscreen wash/wipe system 2439
1 Washer fluid lines 2439
1 1 Pulling off and fitting washer fluid hoses 2439
1 2 Repairing smooth tube 2439
1 3 Repairing corrugated tube 2439
97 – Wiring 2441
1 Wires and lines 2441
1 1 Repairing wiring harnesses 2441
1 1 1 Repair notes on airbag and belt tensioner lines 2441
1 1 2 Repair notes on CAN bus wires 2441
1 1 3 Repair notes on FlexRay wires 2442
1 1 4 Repairing wires with a cross section of 0 13 mm² to 6 mm² 2444
1 1 5 Repairing wires with a cross section of 10 mm² or 16 mm² 2447
1 1 6 Repairing 2 5 mm, 4 mm or 6 mm aluminium wires with a single crimp connector 2450
1 1 7 Repairing Ethernet lines 2454
1 1 8 Section repairs to electrical wiring 2454
1 1 9 Fitting single wire seals 2454
1 2 Repairing fibre optic cables 2455
1 2 1 Repairing fibre optic cables 2455
1 2 2 Removing and installing fibre optic cable of wiring harness connector 2458
1 3 Repair of aerial wires 2459
1 3 1 Repairing aerial wires 2459
2 Cleaning contact surfaces 2465
2 1 Cleaning battery clamp and battery terminal 2465
2 2 Anti-corrosion treatment of contact surfaces 2466
2 3 Cleaning terminals 2466
2 4 Cleaning threaded connections 2467
3 Connector housing 2469
3 1 Dismantling connector housings 2469
3 2 Repairing contacts in connector housings 2469
4 ESD workplace 2470
4 1 Repair notes on ESD workplace 2470
D4D8081A045 Brake system 2471
00 – Technical data 2475
1 Safety information and repair notes 2475
1 1 Safety information 2475
1 2 Repair instructions 2475
2 Identification 2476
2 1 Allocation of PR number – brakes 2476
2 1 1 Front brakes 2476
2 1 2 Rear brakes 2476
3 Technical data 2477
3 1 Technical data for brakes 2477
3 1 1 Brake master cylinder and brake servo 2477
3 1 2 Front brakes 2477
3 1 3 Rear brakes 2478
4 Brake test 2479
4 1 Brake check on single-axle roller dynamometer 2479
4 2 Checking electromechanical parking brake 2479
5 Electrical components 2480
5 1 Access to diagnoses 2480
45 – Anti-lock brake system 2482
1 Safety information and repair notes 2482
1 1 Safety information 2482
1 2 Repair instructions 2482
2 Overview of fitting locations 2483
2 1 Overview of fitting locations – ABS/ESP 2483
3 Control unit and hydraulic unit 2485
3 1 Assembly overview – control unit and hydraulic unit 2485
3 1 1 Assembly overview – control unit and hydraulic unit, left-hand drive vehicles 2485
3 1 2 Assembly overview – control unit and hydraulic unit, right-hand drive 2487
3 2 Removing and installing ABS control unit [J104]/ABS hydraulic unit [N55] 2490
3 2 1 Removing and installing ABS control unit [J104]/ABS hydraulic unit [N55], left-hand drive vehicles 2490
3 2 2 Removing and installing ABS control unit [J104]/ABS hydraulic unit [N55], right-hand drive vehicles 2494
3 3 Separating control unit from and connecting to hydraulic unit 2498
3 4 Connecting brake lines to hydraulic unit 2500
3 4 1 Connecting brake lines to hydraulic unit, left-hand drive vehicles 2500
3 4 2 Connecting brake lines to hydraulic unit, right-hand drive vehicles 2502
4 Sensors 2505
4 1 Assembly overview – speed sensor on front axle 2505
4 2 Assembly overview – speed sensors on rear axle 2505
4 3 Removing and installing speed sensor on front axle [G45]/[G47] 2506
4 4 Removing and installing speed sensor on rear axle [G44]/[G46] 2507
4 5 Checking ABS sensor ring 2508
46 – Brakes – mechanism 2509
1 Safety information and repair notes 2509
1 1 Safety information 2509
1 2 Repair instructions 2509
2 Front brake 2510
2 1 Assembly overview – front brake 2510
2 2 Removing and installing brake pads 2512
2 3 Removing and installing brake caliper 2517
2 4 Removing and installing brake disc 2520
3 Rear brake 2521
3 1 Assembly overview – rear brake, drum brake 2521
3 2 Assembly overview – brake shoes 2523
3 3 Removing and installing brake shoes 2525
3 4 Removing and installing brake drum 2532
4 Parking brake 2533
4 1 Assembly overview – parking brake 2533
4 2 Removing and installing control unit for electromechanical parking brake [J540] 2533
4 3 Removing and installing parking brake motor [V282]/[V283] 2534
5 Brake pedal 2535
5 1 Assembly overview – brake pedal 2535
5 1 1 Assembly overview – brake pedal, left-hand drive vehicles 2535
5 1 2 Assembly overview – brake pedal, right-hand drive vehicles 2535
5 2 Separating brake pedal from and joining to brake servo 2536
5 3 Removing and installing brake pedal 2538
5 3 1 Removing and installing brake pedal, left-hand drive vehicles 2538
5 3 2 Removing and installing brake pedal, right-hand drive vehicles 2538
5 4 Removing and installing mounting of brake pedal on push rod 2539
5 5 Removing and installing mounting bracket 2540
5 5 1 Removing and installing mounting bracket, left-hand drive vehicles 2540
5 5 2 Removing and installing mounting bracket, right-hand drive vehicles 2542
47 – Brakes – hydraulics 2544
1 Safety information and repair notes 2544
1 1 Safety information 2544
1 2 Repair instructions 2544
2 Brake servo and brake master cylinder 2545
2 1 Assembly overview – brake servo/brake master cylinder 2545
2 1 1 Assembly overview – brake servo/brake master cylinder, left-hand drive vehicles 2545
2 1 2 Assembly overview – brake servo/brake master cylinder, right-hand drive vehicles 2547
2 2 Removing and installing brake master cylinder 2549
2 3 Removing and installing brake servo 2551
2 3 1 Removing and installing brake servo [NX6], left-hand drive vehicles 2551
2 3 2 Removing and installing brake servo [NX6], right-hand drive vehicles 2555
3 Hydraulic system 2561
3 1 Bleeding hydraulic system 2561
3 2 Subsequent bleeding of hydraulic system 2562
3 3 Brake fluid change 2563
3 4 Leak test 2563
3 5 Checking wheel brake cylinder for leaks 2563
D4D8095E40B Body repairs 2565
00 – Technical data 2571
1 Safety information and repair notes 2571
1 1 Safety information 2571
1 2 Repair instructions 2571
2 Tools 2572
2 1 Tools 2572
3 Vehicle identification data 2573
3 1 Vehicle identification data 2573
3 1 1 Vehicle identification number 2573
3 1 2 Type plate 2574
3 1 3 Safety certificate 2575
4 Safety information 2577
4 1 Safety information – body repairs 2577
4 2 The following body repairs require the HV electrical system to be de-energised 2577
4 3 When the high-voltage battery is removed, observe the following: 2577
5 Body parts and materials 2578
5 1 Moulded foam inserts 2578
5 2 Galvanized body parts, high/highest strength and hot-formed body panels 2578
6 Technical data 2581
6 1 Body dimensions 2581
6 1 1 Preliminary work for determining body dimensions 2581
6 1 2 Front body 2581
6 1 3 Body – centre 2582
6 1 4 Body – rear 2586
6 1 5 Floor panel, front 2587
6 1 6 Floor panel, centre 2588
6 1 7 Floor panel, rear 2589
7 Alignment jig 2591
7 1 Procedure for structural damage on body 2591
7 2 Alignment jig 2591
7 3 Portal gauge 2591
50 – Body – front 2592
1 Safety information and repair notes 2592
1 1 Safety information 2592
1 2 Repair instructions 2592
2 Overview of fitting locations 2593
2 1 Overview of fitting locations – front of body 2593
3 Longitudinal member cross panel 2595
3 1 Assembly overview – front longitudinal member cross panel 2595
3 2 Renewing front longitudinal member cross panel 2595
4 Longitudinal member 2598
4 1 Assembly overview – front left longitudinal member, part section 2598
4 2 Assembly overview – front left longitudinal member, part section (second separating cut) 2598
4 3 Assembly overview – front right longitudinal member, part section 2599
4 4 Assembly overview – front right longitudinal member, part section (second separating cut) 2600
4 5 Assembly overview – upper longitudinal member 2601
4 6 Assembly overview – upper inner longitudinal member 2602
4 7 Renewing front left longitudinal member, part section 2603
4 8 Renewing front left longitudinal member, part section (2nd separating cut) 2608
4 9 Renewing front right longitudinal member, part section 2614
4 10 Renewing front right longitudinal member, part section (second separating cut) 2619
4 11 Renewing upper longitudinal member 2625
4 12 Renewing upper inner longitudinal member 2628
5 Battery tray 2632
5 1 Assembly overview – battery tray 2632
5 2 Renewing battery tray 2632
6 Front wheel housing 2635
6 1 Assembly overview – front wheel housing 2635
6 2 Assembly overview – front wheel housing, part section 2635
6 3 Renewing front wheel housing 2636
6 4 Renewing front wheel housing (part section) 2642
51 – Body – centre 2649
1 Safety information and repair notes 2649
1 1 Safety information 2649
1 2 Repair instructions 2649
2 Overview of fitting locations 2650
2 1 Overview of fitting locations – centre of body 2650
3 Roof 2652
3 1 Assembly overview – vehicle without glass panel 2652
3 2 Assembly overview – vehicle with glass panel 2652
3 3 Assembly overview – roof side member 2653
3 4 Renewing roof – vehicle without glass panel 2654
3 5 Renewing roof – vehicle with glass panel 2662
3 6 Renewing roof side member 2670
4 A-pillar 2675
4 1 Assembly overview – A-pillar 2675
4 2 Assembly overview – A-pillar reinforcement 2675
4 3 Renewing A-pillar 2676
4 4 Renewing A-pillar reinforcement, part section 2680
5 B-pillar 2686
5 1 Assembly overview – B-pillar 2686
5 2 Assembly overview – B-pillar reinforcement 2686
5 3 Renewing B-pillar 2687
5 4 Renewing B-pillar reinforcement 2691
6 Side member 2695
6 1 Assembly overview – outer side member 2695
6 2 Assembly overview – side member reinforcement 2695
6 3 Assembly overview – side panel reinforcement (crash bar) 2696
6 4 Renewing outer side member 2697
6 5 Renewing side member reinforcement 2701
6 6 Renewing side member reinforcement (crash bar) 2704
53 – Body – rear 2708
1 Safety information and repair notes 2708
1 1 Safety information 2708
1 2 Repair instructions 2708
2 Overview of fitting locations 2709
2 1 Overview of fitting locations – rear of body 2709
3 Rear cross member 2711
3 1 Assembly overview – rear cross member 2711
3 2 Renewing rear cross member 2711
4 Rear cross panel 2715
4 1 Assembly overview – rear apron 2715
4 2 Renewing rear apron 2715
5 Luggage compartment floor 2719
5 1 Assembly overview – sealing channel support 2719
5 2 Assembly overview – floor panel reinforcement 2719
5 3 Assembly overview – centre luggage compartment floor 2720
5 4 Assembly overview – rear luggage compartment floor 2721
5 5 Assembly overview – luggage compartment floor cross member 2722
5 6 Renewing sealing channel support 2723
5 7 Renewing floor panel reinforcement 2725
5 8 Renewing centre luggage compartment floor 2728
5 9 Renewing rear luggage compartment floor 2731
5 10 Renewing luggage compartment floor cross member 2734
6 Rear longitudinal member 2738
6 1 Assembly overview – longitudinal member cover plate 2738
6 2 Assembly overview – rear longitudinal member, part section 2738
6 3 Assembly overview – rear longitudinal member, part section (second separating cut) 2739
6 4 Renewing longitudinal member cover plate 2740
6 5 Renewing rear longitudinal member, part section 2744
6 6 Renewing rear longitudinal member, part section (second parting cut) 2748
7 Side panel 2755
7 1 Assembly overview – side panel 2755
7 2 Permitted separating cuts on side panel 2755
7 3 Renewing side panel, part section 2756
8 Rear wheel housing 2761
8 1 Assembly overview – rear wheel housing 2761
8 2 Renewing rear wheel housing 2761
D4D80807BD1 1 speed gearbox 0MJ front 2766
00 – Technical data 2770
1 Safety information and repair notes 2770
1 1 Safety information 2770
1 2 Repair instructions 2770
2 Identification 2771
2 1 Gearbox identification 2771
3 Technical data 2772
3 1 Allocation gearbox – engine 2772
3 2 Capacities 2772
34 – Controls, housing 2773
1 Safety information and repair notes 2773
1 1 Safety information 2773
1 2 Repair instructions 2773
2 Removing and installing gearbox 2774
2 1 Removing gearbox 2774
2 2 Installing gearbox 2774
3 Gearbox housing, clutch housing 2775
3 1 Assembly overview – gearbox housing 2775
4 Gear oil 2776
4 1 Checking gear oil level 2776
4 2 Draining and filling gear oil 2776
39 – Final drive – differential 2777
1 Safety information and repair notes 2777
1 1 Safety information 2777
1 2 Repair instructions 2777
2 Oil seals 2778
2 1 Assembly overview – seals 2778
2 2 Renewing left seal 2778
2 3 Renewing right seal 2779
2 3 1 Renewing right seal, left-hand drive vehicles 2779
2 3 2 Renewing right seal, right-hand drive vehicles 2780
D4D8082553C Driver assist systems 2782
00 – Technical data 2786
1 Electrical components 2786
1 1 Access to diagnoses 2786
98 – Assist systems 2788
1 Safety information and repair notes 2788
1 1 Safety information 2788
1 2 Repair instructions 2788
2 Fitting locations 2789
2 1 Overview of fitting locations – senders, sensors and control units, ID 4 2789
2 1 1 Overview of fitting locations – senders, sensors and control units in front section of vehicle 2789
2 1 2 Overview of fitting locations – senders, sensors and control units in centre section of vehicle 2790
2 1 3 Overview of fitting locations – senders, sensors and control units in rear section of vehicle 2790
2 2 Overview of fitting locations – senders, sensors and control units, ID 5 2792
2 2 1 Overview of fitting locations – senders, sensors and control units in front section of vehicle 2792
2 2 2 Overview of fitting locations – senders, sensors and control units in centre section of vehicle 2793
2 2 3 Overview of fitting locations – senders, sensors and control units in rear section of vehicle 2793
3 Senders/sensors/control units 2796
3 1 Removing and installing front parking aid senders [G252]/[G253]/[G254]/[G255] 2796
3 2 Removing and installing rear parking aid senders [G203]/[G204]/[G205]/[G206] 2797
3 3 Removing and installing front park assist steering senders [G568]/[G569] 2799
3 4 Removing and installing rear park assist steering senders [G716]/[G717] 2800
3 5 Removing and installing adaptive cruise control unit [J428] 2801
3 6 Removing and installing lane change assist control unit [J769]/[J770] 2802
3 7 Removing and installing lane change assist warning lamp in exterior mirror 2803
3 8 Removing and installing control unit for overhead view camera [J928] 2803
3 8 1 Removing and installing control unit for overhead view camera [J928] 2803
3 8 2 Removing and installing holder for control unit for overhead view camera [J928] 2804
3 9 Removing and installing left/right overhead view camera R244/R245 2805
3 10 Removing and installing front camera for driver assist systems [R242] 2806
3 10 1 Removing and installing front camera for driver assist systems [R242] 2806
3 10 2 Removing and installing windscreen heater for front sensors [Z113] 2806
3 11 Removing and installing parking aid control unit [J446] 2807
3 12 Removing and installing front overhead view camera R243 2808
3 13 Removing and installing reversing camera [R189] 2808
3 14 Removing and installing rear overhead view camera [R246] 2809
4 Adaptive cruise control 2810
4 1 Necessity of calibration 2810
4 2 Adjusting/calibrating adaptive cruise control unit 2812
4 2 1 Dynamic calibration of adaptive cruise control 2812
4 2 2 Static calibration of adaptive cruise control 2812
5 Reversing camera system 2816
5 1 Calibrating reversing camera R189 2816
6 Front camera for driver assist systems 2821
6 1 Calibrating front camera for driver assist systems [R242] 2821
6 1 1 Calibrating front camera for driver assist systems R242, dynamic 2821
6 1 2 Calibrating front camera for driver assist systems R242, static 2821
7 Overhead view camera 2829
7 1 Calibrating overhead view camera system 2829

S.V 28/01/2025