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Diagnostic system: reading out fault memory and activating systems
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Diagnostic system: reading out fault memory and activating systems
Table of Contents
01 01 IN Diagnostic system: reading out fault memory and activating systems - as of MY 2005..............1
Tools........................................................................................................................................................1
Performing vehicle handover............................................................................................................1
Reading out and erasing fault memory..............................................................................................2
10 01 TW Technical data, engine - as of MY 2005..........................................................................................5
Technical values......................................................................................................................................5
M96/05 and M97/01 engines.............................................................................................................5
Engine design....................................................................................................................................6
Engine control...................................................................................................................................7
13 44 IN Mounting specification for connecting rod bolts - as of MY 2005...............................................10
Tools......................................................................................................................................................10
Securing connecting rod bolts...............................................................................................................10
Securing connecting rod bolts........................................................................................................10
17 01 TW Technical data, lubrication system - as of MY 2005...................................................................13
Technical values....................................................................................................................................13
Engine lubrication...........................................................................................................................13
19 01 TW Technical data, cooling system - as of MY 2005..........................................................................16
Technical values....................................................................................................................................16
Engine cooling.................................................................................................................................16
20 01 AW Basic safety instructions for working with the fuel system - as of MY 2005............................19
Information...........................................................................................................................................19
Safety instructions when working on fuel system...........................................................................19
20 01 TW Technical data, fuel system - as of MY 2005................................................................................22
Technical values....................................................................................................................................22
Fuel supply......................................................................................................................................22
20 10 EN Emptying and filling the fuel tank - as of MY 2005.....................................................................25
Tools......................................................................................................................................................25
Preliminary work..................................................................................................................................25
Preliminary work.............................................................................................................................25
Emptying the fuel tank..........................................................................................................................26
Emptying the fuel tank....................................................................................................................26
Filling the fuel tank...............................................................................................................................30
Filling the fuel tank.........................................................................................................................30
Subsequent work...................................................................................................................................32
Subsequent work.............................................................................................................................32
20 15 IN Calibrating fuel-level sensor system - as of MY 2005...................................................................34
Warning notes for calibrating fuel-level sensor system.........................................................................34
Calibrating fuel-level sensor system, C4.........................................................................................35
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20 15 IN Calibrating fuel-level sensor system - as of MY 2005...................................................................38
Warning notes for calibrating fuel-level sensor system.........................................................................38
Calibrating fuel-level sensor system, C2.........................................................................................39
24 46 TW Technical data, intake system - as of MY 2005............................................................................42
Technical values....................................................................................................................................42
Intake system...................................................................................................................................42
Intake system tightening torques.....................................................................................................42
26 01 TW Technical data, exhaust system - as of MY 2005.........................................................................45
Technical values....................................................................................................................................45
Exhaust system and emission control..............................................................................................45
Exhaust system tightening torques..................................................................................................45
27 06 IN External power connection, jump lead starting - as of MY 2005.................................................48
Preliminary work..................................................................................................................................48
Preliminary work for external power connection, jump lead starting.............................................48
General warning notes..........................................................................................................................49
Warning notes for external power connection, jump lead starting..................................................49
Information...........................................................................................................................................49
External power connection..............................................................................................................49
Jump lead starting............................................................................................................................50
Subsequent work...................................................................................................................................51
Rework on external power connection, jump lead starting.............................................................51
27 06 IN Work instructions after disconnecting the battery - as of MY 2005............................................54
Disconnecting and connecting the battery............................................................................................54
Disconnecting and connecting the battery.......................................................................................54
Effect of disconnection or total discharge of battery on electrical systems in the vehicle and
the precautions to be taken.......................................................................................................55
Test drive after disconnecting battery.............................................................................................59
Effects of overvoltage on electrical and electronic systems during welding work and the
precautions to be taken............................................................................................................59
27 06 IN Electrical emergency release for lid - as of MY 2005....................................................................62
Electrical emergency release, front lid...................................................................................................62
34 35 TW Technical data, transmission - as of MY 2005.............................................................................65
Technical values....................................................................................................................................65
Technical data..................................................................................................................................65
Transmission ratios..........................................................................................................................65
Filling capacities..............................................................................................................................65
34 35 TW Technical data, transmission - as of MY 2005.............................................................................68
Technical values....................................................................................................................................68
Technical data..................................................................................................................................68
Transmission ratios..........................................................................................................................68
Filling capacities..............................................................................................................................68
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Diagnostic system: reading out fault memory and activating systems
Table of Contents
37 35 TW Technical data, automatic transmission - as of MY 2005...........................................................71
Technical values....................................................................................................................................71
Technical data..................................................................................................................................71
Transmission ratios..........................................................................................................................71
Filling capacities..............................................................................................................................71
37 35 TW Technical data, automatic transmission - as of MY 2005...........................................................74
Technical values....................................................................................................................................74
Technical data..................................................................................................................................74
Transmission ratios..........................................................................................................................74
Filling capacities..............................................................................................................................74
39 88 TW Technical data on front final drive - as of MY 2006...................................................................77
Technical values....................................................................................................................................77
Technical values..............................................................................................................................77
Transmission ratio...........................................................................................................................77
Filling capacities..............................................................................................................................77
61 01 IN Convertible top service position - as of MY 2005..........................................................................80
Convertible top service position...........................................................................................................80
Move convertible top to service position........................................................................................80
Ending convertible top service position..........................................................................................81
61 01 IN Overview of convertible-top components - as of MY 2005...........................................................85
Overview of convertible-top components..............................................................................................85
61 01 IN Diagram of convertible top - as of MY 2005..................................................................................88
Diagram of convertible top....................................................................................................................88
61 01 K2 Calibrating convertible top - as of MY 2005.................................................................................91
Preliminary work..................................................................................................................................91
Preliminary work for calibration.....................................................................................................91
General warning notes..........................................................................................................................91
Warning note on calibration............................................................................................................91
Calibrating convertible top..............................................................................................................92
61 02 IN Assembly instructions for hardtop assembly fixture - as of MY 2005.........................................94
Tools......................................................................................................................................................94
Tools and materials...............................................................................................................................94
Tools and materials.........................................................................................................................94
Assembly instructions for hardtop assembly fixture............................................................................95
Making support cheeks....................................................................................................................96
Making swivel arm..........................................................................................................................96
Fitting swivel and support cheeks on the basic plate......................................................................97
Fitting mounting points for the hardtop locking lever on the plate.................................................98
Fitting horizontal banner arm and support on the base plate..........................................................99
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61 28 IN Care and cleaning of the convertible top - as of MY 2005..........................................................102
Care and cleaning of the convertible top............................................................................................102
General information......................................................................................................................102
Cleaning the convertible top..........................................................................................................103
Care of convertible top..................................................................................................................103
Care of convertible-top seals.........................................................................................................103
64 12 IN Processing of Porsche 2-component window bonding agents - as of MY 2005.........................106
Pre-treatment of bonding surfaces......................................................................................................106
Pre-treating adhesive flanges on vehicle windows........................................................................106
Pre-treating adhesive flanges on vehicle body..............................................................................107
Handling processing device................................................................................................................107
Double cartridge press...................................................................................................................107
69 68 K2 Calibrating AWS control unit - as of MY 2005...........................................................................113
Tools....................................................................................................................................................113
Calibrating AWS control unit.............................................................................................................113
Calibrating AWS control unit........................................................................................................113
87 43 IN Laying compressor/condenser line - as of MY 2005....................................................................118
Laying compressor/condenser line.....................................................................................................118
87 45 IN Laying compressor/evaporator line - as of MY 2005..................................................................122
Laying compressor/evaporator line......................................................................................................122
94 15 IN Converting headlights for left/right-hand driving - as of MY 2005...........................................126
Converting halogen headlights for left/right-hand driving..................................................................126
Converting Bi-Xenon headlights for left/right-hand driving........................................................127
94 23 IN Bulb table and installation instructions - as of MY 2005............................................................130
Bulb table............................................................................................................................................130
Bulb table......................................................................................................................................130
Installation instructions.......................................................................................................................131
Installation instructions for bulbs..................................................................................................131
97 72 IN Optical waveguide (LWL) - MOST bus - as of MY 2005...........................................................134
Tools....................................................................................................................................................134
Optical waveguide (LWL) - MOST bus.............................................................................................134
Requirements when working with LWL.......................................................................................134
Storage, Packing, Transport..........................................................................................................134
Installing the LWL in the vehicle..................................................................................................135
Repair............................................................................................................................................135
Push-on connector - dust boots.....................................................................................................135
Control unit plug connector (wiring harness side)........................................................................136
Push-on connector - connection points.........................................................................................136
Optical fiber (LWL) - module.......................................................................................................136
Optical waveguide variants...........................................................................................................137
Removing and installing optical contacts on connector side........................................................140
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97 72 IN Optical waveguide (LWL) - MOST bus - as of MY 2005
Installing optical contacts on connector side.................................................................................141
Removing and installing optical contacts on socket side..............................................................141
Installing optical contacts on socket side......................................................................................142
97 97 IN Connector - General information - as of MY 2005......................................................................146
Tools....................................................................................................................................................146
Connector - General information..................................................................................................146
Procedure for releasing connectors that are difficult to move.......................................................149
01 01 00 Sales check - as of MY 2005...........................................................................................................153
Sales check..........................................................................................................................................153
03 24 00 Minor maintenance - as of MY 2005.............................................................................................157
Minor maintenance.............................................................................................................................157
03 26 00 Major maintenance - as of MY 2005.............................................................................................161
Major maintenance..............................................................................................................................161
03 35 00 On-board diagnosis (OBD) - as of MY 2005.................................................................................165
Tools....................................................................................................................................................165
Reading out and erasing fault memory...............................................................................................165
Reading out and erasing fault memory..........................................................................................165
03 60 00 Additional maintenance of drive belt - as of MY 2005................................................................168
Additional maintenance of drive belt..................................................................................................168
03 81 00 Additional maintenance of spark plugs - as of MY 2005............................................................171
Additional maintenance of spark plugs...............................................................................................171
Additional maintenance for spark plugs........................................................................................171
03 83 00 Additional maintenance every 90,000 km/60.000 mls or every 6 years - as of MY 2005.........174
Additional maintenance every 90,000 km/60.000 mls or every 6 years.............................................174
03 88 00 Additional maintenance every 180,000 km/120.000 mls or every 12 years - as of MY 2005...177
Additional maintenance every 180,000 km/120.000 mls or every 12 years.......................................177
Notes..............................................................................................................................................177
Additional maintenance every 180,000 km/120,000 mls or every 12 years.................................177
Additional maintenance every 180,000 km/120,000 mls or every 12 years.................................177
03 88 00 Additional maintenance every 180,000 km/120.000 mls or every 12 years - as of MY 2005...180
Additional maintenance every 180,000 km/120.000 mls or every 12 years.......................................180
Notes..............................................................................................................................................180
Additional maintenance every 180,000 km/120,000 mls or every 12 years.................................180
Additional maintenance every 180,000 km/120,000 mls or every 12 years.................................180
Additional maintenance every 180,000 km/120,000 mls or every 12 years.................................181
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Table of Contents
10 01 19 Removing and installing engine - as of MY 2005.........................................................................183
Tools....................................................................................................................................................183
Preliminary work for removing the engine.........................................................................................184
Preparations for removing the engine...........................................................................................185
Removing engine................................................................................................................................186
Removing engine...........................................................................................................................186
Installing engine..................................................................................................................................201
Installing engine............................................................................................................................201
Subsequent work for installation of engine........................................................................................208
Installing engine - subsequent work..............................................................................................209
10 01 37 Disassembling and assembling engine - as of MY 2005...............................................................212
Tools....................................................................................................................................................212
Preliminary work for disassembling engine.......................................................................................214
Preliminary work for disassembling engine..................................................................................214
Component overview - engine............................................................................................................215
Component overview - engine......................................................................................................215
Disassembling engine - up to crankcase.............................................................................................217
Disassembling engine - up to crankcase........................................................................................217
Assembling engine - from crankcase..................................................................................................231
Assembling engine - from crankcase............................................................................................231
Assembling engine, subsequent work.................................................................................................237
Assembling engine, touching up...................................................................................................237
10 30 19 Removing and installing engine carrier - as of MY 2005............................................................240
Preliminary work................................................................................................................................240
Preliminary work...........................................................................................................................240
Removing engine carrier.....................................................................................................................240
Removing engine carrier...............................................................................................................240
Installing engine carrier......................................................................................................................242
Installing engine carrier.................................................................................................................242
Subsequent work.................................................................................................................................242
Subsequent work...........................................................................................................................242
10 55 19 Removing and installing oil separator - as of MY 2005..............................................................245
Tools....................................................................................................................................................245
Preliminary work................................................................................................................................245
Preliminary work for removing oil separator................................................................................245
Removing oil separator.......................................................................................................................245
Removing oil separator.................................................................................................................245
Installing oil separator.........................................................................................................................249
Installing oil separator...................................................................................................................249
Subsequent work.................................................................................................................................251
Subsequent work for installing oil separator.................................................................................251
13 10 20 Removing and installing pistons - as of MY 2005........................................................................254
Tools....................................................................................................................................................254
Removing pistons, preliminary work..................................................................................................257
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13 10 20 Removing and installing pistons - as of MY 2005
Removing pistons, preliminary work............................................................................................257
Removing pistons...............................................................................................................................257
Removing pistons..........................................................................................................................258
Disassembling pistons/connecting rods, cylinder 1-3.........................................................................262
Disassembling pistons/connecting rods, cylinder 1-3...................................................................262
Assembling pistons/connecting rods, cylinder 1-3.............................................................................263
Assembling pistons/connecting rods, cylinder 1-3........................................................................264
Piston markings...................................................................................................................................266
Piston markings.............................................................................................................................266
Installing pistons.................................................................................................................................267
Installing pistons............................................................................................................................267
Installing pistons, touching up............................................................................................................280
Installing pistons, touching up.......................................................................................................280
13 48 19 Removing and installing crankshaft - as of MY 2005..................................................................283
Tools....................................................................................................................................................283
Removing crankshaft, preliminary work............................................................................................284
Removing crankshaft, preliminary work.......................................................................................284
Removing crankshaft..........................................................................................................................287
Removing crankshaft.....................................................................................................................287
Installing crankshaft............................................................................................................................290
Installing crankshaft......................................................................................................................290
Installing crankshaft, touching up.......................................................................................................294
Installing crankshaft, touching up.................................................................................................294
13 59 19 Removing and installing crankshaft sealing ring - Flywheel side - as of MY 2005..................299
Tools....................................................................................................................................................299
Preliminary work for crankshaft sealing ring on flywheel side..........................................................300
Preliminary work for crankshaft sealing ring on flywheel side....................................................300
Removing crankshaft sealing ring on flywheel side...........................................................................301
Removing crankshaft sealing ring on flywheel side.....................................................................301
Installing crankshaft sealing ring on flywheel side.............................................................................303
Installing crankshaft sealing ring (PTFE) on flywheel side..........................................................303
Subsequent work for crankshaft sealing ring on flywheel side..........................................................307
Subsequent work for crankshaft sealing ring on flywheel side.....................................................307
13 60 19 Removing and installing double-mass flywheel - as of MY 2005................................................310
Tools....................................................................................................................................................310
Preliminary work................................................................................................................................310
Preliminary work for double-mass flywheel.................................................................................310
Removing double-mass flywheel - 3.8 l.............................................................................................310
Removing double-mass flywheel - 3.8 l........................................................................................310
Installing double-mass flywheel.........................................................................................................312
Installing double-mass flywheel....................................................................................................312
Subsequent work.................................................................................................................................312
Subsequent work for double-mass flywheel.................................................................................312
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13 60 19 Removing and installing double-mass flywheel - as of MY 2005................................................315
Tools....................................................................................................................................................315
Preliminary work................................................................................................................................315
Preliminary work for double-mass flywheel.................................................................................315
Removing double-mass flywheel - 3.6 l.............................................................................................315
Removing double-mass flywheel - 3.6 l........................................................................................315
Installing double-mass flywheel.........................................................................................................317
Installing double-mass flywheel....................................................................................................317
Subsequent work.................................................................................................................................317
Subsequent work for double-mass flywheel.................................................................................317
13 63 19 Removing and installing drive plate for converter - as of MY 2005..........................................320
Tools....................................................................................................................................................320
Preliminary work for drive plate for converter...................................................................................320
Preliminary work for drive plate for converter.............................................................................320
Removing drive plate for converter....................................................................................................320
Removing drive plate for converter...............................................................................................320
Installing drive plate for converter......................................................................................................321
Installing drive plate for converter................................................................................................321
Subsequent work for drive plate for converter...................................................................................322
Subsequent work for drive plate for converter..............................................................................322
13 74 19 Removing and installing crankshaft sealing ring - belt pulley side - as of MY 2005................324
Tools....................................................................................................................................................324
Preliminary work for crankshaft sealing ring - belt pulley side..........................................................324
Preliminary work for crankshaft sealing ring - belt pulley side....................................................324
Removing crankshaft sealing ring - belt pulley side...........................................................................324
Removing the crankshaft sealing ring - belt pulley side...............................................................324
Installing crankshaft sealing ring - belt pulley side............................................................................326
Installing crankshaft sealing ring - belt pulley side.......................................................................326
Subsequent work for crankshaft sealing ring - belt pulley side..........................................................327
Subsequent work for crankshaft sealing ring - belt pulley side....................................................327
13 76 19 Removing and installing belt pulley/vibration damper - engine installed - as of MY 2005.....330
Tools....................................................................................................................................................330
Preliminary work - engine installed....................................................................................................330
Preliminary work for removing belt pulley/vibration damper - engine installed..........................330
Removing belt pulley/vibration damper - engine installed.................................................................331
Removing belt pulley (3.6 l) - engine installed.............................................................................331
Installing belt pulley/vibration damper - engine installed..................................................................332
Installing belt pulley - 3.6 l engine installed.................................................................................332
Subsequent work for installing belt pulley - engine installed.............................................................332
Subsequent work for installing belt pulley - engine installed.......................................................332
13 76 19 Removing and installing belt pulley/vibration damper - engine installed - as of MY 2005.....335
Tools....................................................................................................................................................335
Preliminary work - engine installed....................................................................................................335
Preliminary work for removing belt pulley/vibration damper - engine installed..........................335
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13 76 19 Removing and installing belt pulley/vibration damper - engine installed - as of MY 2005
Removing belt pulley/vibration damper - engine installed.................................................................336
Removing vibration damper (3.8 l) - engine installed...................................................................336
Installing belt pulley/vibration damper - engine installed..................................................................337
Installing vibration damper - 3.8 l engine installed.......................................................................337
Subsequent work for installing belt pulley - engine installed.............................................................338
Subsequent work for installing belt pulley - engine installed.......................................................338
13 78 19 Removing and installing drive belt - as of MY 2005....................................................................341
Preliminary work................................................................................................................................341
Preliminary work for removing drive belt.....................................................................................341
removing.............................................................................................................................................341
Removing drive belt......................................................................................................................341
Installing.............................................................................................................................................342
Installing drive belt........................................................................................................................342
Reworking...........................................................................................................................................343
Work subsequent to installing drive belt.......................................................................................343
15 05 20 Removing and installing camshaft, adjusting timing - engine removed - as of MY 2005........345
Tools....................................................................................................................................................345
Camshaft designation M96/05............................................................................................................346
Camshaft designation M96/05.......................................................................................................346
Allocation of inlet camshaft adjustment device..................................................................................347
Allocation of inlet camshaft adjustment device............................................................................347
Allocation of chain tensioners............................................................................................................348
Allocation of chain tensioners.......................................................................................................348
Preliminary work for removing camshafts.........................................................................................349
Preliminary work for removing camshafts....................................................................................349
Removing camshaft - engine removed...............................................................................................351
Removing camshafts - engine removed........................................................................................351
Installing camshaft - engine removed.................................................................................................354
Installing camshafts, adjusting timing - engine removed..............................................................354
Subsequent work for installing camshafts..........................................................................................363
Subsequent work for installing camshafts.....................................................................................363
15 05 20 Removing and installing camshaft, adjusting timing - engine removed - as of MY 2005........367
Tools....................................................................................................................................................367
Allocation of inlet camshaft adjustment device..................................................................................368
Allocation of inlet camshaft adjustment device............................................................................368
Allocation of chain tensioners............................................................................................................369
Allocation of chain tensioners.......................................................................................................369
Preliminary work for removing camshafts.........................................................................................370
Preliminary work for removing camshafts....................................................................................370
Removing camshaft - engine removed...............................................................................................372
Removing camshafts - engine removed........................................................................................372
Installing camshaft - engine removed.................................................................................................375
Installing camshafts, adjusting timing - engine removed..............................................................375
Subsequent work for installing camshafts..........................................................................................384
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15 05 20 Removing and installing camshaft, adjusting timing - engine removed - as of MY 2005
Subsequent work for installing camshafts.....................................................................................384
15 05 20 Removing and installing camshaft, adjusting timing - engine removed - as of MY 2005........388
Tools....................................................................................................................................................388
Camshaft designation M97/01............................................................................................................389
Camshaft designation M97/01.......................................................................................................389
Allocation of inlet camshaft adjustment device..................................................................................390
Allocation of inlet camshaft adjustment device............................................................................390
Allocation of chain tensioners............................................................................................................391
Allocation of chain tensioners.......................................................................................................391
Preliminary work for removing camshafts.........................................................................................392
Preliminary work for removing camshafts....................................................................................392
Removing camshaft - engine removed...............................................................................................394
Removing camshafts - engine removed........................................................................................394
Installing camshaft - engine removed.................................................................................................397
Installing camshafts, adjusting timing - engine removed..............................................................397
Subsequent work for installing camshafts..........................................................................................406
Subsequent work for installing camshafts.....................................................................................406
15 21 19 Removing and installing bearing cover for intermediate shaft - as of MY 2005......................410
Tools....................................................................................................................................................410
Preliminary work for bearing cover for intermediate shaft................................................................411
Preliminary work for bearing cover for intermediate shaft...........................................................411
Removing bearing cover for intermediate shaft..................................................................................411
Removing bearing cover for intermediate shaft............................................................................412
Installing bearing cover for intermediate shaft...................................................................................415
Installing bearing cover for intermediate shaft..............................................................................415
Subsequent work for bearing cover for intermediate shaft.................................................................417
Subsequent work for bearing cover for intermediate shaft...........................................................417
15 21 19 Removing and installing bearing cover for intermediate shaft - M97/01 - as of MY 2005......420
Tools....................................................................................................................................................420
Preliminary work for bearing cover for intermediate shaft................................................................421
Preliminary work for bearing cover for intermediate shaft...........................................................421
Removing bearing cover for intermediate shaft..................................................................................422
Removing bearing cover for intermediate shaft - up to engine number 685 09 790.....................422
Removing bearing cover for intermediate shaft - from engine number 685 09 791.....................426
Installing bearing cover for intermediate shaft...................................................................................431
Installing bearing cover for intermediate shaft - up to engine number 685 09 790......................432
Installing bearing cover for intermediate shaft - from engine number 685 09 791.......................434
Subsequent work for bearing cover for intermediate shaft.................................................................437
Subsequent work for bearing cover for intermediate shaft...........................................................437
15 21 19 Removing and installing bearing cover for intermediate shaft - M96/05 - as of MY 2005......440
Tools....................................................................................................................................................440
Removing bearing cover for intermediate shaft..................................................................................441
Removing bearing cover for intermediate shaft - up to engine number 695 07 475.....................441
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15 21 19 Removing and installing bearing cover for intermediate shaft - M96/05 - as of MY 2005
Removing bearing cover for intermediate shaft - from engine number 695 07 476.....................445
Installing bearing cover for intermediate shaft...................................................................................451
Installing bearing cover for intermediate shaft - up to engine number 695 07 475......................451
Installing bearing cover for intermediate shaft - from engine number 695 07 476.......................453
15 23 55 Replacing sealing ring for bearing cover for intermediate shaft - as of MY 2005....................458
Preliminary work for bearing cover sealing ring................................................................................458
Preliminary work for bearing cover sealing ring...........................................................................458
Replacing sealing ring for bearing cover for intermediate shaft.........................................................458
Replacing sealing ring for bearing cover for intermediate shaft...................................................458
Subsequent work for bearing cover sealing ring.................................................................................459
Subsequent work for bearing cover sealing ring...........................................................................459
15 37 19 Removing and installing solenoid hydraulic valve (camshaft timing) - as of MY 2005...........462
Tools....................................................................................................................................................462
Removing hydraulic valve for camshaft timing..................................................................................462
Removing hydraulic valve for camshaft timing............................................................................462
Installing hydraulic valve for camshaft timing...................................................................................465
Installing hydraulic valve for camshaft timing..............................................................................465
15 55 19 Removing and installing solenoid hydraulic valve (valve lift control) - as of MY 2005...........470
Removing hydraulic valve for valve lift control.................................................................................470
Removing hydraulic valve for valve lift control...........................................................................470
Installing hydraulic valve for valve lift control..................................................................................472
Installing hydraulic valve for valve lift control.............................................................................472
15 70 19 Removing and installing cylinder head - engine removed - as of MY 2005...............................475
Tools....................................................................................................................................................475
Preliminary work for removing cylinder head....................................................................................475
Preliminary work for removing cylinder head..............................................................................475
Removing cylinder head.....................................................................................................................477
Removing cylinder head................................................................................................................477
Installing cylinder head.......................................................................................................................478
Installing cylinder head.................................................................................................................478
Subsequent work for installing cylinder head.....................................................................................480
Subsequent work for installing cylinder head...............................................................................480
15 70 37 Disassembling and assembling cylinder head - as of MY 2005...................................................484
Tools....................................................................................................................................................484
Preliminary work for disassembling cylinder head............................................................................485
Preliminary work for disassembling cylinder head.......................................................................485
Disassembling cylinder head..............................................................................................................485
Disassembling cylinder head.........................................................................................................485
Assembling cylinder head...................................................................................................................489
Assembling cylinder head.............................................................................................................489
Assembling cylinder head, touching up..............................................................................................491
Assembling cylinder head, touching up........................................................................................491
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15 70 49 Machining the cylinder head - as of MY 2005..............................................................................493
Preliminary work................................................................................................................................493
Preliminary work for machining cylinder head.............................................................................493
Machining the cylinder head...............................................................................................................493
Machining the cylinder head.........................................................................................................493
Subsequent work.................................................................................................................................494
Subsequent work for machining cylinder head.............................................................................494
15 75 02 Checking valve guide (valve lateral play) - as of MY 2005.........................................................497
Tools....................................................................................................................................................497
Preliminary work................................................................................................................................497
Preliminary work...........................................................................................................................497
Checking valve guide (valve lateral play)..........................................................................................498
Checking valve guide (valve lateral play).....................................................................................498
Subsequent work.................................................................................................................................499
Subsequent work...........................................................................................................................499
15 84 19 Removing and installing actuator for inlet camshaft - as of MY 2005......................................502
Tools....................................................................................................................................................502
Removing actuator - camshaft removed.............................................................................................502
Removing actuator - camshaft removed........................................................................................502
Installing actuator - camshaft removed...............................................................................................503
Installing actuator - camshaft removed.........................................................................................503
15 91 19 Removing and installing cylinder head cover - engine removed - as of MY 2005....................507
Tools....................................................................................................................................................507
Preliminary work for removing cylinder head cover..........................................................................507
Preliminary work for removing cylinder head cover....................................................................507
Removing cylinder head cover - engine removed..............................................................................507
Removing cylinder head cover - engine removed.........................................................................507
Installing cylinder head cover - engine removed................................................................................510
Installing cylinder head cover - engine removed..........................................................................511
Touch up for installing cylinder head cover.......................................................................................514
Touch up for installing cylinder head cover..................................................................................514
17 01 01 Checking engine oil level - as of MY 2005....................................................................................516
Checking engine oil level....................................................................................................................516
Checking engine oil level..............................................................................................................516
17 01 55 Engine oil and oil filter change - as of MY 2005..........................................................................522
Tools....................................................................................................................................................522
Draining engine oil.............................................................................................................................522
Draining engine oil........................................................................................................................522
Changing oil filter...............................................................................................................................524
Changing oil filter.........................................................................................................................524
Refilling engine oil.............................................................................................................................526
Fill in engine oil............................................................................................................................526
Reworking...........................................................................................................................................527
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Diagnostic system: reading out fault memory and activating systems
Table of Contents
17 01 55 Engine oil and oil filter change - as of MY 2005
Subsequent work - topping up engine oil......................................................................................527
17 04 19 Removing and installing oil-pressure sender - as of MY 2005....................................................529
Tools....................................................................................................................................................529
Removing oil-pressure sender.............................................................................................................529
Removing oil-pressure sender.......................................................................................................529
Installing oil-pressure sender..............................................................................................................531
Installing oil-pressure sender.........................................................................................................531
17 15 19 Removing and installing oil filler neck - as of MY 2005..............................................................534
Preliminary work................................................................................................................................534
Preliminary work...........................................................................................................................534
Removing oil filler neck.....................................................................................................................535
Removing oil filler neck................................................................................................................536
Installing oil filler neck.......................................................................................................................536
Installing oil filler neck.................................................................................................................536
Subsequent work.................................................................................................................................537
Subsequent work...........................................................................................................................537
19 01 01 Checking cooling system - as of MY 2005.....................................................................................541
Tools....................................................................................................................................................541
checking..............................................................................................................................................541
Coolant - check antifreeze and fluid level.....................................................................................541
Checking the cooling system for leaks..........................................................................................542
Cleaning the cooling air guides.....................................................................................................543
Checking the antifreeze content using a refractometer.................................................................543
19 24 19 Removing and installing air guide - as of MY 2005.....................................................................548
Preliminary work................................................................................................................................548
Preliminary work for removing air guide......................................................................................548
Removing air guide.............................................................................................................................548
Removing air guide for middle radiator........................................................................................548
Removing air guide for side radiator.............................................................................................549
Installing air guide..............................................................................................................................550
Installing air guide for middle radiator..........................................................................................550
Installing air guide for side radiator..............................................................................................550
Subsequent work.................................................................................................................................552
Subsequent work for installing air guide.......................................................................................552
19 38 17 Draining and filling in coolant - as of MY 2005...........................................................................554
Tools....................................................................................................................................................554
Preliminary work................................................................................................................................554
Preliminary work...........................................................................................................................554
Draining coolant..................................................................................................................................555
Draining coolant............................................................................................................................555
Filling with coolant.............................................................................................................................558
Filling coolant (includes bleeding)................................................................................................558
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Diagnostic system: reading out fault memory and activating systems
Table of Contents
19 38 17 Draining and filling in coolant - as of MY 2005
Reworking...........................................................................................................................................561
Subsequent work...........................................................................................................................561
19 40 19 Removing and installing reservoir for coolant - as of MY 2005.................................................564
Tools....................................................................................................................................................564
Preliminary work................................................................................................................................564
Preliminary work...........................................................................................................................564
Removing reservoir for coolant..........................................................................................................566
Removing reservoir for coolant.....................................................................................................566
Installing reservoir for coolant............................................................................................................569
Installing reservoir for coolant......................................................................................................569
Subsequent work.................................................................................................................................570
Subsequent work...........................................................................................................................570
19 50 19 Removing and installing coolant pump - as of MY 2005.............................................................573
Preliminary work................................................................................................................................573
Preliminary work...........................................................................................................................573
Removing coolant pump.....................................................................................................................574
Removing coolant pump...............................................................................................................574
Installing coolant pump......................................................................................................................575
Installing coolant pump.................................................................................................................575
Subsequent work.................................................................................................................................576
Subsequent work...........................................................................................................................577
19 58 19 Removing and installing coolant regulator - as of MY 2005.......................................................580
Tools....................................................................................................................................................580
Preliminary work................................................................................................................................580
Preliminary work...........................................................................................................................580
Removing coolant regulator................................................................................................................581
Remove coolant regulator.............................................................................................................581
Installing coolant regulator.................................................................................................................582
Installing coolant regulator............................................................................................................583
Subsequent work.................................................................................................................................583
Subsequent work...........................................................................................................................583
19 70 19 Removing and installing radiator - as of MY 2005......................................................................586
Preliminary work................................................................................................................................586
Preliminary work for removing radiator.......................................................................................586
Removing radiator..............................................................................................................................586
Removing radiator.........................................................................................................................586
Installing radiator................................................................................................................................590
Installing radiator..........................................................................................................................590
Subsequent work.................................................................................................................................593
Subsequent work for installing radiator........................................................................................594
xiv
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Diagnostic system: reading out fault memory and activating systems
Table of Contents
19 80 19 Removing and installing middle radiator - as of MY 2005.........................................................596
Preliminary work................................................................................................................................596
Preliminary work for removing middle radiator...........................................................................596
Removing middle radiator..................................................................................................................596
Removing middle radiator.............................................................................................................596
Installing middle radiator....................................................................................................................597
Installing middle radiator..............................................................................................................597
Subsequent work.................................................................................................................................598
Subsequent work for installing middle radiator............................................................................598
20 02 01 Checking fuel pressure - as of MY 2005.......................................................................................601
Tools....................................................................................................................................................601
Checking fuel pressure........................................................................................................................601
Checking fuel pressure..................................................................................................................601
20 07 19 Removing and installing filler neck - as of MY 2005...................................................................607
Tools....................................................................................................................................................607
Preliminary work................................................................................................................................607
Preliminary work...........................................................................................................................607
Removing filler neck...........................................................................................................................607
Removing filler neck.....................................................................................................................608
Installing filler neck............................................................................................................................609
Installing filler neck.......................................................................................................................609
Subsequent work.................................................................................................................................610
Subsequent work...........................................................................................................................610
20 10 19 Removing and installing fuel tank - as of MY 2005.....................................................................613
Tools....................................................................................................................................................613
Preliminary work................................................................................................................................613
Preliminary work - Carrera 4.........................................................................................................613
Removing fuel tank.............................................................................................................................617
Removing fuel tank - Carrera 4.....................................................................................................618
Installing fuel tank..............................................................................................................................620
Installing fuel tank - Carrera 4......................................................................................................620
Subsequent work.................................................................................................................................622
Subsequent work - Carrera 4.........................................................................................................622
20 10 19 Removing and installing fuel tank - as of MY 2005.....................................................................625
Tools....................................................................................................................................................625
Preliminary work................................................................................................................................626
Preliminary work - Carrera 2.........................................................................................................626
Removing fuel tank.............................................................................................................................630
Removing fuel tank - Carrera 2.....................................................................................................630
Installing fuel tank..............................................................................................................................633
Installing fuel tank - Carrera 2......................................................................................................633
Subsequent work.................................................................................................................................633
Subsequent work - Carrera 2.........................................................................................................633
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Diagnostic system: reading out fault memory and activating systems
Table of Contents
20 25 19 Removing and installing carbon canister - as of MY 2005..........................................................637
Tools....................................................................................................................................................637
Preliminary work for carbon canister.................................................................................................637
Preliminary work for carbon canister............................................................................................637
Removing carbon canister...................................................................................................................638
Removing carbon canister - RoW Version....................................................................................638
Removing carbon canister - USA Version....................................................................................639
Installing carbon canister....................................................................................................................640
Installing carbon canister - RoW Version.....................................................................................640
Installing carbon canister - USA Version......................................................................................641
Subsequent work for carbon canister..................................................................................................642
Subsequent work for carbon canister............................................................................................642
20 66 01 Checking quantity delivered by fuel pump - as of MY 2005.......................................................646
Tools....................................................................................................................................................646
Preliminary work for quantity delivered by fuel pump......................................................................646
Preliminary work for quantity delivered by fuel pump.................................................................646
Checking quantity delivered by fuel pump.........................................................................................647
Checking quantity delivered by fuel pump...................................................................................647
Subsequent work for quantity delivered by fuel pump.......................................................................650
Subsequent work for quantity delivered by fuel pump.................................................................650
20 66 19 Removing and installing fuel pump - as of MY 2005...................................................................653
Preliminary work................................................................................................................................653
Preliminary work - Carrera 2.........................................................................................................653
Removing fuel pump..........................................................................................................................653
Removing fuel pump - Carrera 2...................................................................................................653
Installing fuel pump............................................................................................................................654
Installing fuel pump - Carrera 2....................................................................................................654
Subsequent work.................................................................................................................................654
Subsequent work - Carrera 2.........................................................................................................655
20 66 19 Removing and installing fuel pump - as of MY 2005...................................................................657
Preliminary work................................................................................................................................657
Preliminary work - Carrera 4.........................................................................................................657
Removing fuel pump..........................................................................................................................657
Removing fuel pump - Carrera 4...................................................................................................657
Installing fuel pump............................................................................................................................658
Installing fuel pump - Carrera 2....................................................................................................659
Installing fuel pump - Carrera 4....................................................................................................659
Subsequent work.................................................................................................................................660
Subsequent work - Carrera 4.........................................................................................................660
20 66 19 Removing and installing fuel pump - as of MY 2005...................................................................663
Preliminary work................................................................................................................................663
Preliminary work - Carrera 4.........................................................................................................663
Removing fuel pump..........................................................................................................................663
Removing fuel pump - Carrera 4...................................................................................................663
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Diagnostic system: reading out fault memory and activating systems
Table of Contents
20 66 19 Removing and installing fuel pump - as of MY 2005
Installing fuel pump............................................................................................................................664
Installing fuel pump - Carrera 4....................................................................................................665
Subsequent work.................................................................................................................................665
Subsequent work - Carrera 4.........................................................................................................665
24 24 19 Removing and installing air cleaner element - as of MY 2005...................................................668
Preliminary work for removing air-cleaner element...........................................................................668
Preliminary work for air cleaner element......................................................................................668
Removing air-cleaner element...........................................................................................................668
Removing air cleaner element.......................................................................................................668
Installing air cleaner element..............................................................................................................669
Installing air cleaner element........................................................................................................669
Subsequent work for installing air-cleaner element............................................................................670
Rework on air cleaner element......................................................................................................670
24 25 19 Removing and installing air cleaner housing - as of MY 2005...................................................673
Removing air cleaner housing............................................................................................................673
Removing air cleaner housing.......................................................................................................673
Installing air cleaner housing..............................................................................................................674
Installing air cleaner housing........................................................................................................674
24 40 19 Removing and installing injection valves - as of MY 2005..........................................................678
Preliminary work................................................................................................................................678
Preliminary work for removing injection valves...........................................................................678
General warning notes........................................................................................................................678
Danger from fuel...........................................................................................................................678
Hot engine components.................................................................................................................679
Removing injection valves..................................................................................................................679
Removing injection valves of cylinder bank 1-3...........................................................................679
Removing injection valves of cylinder bank 4-6...........................................................................682
Installing injection valves...................................................................................................................684
Installing injection valves of cylinder bank 1-3............................................................................684
Installing injection valves of cylinder bank 4-6............................................................................686
Subsequent work.................................................................................................................................687
Work subsequent to installing injection valves.............................................................................687
24 42 19 Removing and installing throttle body - as of MY 2005..............................................................690
Preliminary work................................................................................................................................690
Preliminary work for removing throttle body...............................................................................690
Removing throttle body......................................................................................................................690
Removing throttle body.................................................................................................................690
Installing throttle body........................................................................................................................691
Installing throttle body..................................................................................................................691
Subsequent work.................................................................................................................................691
Work subsequent to installing throttle body..................................................................................691
xvii
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Diagnostic system: reading out fault memory and activating systems
Table of Contents
24 46 19 Removing and installing intake distributor - as of MY 2005......................................................694
Tools....................................................................................................................................................694
Preliminary work................................................................................................................................694
Preliminary work for removing intake distributor........................................................................694
General warning notes........................................................................................................................694
Danger from Pentosin....................................................................................................................695
Removing intake distributor, cylinder bank 1-3.................................................................................695
Removing intake distributor, cylinder bank 1-3............................................................................695
Removing intake distributor, cylinder bank 1-3.................................................................................698
Installing intake distributor, cylinder bank 1-3.............................................................................698
Removing intake distributor, cylinder bank 4-6.................................................................................701
Removing intake distributor, cylinder bank 4-6............................................................................701
Installing intake distributor, cylinder bank 4-6...................................................................................705
Installing intake distributor, cylinder bank 4-6.............................................................................705
Subsequent work.................................................................................................................................709
Subsequent work for installing intake distributor.........................................................................709
24 69 19 Removing and installing oxygen sensor in front of catalytic converter - as of MY 2005.........712
Tools....................................................................................................................................................712
Preliminary work................................................................................................................................712
Preliminary work for removing oxygen sensors in front of catalytic converter...........................712
Removing oxygen sensors in front of catalytic converter..................................................................713
Removing oxygen sensor in front of catalytic converter of cylinder bank 1-3.............................713
Removing oxygen sensor in front of catalytic converter of cylinder bank 4-6.............................713
Installing oxygen sensors in front of catalytic converter....................................................................714
Installing oxygen sensor in front of catalytic converter of cylinder bank 1-3..............................714
Installing oxygen sensor in front of catalytic converter of cylinder bank 4-6..............................715
Subsequent work.................................................................................................................................715
Subsequent work for installing oxygen sensors in front of catalytic converter............................715
24 70 19 Removing and installing DME control module - as of MY 2005................................................718
Tools....................................................................................................................................................718
Preliminary work................................................................................................................................718
Preliminary work for DME control module in Cabriolet..............................................................718
General warning notes........................................................................................................................719
General warning notes for control units........................................................................................719
Removing DME control module.........................................................................................................719
Removing DME control module in Cabriolet...............................................................................719
Installing DME control module..........................................................................................................720
Installing DME control module in cabriolet..................................................................................720
Subsequent work.................................................................................................................................721
Subsequent work on DME control unit.........................................................................................721
Subsequent work for DME control module in Cabriolet..............................................................721
Programming DME control module...................................................................................................722
Programming new DME control module......................................................................................722
Programming DME control module..............................................................................................723
Exhaust-gas standard.....................................................................................................................725
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Diagnostic system: reading out fault memory and activating systems
Table of Contents
24 70 19 Removing and installing DME control module - as of MY 2005................................................728
Tools....................................................................................................................................................728
Preliminary work................................................................................................................................728
Subsequent work on DME control unit.........................................................................................728
Preliminary work for DME control module in Cabriolet..............................................................729
General warning notes........................................................................................................................729
General warning notes for control units........................................................................................729
Removing DME control module.........................................................................................................730
Removing DME control module in Cabriolet...............................................................................730
Installing DME control module..........................................................................................................731
Installing DME control module in cabriolet..................................................................................731
Subsequent work.................................................................................................................................731
Subsequent work on DME control unit.........................................................................................732
Subsequent work for DME control module in Cabriolet..............................................................732
Programming DME control module...................................................................................................732
Programming new DME control module......................................................................................732
Programming DME control module..............................................................................................733
Exhaust-gas standard.....................................................................................................................735
24 70 19 Removing and installing DME control module - as of MY 2005................................................738
Tools....................................................................................................................................................738
Preliminary work................................................................................................................................738
Subsequent work on DME control unit.........................................................................................738
General warning notes........................................................................................................................739
General warning notes for control units........................................................................................739
Removing DME control module.........................................................................................................739
Removing DME control module...................................................................................................739
Installing DME control module..........................................................................................................741
Installing DME control module.....................................................................................................741
Subsequent work.................................................................................................................................742
Subsequent work on DME control unit.........................................................................................742
Programming DME control module...................................................................................................742
Programming new DME control module......................................................................................742
Programming DME control module..............................................................................................744
Exhaust-gas standard.....................................................................................................................745
24 73 19 Removing and installing oxygen sensor behind catalytic converter - as of MY 2005...............748
Tools....................................................................................................................................................748
Preliminary work................................................................................................................................748
Preliminary work for removing oxygen sensor behind the catalytic converter............................748
Removing oxygen sensor behind the catalytic converter...................................................................749
Removing oxygen sensor behind catalytic converter of cylinder bank 1-3..................................749
Removing oxygen sensor behind catalytic converter of cylinder bank 4-6..................................750
Installing oxygen sensor behind the catalytic converter.....................................................................750
Installing oxygen sensor behind catalytic converter of cylinder bank 1-3....................................751
Installing oxygen sensor behind catalytic converter of cylinder bank 4-6....................................751
Subsequent work.................................................................................................................................752
Subsequent work for installing oxygen sensor behind the catalytic converter.............................752
xix
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Diagnostic system: reading out fault memory and activating systems
Table of Contents
24 74 19 Removing and installing tuning pipe - as of MY 2005.................................................................754
Preliminary work................................................................................................................................754
Preliminary work for removing tuning pipe..................................................................................754
Removing tuning pipe.........................................................................................................................754
Removing tuning pipe...................................................................................................................754
Installing tuning pipe..........................................................................................................................756
Installing tuning pipe.....................................................................................................................756
Subsequent work.................................................................................................................................757
Work subsequent to installing tuning pipe....................................................................................757
26 10 19 Removing and installing exhaust manifold - as of MY 2005.......................................................760
Removing exhaust manifold...............................................................................................................760
Removing exhaust manifold..........................................................................................................760
Installing exhaust manifold.................................................................................................................762
Installing exhaust manifold...........................................................................................................762
26 33 19 Removing and installing rear silencer - as of MY 2005...............................................................766
Tools....................................................................................................................................................766
Preliminary work................................................................................................................................766
Preliminary work...........................................................................................................................766
Removing rear silencer.......................................................................................................................767
Removing rear silencer..................................................................................................................767
Installing rear silencer.........................................................................................................................769
Installing rear silencer...................................................................................................................769
Subsequent work.................................................................................................................................770
Subsequent work...........................................................................................................................770
26 34 19 Removing and installing tailpipe - as of MY 2005.......................................................................773
Removing tailpipe - 3.6 l....................................................................................................................773
Removing tailpipe - M 96/05 (3.6 l)..............................................................................................773
Installing tailpipe - 3.6 l......................................................................................................................773
Installing tailpipe - 3.6 l................................................................................................................773
26 34 19 Removing and installing tailpipe - as of MY 2005.......................................................................777
Removing tailpipe -3.8 l.....................................................................................................................777
Removing tailpipe - 3.8 l...............................................................................................................777
Installing tailpipe -3.8 l.......................................................................................................................777
Installing tailpipe - 3.8 l................................................................................................................777
26 65 19 Removing and installing secondary air pump - as of MY 2005..................................................781
Preliminary work................................................................................................................................781
Preliminary work for removing secondary air pump....................................................................781
Removing secondary air pump...........................................................................................................781
Removing secondary air pump......................................................................................................781
Installing secondary air pump.............................................................................................................782
Installing secondary air pump.......................................................................................................783
Subsequent work.................................................................................................................................784
Work subsequent to installing secondary air pump.......................................................................784
xx
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Diagnostic system: reading out fault memory and activating systems
Table of Contents
26 73 19 Removing and installing catalytic converter - as of MY 2005....................................................787
Preliminary work................................................................................................................................787
Preliminary work...........................................................................................................................787
Removing catalytic converter.............................................................................................................788
Removing catalytic converter........................................................................................................788
Installing catalytic converter...............................................................................................................790
Installing catalytic converter.........................................................................................................790
Subsequent work.................................................................................................................................791
Subsequent work...........................................................................................................................791
27 06 01 Battery trickle charge - as of MY 2005.........................................................................................794
Preliminary work.................................................................................................................................794
General warning notes...................................................................................................................794
Tools and materials.......................................................................................................................794
Checking battery charging condition with battery tester...............................................................794
Reworking.....................................................................................................................................795
27 06 19 Removing and installing battery - as of MY 2005........................................................................797
Removing battery................................................................................................................................797
Removing battery..........................................................................................................................797
Installing battery.................................................................................................................................798
Installing battery............................................................................................................................798
Subsequent work.................................................................................................................................799
Subsequent work - battery.............................................................................................................800
27 12 19 Removing and installing battery cover - as of MY 2005.............................................................802
Removing battery cover......................................................................................................................802
Removing battery cover................................................................................................................802
Installing battery cover.......................................................................................................................802
Installing battery cover..................................................................................................................803
Subsequent work.................................................................................................................................803
Reworking if cowl panel cover deformed.....................................................................................803
27 22 19 Removing and installing three-phase generator - as of MY 2005..............................................807
Preliminary work................................................................................................................................807
Preliminary work - three-phase generator.....................................................................................807
Removing three-phase generator........................................................................................................807
Removing three-phase generator...................................................................................................807
Installing three-phase generator..........................................................................................................809
Installing three-phase generator....................................................................................................809
Subsequent work.................................................................................................................................811
Subsequent work - three-phase generator.....................................................................................811
27 60 19 Removing and installing starter - as of MY 2005.........................................................................814
Preliminary work................................................................................................................................814
Preliminary work - starter..............................................................................................................814
Removing starter.................................................................................................................................814
Removing starter...........................................................................................................................814
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Diagnostic system: reading out fault memory and activating systems
Table of Contents
27 60 19 Removing and installing starter - as of MY 2005
Installing starter..................................................................................................................................816
Installing starter.............................................................................................................................816
Subsequent work.................................................................................................................................817
Subsequent work - starter..............................................................................................................817
28 04 19 Removing and installing ignition switch - as of MY 2005...........................................................820
Tools....................................................................................................................................................820
Removing ignition switch...................................................................................................................820
Removing ignition switch.............................................................................................................820
Installing ignition switch....................................................................................................................821
Installing ignition switch...............................................................................................................822
Information.........................................................................................................................................822
Emergency operation of the ignition key lock..............................................................................822
28 70 20 Removing and installing spark plugs - as of MY 2005................................................................825
Tools....................................................................................................................................................825
Preliminary work................................................................................................................................825
Preliminary work...........................................................................................................................826
Removing............................................................................................................................................826
Removing spark plugs...................................................................................................................826
Installing.............................................................................................................................................827
Installing spark plugs.....................................................................................................................827
Subsequent work.................................................................................................................................827
Reworking.....................................................................................................................................828
28 72 19 Removing and installing knock sensor - as of MY 2005..............................................................830
Preliminary work................................................................................................................................830
Preliminary work for removing knock sensor...............................................................................830
Removing knock sensor......................................................................................................................830
Removing knock sensor, cylinder bank 1-3..................................................................................830
Removing knock sensor, cylinder bank 4-6..................................................................................831
Installing knock sensor.......................................................................................................................831
Installing knock sensor, cylinder bank 1 -3...................................................................................831
Installing knock sensor, cylinder bank 4 -6...................................................................................832
Subsequent work.................................................................................................................................832
Work subsequent to installing knock sensor.................................................................................832
30 01 07 Bleeding the clutch system - as of MY 2005.................................................................................835
Information.........................................................................................................................................835
Important notes on bleeding..........................................................................................................835
Filling/bleeding.............................................................................................................................835
30 05 01 Checking clutch pedal (end position) - as of MY 2005................................................................839
Clutch pedal: checking play and pedal end position...........................................................................839
Checking clutch free play..............................................................................................................839
Clutch: Checking pedal end position (pedal return/return force)..................................................839
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Diagnostic system: reading out fault memory and activating systems
Table of Contents
30 05 19 Removing and installing the clutch pedal - as of MY 2005.........................................................842
............................................................................................................................................................842
Preliminary work...........................................................................................................................842
............................................................................................................................................................843
General warning notes...................................................................................................................843
............................................................................................................................................................843
Technical values............................................................................................................................843
............................................................................................................................................................844
Removing......................................................................................................................................844
............................................................................................................................................................845
Installing........................................................................................................................................845
............................................................................................................................................................847
Subsequent work...........................................................................................................................847
30 30 19 Removing and installing clutch slave cylinder - as of MY 2005.................................................850
Removing and installing.....................................................................................................................850
Removing clutch slave cylinder....................................................................................................850
Installing clutch slave cylinder......................................................................................................850
30 47 19 Removing and installing guide sleeve - as of MY 2005................................................................854
Preliminary work................................................................................................................................854
Preliminary work...........................................................................................................................854
Removing guide sleeve.......................................................................................................................854
Removing guide sleeve.................................................................................................................854
Installing guide sleeve.........................................................................................................................855
Installing guide sleeve...................................................................................................................855
Subsequent work.................................................................................................................................856
Subsequent work...........................................................................................................................856
30 50 19 Removing and installing clutch - as of MY 2005..........................................................................859
Tools....................................................................................................................................................859
Preliminary work................................................................................................................................859
Preliminary work...........................................................................................................................859
Removing clutch.................................................................................................................................860
Removing clutch............................................................................................................................860
Removing clutch............................................................................................................................860
Installing clutch...................................................................................................................................861
Installing clutch.............................................................................................................................861
Reworking...........................................................................................................................................862
Subsequent work...........................................................................................................................862
30 56 01 Checking clutch plate for wear - as of MY 2005..........................................................................865
Preliminary work................................................................................................................................865
Preliminary work...........................................................................................................................865
Checking clutch plate for wear...........................................................................................................865
Checking clutch plate for wear......................................................................................................865
Subsequent work.................................................................................................................................866
Subsequent work...........................................................................................................................866
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Diagnostic system: reading out fault memory and activating systems
Table of Contents
32 43 19 Removing and installing converter housing - as of MY 2005.....................................................869
Preliminary work................................................................................................................................869
Preliminary work...........................................................................................................................869
Removing converter housing..............................................................................................................870
Removing converter housing.........................................................................................................870
Installing converter housing................................................................................................................870
Installing converter housing..........................................................................................................870
Subsequent work.................................................................................................................................872
Subsequent work...........................................................................................................................872
32 47 19 Removing and installing torque converter sealing ring - as of MY 2005..................................874
Tools....................................................................................................................................................874
Information.........................................................................................................................................874
Notes..............................................................................................................................................875
Preliminary work................................................................................................................................875
Preliminary work...........................................................................................................................875
Removing the torque converter.....................................................................................................875
Removing the torque converter sealing ring.......................................................................................876
Removing the torque-converter sealing ring.................................................................................876
Installing the torque converter sealing ring........................................................................................876
Installing the torque-converter sealing ring...................................................................................877
Subsequent work.................................................................................................................................877
Installing the torque converter.......................................................................................................877
Reworking.....................................................................................................................................878
32 50 19 Removing and installing torque converter - as of MY 2005.......................................................881
Tools....................................................................................................................................................881
Information.........................................................................................................................................881
Notes..............................................................................................................................................881
Preliminary work................................................................................................................................882
Preliminary work...........................................................................................................................882
Removing torque converter.................................................................................................................882
Removing the torque converter.....................................................................................................882
Installing torque converter..................................................................................................................883
Installing the torque converter.......................................................................................................883
Subsequent work.................................................................................................................................884
Reworking.....................................................................................................................................884
34 01 35 Checking and topping up transmission oil - as of MY 2005.......................................................886
Information.........................................................................................................................................886
Notes..............................................................................................................................................886
Preliminary work................................................................................................................................886
Preliminary work...........................................................................................................................886
Checking and topping up transmission oil..........................................................................................886
Checking and topping up transmission oil....................................................................................887
Subsequent work.................................................................................................................................887
Reworking.....................................................................................................................................887
xxiv
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Diagnostic system: reading out fault memory and activating systems
Table of Contents
34 01 55 Changing transmission oil - as of MY 2005..................................................................................890
Information.........................................................................................................................................890
Notes..............................................................................................................................................890
Technical values..................................................................................................................................890
Filling capacities............................................................................................................................890
Preliminary work................................................................................................................................891
Preliminary work...........................................................................................................................891
Draining transmission oil....................................................................................................................891
Draining transmission oil..............................................................................................................891
Refilling transmission oil....................................................................................................................892
Filling in transmission oil..............................................................................................................892
Subsequent work.................................................................................................................................892
Reworking.....................................................................................................................................892
34 04 19 Removing and installing shift lever knob - as of MY 2005.........................................................895
Removing shift lever knob..................................................................................................................895
Removing shift-lever knob............................................................................................................895
Installing shift lever knob...................................................................................................................896
Installing shift-lever knob.............................................................................................................896
34 08 19 Removing and installing shift console - as of MY 2005...............................................................900
Tools....................................................................................................................................................900
Preliminary work................................................................................................................................900
Preliminary work...........................................................................................................................900
Removing shift console......................................................................................................................901
Removing gearshift bracket...........................................................................................................901
Installing shift console........................................................................................................................902
Installing gearshift bracket............................................................................................................903
Subsequent work.................................................................................................................................905
Subsequent work...........................................................................................................................905
34 12 19 Removing and installing shift and selector cables - as of MY 2005............................................908
Tools....................................................................................................................................................908
Preliminary work................................................................................................................................908
Preliminary work...........................................................................................................................908
Removing shift and selector cables.....................................................................................................908
Detaching shift and selector cables at transmission......................................................................908
Detaching shift and selector cables inside vehicle........................................................................909
Installing shift and selector cables......................................................................................................910
Fastening shift and select. cables to the transmission...................................................................910
Securing shift and selector cables inside vehicle..........................................................................912
Subsequent work.................................................................................................................................913
Subsequent work...........................................................................................................................913
34 35 19 Removing and installing transmission - as of MY 2005..............................................................916
Tools....................................................................................................................................................916
Preliminary work................................................................................................................................916
Preliminary work...........................................................................................................................916
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Table of Contents
34 35 19 Removing and installing transmission - as of MY 2005
Removing transmission.......................................................................................................................916
Dismantling...................................................................................................................................916
Removing transmission.................................................................................................................919
Installing transmission........................................................................................................................920
Installing transmission...................................................................................................................920
Assembly work..............................................................................................................................923
Subsequent work.................................................................................................................................925
Subsequent work...........................................................................................................................925
34 35 19 Removing and installing transmission - as of MY 2005..............................................................928
Tools....................................................................................................................................................928
Preliminary work................................................................................................................................928
Preliminary work...........................................................................................................................928
Removing transmission.......................................................................................................................928
Dismantling...................................................................................................................................928
Removing transmission.................................................................................................................931
Installing transmission........................................................................................................................932
Installing transmission...................................................................................................................932
Assembly work..............................................................................................................................935
Subsequent work.................................................................................................................................937
Subsequent work...........................................................................................................................937
34 35 27 Removing and refitting transmission - as of MY 2005................................................................940
Preliminary work................................................................................................................................940
Preliminary work...........................................................................................................................940
Removing transmission.......................................................................................................................940
Removing transmission.................................................................................................................940
Refitting transmission.........................................................................................................................941
Refitting transmission....................................................................................................................941
Subsequent work.................................................................................................................................943
Subsequent work...........................................................................................................................943
35 50 19 Removing and installing sealing ring for input shaft - as of MY 2005.......................................945
Tools....................................................................................................................................................945
Preliminary work................................................................................................................................945
Preliminary work...........................................................................................................................946
Removing sealing ring for input shaft................................................................................................946
Removing sealing ring for drive shaft...........................................................................................946
Installing sealing ring for input shaft..................................................................................................947
Installing sealing ring for input shaft............................................................................................947
Subsequent work.................................................................................................................................949
Subsequent work...........................................................................................................................949
37 02 35 Checking and topping up the ATF - as of MY 2005....................................................................951
Tools....................................................................................................................................................951
Information.........................................................................................................................................951
Notes..............................................................................................................................................951
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Table of Contents
37 02 35 Checking and topping up the ATF - as of MY 2005
Preliminary work................................................................................................................................952
Preliminary work...........................................................................................................................952
Checking and topping up the ATF......................................................................................................953
Checking and topping up the ATF................................................................................................953
Reworking...........................................................................................................................................954
Reworking.....................................................................................................................................954
37 02 55 Changing ATF - as of MY 2005.....................................................................................................956
Tools....................................................................................................................................................956
Information.........................................................................................................................................956
Notes..............................................................................................................................................956
Technical values..................................................................................................................................957
Filling capacities............................................................................................................................957
Preliminary work................................................................................................................................957
Preliminary work...........................................................................................................................957
Changing ATF....................................................................................................................................957
Draining ATF................................................................................................................................957
Topping up ATF............................................................................................................................958
Checking and topping up the ATF................................................................................................960
Subsequent work.................................................................................................................................960
Reworking.....................................................................................................................................960
37 04 19 Removing and installing selector knob - as of MY 2005.............................................................963
Removing selector knob.....................................................................................................................963
Removing selector knob................................................................................................................963
Installing selector knob.......................................................................................................................964
Installing selector knob.................................................................................................................964
37 08 19 Removing and installing selector support - as of MY 2005.........................................................967
Preliminary work................................................................................................................................967
Preliminary work...........................................................................................................................967
Removing selector support.................................................................................................................967
Removing selector frame...............................................................................................................967
Installing selector support...................................................................................................................969
Installing selector frame................................................................................................................969
Subsequent work.................................................................................................................................971
Subsequent work...........................................................................................................................971
37 15 19 Removing and installing selector lever cable - as of MY 2005....................................................974
Preliminary work................................................................................................................................974
Preliminary work...........................................................................................................................974
Removing selector lever cable............................................................................................................974
Removing selector lever cable from transmission........................................................................974
Detaching selector lever cable inside vehicle................................................................................975
Installing selector lever cable..............................................................................................................976
Fastening selector lever cable on transmission.............................................................................976
Securing selector lever cable inside vehicle..................................................................................978
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Table of Contents
37 15 19 Removing and installing selector lever cable - as of MY 2005
Subsequent work.................................................................................................................................979
Subsequent work...........................................................................................................................979
37 18 20 Removing and installing Tiptronic rocker switch - as of MY 2005............................................982
Preliminary work................................................................................................................................982
Preliminary work...........................................................................................................................982
Removing Tiptronic rocker switch.....................................................................................................982
Removing Tiptronic rocker switch................................................................................................982
Installing Tiptronic rocker switch.......................................................................................................983
Installing Tiptronic rocker switch.................................................................................................983
Subsequent work.................................................................................................................................984
Subsequent work...........................................................................................................................984
37 30 19 Removing and installing the Tiptronic control module - as of MY 2005...................................987
Tools....................................................................................................................................................987
Preliminary work................................................................................................................................987
Preliminary work for Tiptronic control module (also referred to generally as control unit
below)....................................................................................................................................987
General warning notes........................................................................................................................988
General warning notes for control units........................................................................................988
Removing Tiptronic control module...................................................................................................988
Removing Tiptronic control module (also referred to generally as control unit below)...............988
Installing Tiptronic control module....................................................................................................991
Installing Tiptronic control unit (also referred to generally as control unit below)......................991
Subsequent work.................................................................................................................................993
Subsequent work for Tiptronic control module (also referred to generally as control unit
below)....................................................................................................................................993
Programming Tiptronic control module.............................................................................................993
Reading out from and writing in to the Tiptronic control unit (also referred to generally as
control unit below).................................................................................................................993
Coding Tiptronic control module.......................................................................................................994
Coding Tiptronic control unit........................................................................................................994
37 35 27 Removing and refitting the automatic transmission - as of MY 2005........................................998
Tools....................................................................................................................................................998
Information.........................................................................................................................................999
Notes..............................................................................................................................................999
Preliminary work................................................................................................................................999
Preliminary work...........................................................................................................................999
Removing the automatic transmission................................................................................................999
Disassembly work.......................................................................................................................1000
Releasing torque converter..........................................................................................................1001
Removing the automatic transmission........................................................................................1002
Refitting the automatic transmission................................................................................................1003
Refitting the automatic transmission...........................................................................................1003
Fastening torque converter..........................................................................................................1003
Assembly work............................................................................................................................1004
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Table of Contents
37 35 27 Removing and refitting the automatic transmission - as of MY 2005
Reworking.........................................................................................................................................1005
Reworking...................................................................................................................................1006
37 55 19 Removing and installing ATF pan - as of MY 2005...................................................................1008
Tools..................................................................................................................................................1008
Information.......................................................................................................................................1008
Notes............................................................................................................................................1008
Technical values................................................................................................................................1009
Filling capacities..........................................................................................................................1009
Preliminary work..............................................................................................................................1009
Preliminary work.........................................................................................................................1009
Draining ATF..............................................................................................................................1009
Removing ATF pan..........................................................................................................................1010
Removing ATF pan.....................................................................................................................1010
Installing ATF pan............................................................................................................................1011
Installing ATF pan.......................................................................................................................1012
Reworking.........................................................................................................................................1012
Topping up ATF..........................................................................................................................1012
Checking and topping up the ATF..............................................................................................1014
Reworking...................................................................................................................................1015
37 58 55 Replacing ATF filter - as of MY 2005.........................................................................................1017
Tools..................................................................................................................................................1017
Notes.................................................................................................................................................1017
Notes............................................................................................................................................1017
Filling capacities...............................................................................................................................1018
Filling capacities..........................................................................................................................1018
Preliminary work..............................................................................................................................1018
Preliminary work.........................................................................................................................1018
Draining ATF..............................................................................................................................1018
Removing ATF pan.....................................................................................................................1019
Removing ATF filter........................................................................................................................1020
Removing ATF filter...................................................................................................................1020
Installing ATF filter..........................................................................................................................1021
Installing ATF filter.....................................................................................................................1021
Subsequent work...............................................................................................................................1021
Installing ATF pan.......................................................................................................................1022
Topping up ATF..........................................................................................................................1022
Checking and topping up the ATF..............................................................................................1024
Reworking...................................................................................................................................1024
38 60 19 Removing and installing ATF cooler - as of MY 2005...............................................................1027
Tools..................................................................................................................................................1027
Preliminary work..............................................................................................................................1027
Preliminary work.........................................................................................................................1027
Removing ATF cooler......................................................................................................................1028
Removing ATF cooler.................................................................................................................1028
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Table of Contents
38 60 19 Removing and installing ATF cooler - as of MY 2005
Installing ATF cooler........................................................................................................................1029
Installing ATF cooler..................................................................................................................1029
Subsequent work...............................................................................................................................1030
Subsequent work.........................................................................................................................1030
38 77 19 Removing and installing electrohydraulic control unit - as of MY 2005.................................1034
Tools..................................................................................................................................................1034
Information.......................................................................................................................................1034
Notes............................................................................................................................................1035
Technical values................................................................................................................................1035
Filling capacities..........................................................................................................................1035
Preliminary work..............................................................................................................................1035
Preliminary work.........................................................................................................................1035
Draining ATF..............................................................................................................................1036
Removing the electrohydraulic control unit.....................................................................................1036
Dismantling.................................................................................................................................1036
Removing the electrohydraulic control unit................................................................................1038
Installing the electrohydraulic control unit.......................................................................................1039
Installing the electrohydraulic control unit.................................................................................1040
Assembly work............................................................................................................................1041
Subsequent work...............................................................................................................................1043
Topping up ATF..........................................................................................................................1043
Checking and topping up the ATF..............................................................................................1045
Reworking...................................................................................................................................1045
38 77 37 Disassembling and assembling electrohydraulic control unit - as of MY 2005.......................1048
Preliminary work..............................................................................................................................1048
Preliminary work.........................................................................................................................1048
Disassembling electrohydraulic control unit....................................................................................1048
Overview.....................................................................................................................................1048
Disconnecting hydraulic and electrical control unit....................................................................1049
Removing solenoid and control valve.........................................................................................1049
Installing solenoid and control valve...........................................................................................1050
Reassembling the hydraulic and electrical control unit...............................................................1050
Subsequent work...............................................................................................................................1050
Reworking...................................................................................................................................1050
39 02 19 Removing and installing cardan shaft - as of MY 2006.............................................................1053
Tools..................................................................................................................................................1053
Preliminary work..............................................................................................................................1053
Preliminary work.........................................................................................................................1053
Removing cardan shaft.....................................................................................................................1053
Removing cardan shaft................................................................................................................1053
Installing cardan shaft.......................................................................................................................1055
Installing cardan shaft.................................................................................................................1055
Subsequent work...............................................................................................................................1057
Subsequent work.........................................................................................................................1058
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39 22 19 Removing and installing sealing ring for right-hand halfshaft flange - as of MY 2005.........1060
Tools..................................................................................................................................................1060
Preliminary work..............................................................................................................................1060
Preliminary work.........................................................................................................................1060
Removing sealing ring for halfshaft flange......................................................................................1060
Removing sealing ring for halfshaft flange.................................................................................1060
Installing sealing ring for halfshaft flange........................................................................................1061
Installing sealing ring for halfshaft flange..................................................................................1061
Subsequent work...............................................................................................................................1062
Subsequent work.........................................................................................................................1062
39 22 19 Removing and installing sealing ring for left halfshaft flange - as of MY 2005......................1065
Tools..................................................................................................................................................1065
Preliminary work..............................................................................................................................1065
Preliminary work.........................................................................................................................1065
Removing sealing ring for halfshaft flange......................................................................................1065
Removing sealing ring for halfshaft flange.................................................................................1065
Installing sealing ring for halfshaft flange........................................................................................1066
Installing sealing ring for halfshaft flange..................................................................................1066
Subsequent work...............................................................................................................................1067
Subsequent work.........................................................................................................................1067
39 22 19 Removing and installing sealing ring for short halfshaft flange - as of MY 2005...................1070
Tools..................................................................................................................................................1070
Preliminary work..............................................................................................................................1070
Preliminary work.........................................................................................................................1071
Removing sealing ring for short halfshaft flange.............................................................................1071
Removing sealing ring for short halfshaft flange........................................................................1071
Installing sealing ring for halfshaft flange........................................................................................1071
Installing sealing ring for short halfshaft flange.........................................................................1071
Subsequent work...............................................................................................................................1072
Subsequent work.........................................................................................................................1072
39 25 19 Removing and installing right halfshaft flange - as of MY 2005..............................................1075
Preliminary work..............................................................................................................................1075
Preliminary work.........................................................................................................................1075
Removing halfshaft flange................................................................................................................1075
Removing halfshaft flange..........................................................................................................1075
Installing halfshaft flange.................................................................................................................1076
Installing halfshaft flange............................................................................................................1076
Subsequent work...............................................................................................................................1077
Subsequent work.........................................................................................................................1077
39 25 19 Removing and installing left halfshaft flange - as of MY 2005.................................................1080
Preliminary work..............................................................................................................................1080
Preliminary work.........................................................................................................................1080
Removing halfshaft flange................................................................................................................1080
Removing halfshaft flange..........................................................................................................1080
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Table of Contents
39 25 19 Removing and installing left halfshaft flange - as of MY 2005
Installing halfshaft flange.................................................................................................................1081
Installing halfshaft flange............................................................................................................1081
Subsequent work...............................................................................................................................1082
Subsequent work.........................................................................................................................1082
39 25 19 Removing and installing short halfshaft flange - as of MY 2005..............................................1084
Preliminary work..............................................................................................................................1084
Preliminary work.........................................................................................................................1084
Removing short halfshaft flange.......................................................................................................1084
Removing short halfshaft flange.................................................................................................1084
Installing short halfshaft flange........................................................................................................1085
Installing short halfshaft flange...................................................................................................1085
Subsequent work...............................................................................................................................1087
Subsequent work.........................................................................................................................1087
39 25 19 Removing and installing long halfshaft flange - as of MY 2005...............................................1090
Tools..................................................................................................................................................1090
Preliminary work..............................................................................................................................1090
Preliminary work.........................................................................................................................1090
Removing long halfshaft flange........................................................................................................1090
Removing long halfshaft flange..................................................................................................1090
Installing long halfshaft flange.........................................................................................................1091
Installing long halfshaft flange....................................................................................................1091
Subsequent work...............................................................................................................................1093
Subsequent work.........................................................................................................................1093
39 58 19 Removing and installing cover for front final drive - as of MY 2006......................................1095
Tools..................................................................................................................................................1095
Preliminary work..............................................................................................................................1095
Preliminary work.........................................................................................................................1095
Removing cover for front final drive................................................................................................1095
Removing cover for front final drive..........................................................................................1096
Installing cover for front final drive..................................................................................................1096
Installing cover for front final drive............................................................................................1096
Subsequent work...............................................................................................................................1097
Subsequent work.........................................................................................................................1097
39 59 19 Removing and installing sealing ring for front halfshaft flange - as of MY 2006...................1100
Tools..................................................................................................................................................1100
Preliminary work..............................................................................................................................1100
Preliminary work.........................................................................................................................1100
Removing sealing ring for front halfshaft flange..............................................................................1100
Removing sealing ring for front halfshaft flange........................................................................1100
Installing sealing ring for front halfshaft flange...............................................................................1101
Installing sealing ring for front halfshaft flange..........................................................................1101
Subsequent work...............................................................................................................................1103
Subsequent work.........................................................................................................................1103
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39 60 01 Checking operation of the viscous clutch - as of MY 2006........................................................1105
Tools..................................................................................................................................................1105
Checking operation of the viscous clutch.........................................................................................1105
Information..................................................................................................................................1105
Checking operation of the viscous clutch....................................................................................1106
39 60 19 Removing and installing the viscous clutch - as of MY 2006....................................................1109
Tools..................................................................................................................................................1109
Preliminary work..............................................................................................................................1109
Preliminary work.........................................................................................................................1109
Removing the viscous clutch............................................................................................................1110
Removing the viscous clutch.......................................................................................................1110
Installing the viscous clutch..............................................................................................................1111
Installing the viscous clutch........................................................................................................1111
Subsequent work...............................................................................................................................1112
Subsequent work.........................................................................................................................1112
39 62 19 Removing and installing support for front final drive - as of MY 2006..................................1115
Preliminary work..............................................................................................................................1115
Preliminary work.........................................................................................................................1115
Removing support for front final drive.............................................................................................1115
Removing support for front final drive.......................................................................................1115
Installing support for front final drive..............................................................................................1116
Installing support for front final drive.........................................................................................1116
Subsequent work...............................................................................................................................1116
Preliminary work.........................................................................................................................1116
39 64 19 Removing and installing cardan flange - as of MY 2006...........................................................1119
Tools..................................................................................................................................................1119
Preliminary work..............................................................................................................................1119
Preliminary work.........................................................................................................................1120
Removing cardan flange..................................................................................................................1120
Removing cardan flange..............................................................................................................1120
Removing cardan flange..............................................................................................................1121
Installing cardan flange.....................................................................................................................1121
Installing cardan flange...............................................................................................................1121
Installing cardan flange...............................................................................................................1122
Subsequent work...............................................................................................................................1123
Subsequent work.........................................................................................................................1123
Subsequent work.........................................................................................................................1123
39 82 19 Removing and installing sealing ring for cardan flange - as of MY 2006................................1126
Tools..................................................................................................................................................1126
Preliminary work..............................................................................................................................1127
Preliminary work.........................................................................................................................1127
Removing sealing ring for cardan flange..........................................................................................1127
Removing sealing ring for cardan flange....................................................................................1127
Removing sealing ring for cardan flange....................................................................................1128
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Table of Contents
39 82 19 Removing and installing sealing ring for cardan flange - as of MY 2006
Installing sealing ring for cardan flange...........................................................................................1129
Installing sealing ring for cardan flange......................................................................................1129
Installing sealing ring for cardan flange......................................................................................1130
Subsequent work...............................................................................................................................1131
Subsequent work.........................................................................................................................1131
Subsequent work.........................................................................................................................1131
39 88 19 Removing and installing front final drive - as of MY 2006.......................................................1134
Preliminary work..............................................................................................................................1134
Preliminary work.........................................................................................................................1134
Removing front final drive................................................................................................................1134
Removing front final drive..........................................................................................................1134
Installing front final drive.................................................................................................................1136
Installing front final drive............................................................................................................1136
Subsequent work...............................................................................................................................1139
Subsequent work.........................................................................................................................1139
39 90 35 Checking and topping up oil for front final drive - as of MY 2006..........................................1141
Information.......................................................................................................................................1141
Notes............................................................................................................................................1141
Preliminary work..............................................................................................................................1141
Preliminary work.........................................................................................................................1141
Checking and topping up oil for front final drive.............................................................................1141
Checking and topping up oil for front-axle final drive...............................................................1142
Subsequent work...............................................................................................................................1142
Subsequent work.........................................................................................................................1142
39 90 35 Checking and topping up oil for final drive - as of MY 2005...................................................1145
Tools..................................................................................................................................................1145
Information.......................................................................................................................................1145
Notes............................................................................................................................................1145
Preliminary work..............................................................................................................................1146
Preliminary work.........................................................................................................................1146
Checking and topping up oil for final drive......................................................................................1146
Checking and topping up oil for final drive................................................................................1146
Subsequent work...............................................................................................................................1147
Reworking...................................................................................................................................1147
39 90 55 Changing oil for front final drive - as of MY 2006....................................................................1150
Information.......................................................................................................................................1150
Notes............................................................................................................................................1150
Technical values................................................................................................................................1150
Technical values..........................................................................................................................1150
Preliminary work..............................................................................................................................1151
Preliminary work.........................................................................................................................1151
Draining oil for final drive................................................................................................................1151
Draining oil for final drive..........................................................................................................1151
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Table of Contents
39 90 55 Changing oil for front final drive - as of MY 2006
Filling in oil for final drive...............................................................................................................1152
Filling in oil for final drive..........................................................................................................1152
Subsequent work...............................................................................................................................1153
Subsequent work.........................................................................................................................1153
39 90 55 Changing oil for final drive - as of MY 2005..............................................................................1156
Tools..................................................................................................................................................1156
Information.......................................................................................................................................1156
Notes............................................................................................................................................1156
Technical values................................................................................................................................1157
Filling capacities..........................................................................................................................1157
Preliminary work..............................................................................................................................1157
Preliminary work.........................................................................................................................1157
Changing oil for final drive...............................................................................................................1157
Draining oil for final drive..........................................................................................................1157
Topping up oil for final drive......................................................................................................1159
Subsequent work...............................................................................................................................1159
Reworking...................................................................................................................................1159
40 78 19 Removing and installing connecting link (suspension/stabiliser) - as of MY 2005.................1162
..........................................................................................................................................................1162
Removing front connecting link (suspension/stabiliser).............................................................1162
..........................................................................................................................................................1162
Installing front connecting link (suspension/stabiliser)...............................................................1163
40 85 19 Removing and installing front spring strut - as of MY 2005....................................................1166
Tools..................................................................................................................................................1166
..........................................................................................................................................................1166
Removing and installing spring strut - preliminary work...........................................................1166
..........................................................................................................................................................1167
Removing front spring strut........................................................................................................1167
..........................................................................................................................................................1168
Installing front spring strut..........................................................................................................1168
..........................................................................................................................................................1168
Removing and installing spring strut - subsequent work............................................................1168
40 85 37 Disassembling and assembling front spring strut - with and without PASM - as of MY
2005................................................................................................................................................................1171
Tools..................................................................................................................................................1171
Information.......................................................................................................................................1172
Component and assembly overview (with and without PASM).................................................1172
Disassembling and assembling spring strut......................................................................................1174
Disassembling spring strut..........................................................................................................1174
Coil spring/compensating plate allocation..................................................................................1175
Allocation of vibration dampers..................................................................................................1176
Assembling spring strut...............................................................................................................1177
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42 21 19 Removing and installing drive shaft - as of MY 2005................................................................1182
Tools..................................................................................................................................................1182
Preliminary work..............................................................................................................................1182
Removing..........................................................................................................................................1182
Removing rear drive shaft...........................................................................................................1183
Installing...........................................................................................................................................1185
Installing rear drive shaft.............................................................................................................1185
Subsequent work...............................................................................................................................1187
Checking wheel-alignment values...............................................................................................1187
42 71 19 Removing and installing rear spring strut - as of MY 2005......................................................1190
..........................................................................................................................................................1190
Removing and installing spring strut - preliminary work...........................................................1190
..........................................................................................................................................................1190
Removing spring strut.................................................................................................................1190
..........................................................................................................................................................1191
Installing spring strut...................................................................................................................1191
..........................................................................................................................................................1193
Removing and installing spring strut - subsequent work............................................................1193
42 71 37 Disassembling and assembling rear spring strut - with and without PASM - as of MY
2005................................................................................................................................................................1195
Tools..................................................................................................................................................1195
Information.......................................................................................................................................1195
Component and assembly overview (with and without PASM).................................................1195
Disassembling rear spring strut...................................................................................................1198
Coil spring/compensating plate allocation..................................................................................1199
Rear vibration damper allocation................................................................................................1200
Assembling spring strut...............................................................................................................1200
42 91 19 Removing and installing connecting link (suspension/stabiliser) - as of MY 2005.................1205
..........................................................................................................................................................1205
Removing rear connecting link (suspension/stabiliser)...............................................................1205
Installing rear connecting link (suspension/stabiliser)................................................................1205
43 16 19 Removing and installing PASM control unit - as of MY 2005..................................................1208
Tools..................................................................................................................................................1208
Removing PASM control unit..........................................................................................................1208
Removing PASM control unit.....................................................................................................1208
Installing PASM control unit............................................................................................................1210
Installing PASM control unit......................................................................................................1210
Programming PASM control unit.....................................................................................................1210
Reading out and writing values for PASM control unit..............................................................1210
44 05 19 Removing and installing wheel - as of MY 2005........................................................................1214
Information.......................................................................................................................................1214
Wheel mounting..........................................................................................................................1214
Removing wheel...............................................................................................................................1214
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44 05 19 Removing and installing wheel - as of MY 2005
Removing wheel..........................................................................................................................1214
Installing wheel.................................................................................................................................1215
Installing wheel...........................................................................................................................1216
44 05 94 Balancing/optimising wheels - as of MY 2005............................................................................1220
Tools..................................................................................................................................................1220
Balancing/optimising wheels............................................................................................................1220
General........................................................................................................................................1220
Explanation of terms...................................................................................................................1221
Balancing/optimising wheels......................................................................................................1222
Further to 1: Fitting the tyre on the rim.......................................................................................1222
Further to 2A: Measuring radial force variations........................................................................1223
Further to 2B: Stationary balancing with optimisation of rolling smoothness............................1224
Further to 3: Fitting the wheel on the vehicle.............................................................................1224
Balancing weights.......................................................................................................................1225
Attaching the balance stick-on weights.......................................................................................1225
44 12 02 Checking disc wheels - as of MY 2005........................................................................................1228
Checking the radial and lateral runout..............................................................................................1228
44 32 19 Removing and installing wheel electronics - as of MY 2005.....................................................1231
Removing wheel electronics.............................................................................................................1231
General information on wheel electronics...................................................................................1231
Removing wheel electronics.......................................................................................................1232
Installing wheel electronics...............................................................................................................1234
44 34 19 Removing and installing tyre pressure monitoring system control unit - as of MY 2005......1237
Tools..................................................................................................................................................1237
Preliminary work..............................................................................................................................1237
Preliminary work for tyre pressure monitoring system (RDK) control module.........................1237
Removing tyre pressure monitoring system (RDK) control unit......................................................1237
Removing tyre pressure monitoring system (RDK) control module..........................................1237
Installing tyre pressure monitoring system (RDK) control unit.......................................................1238
Installing tyre pressure monitoring system (RDK) control module............................................1238
Subsequent work...............................................................................................................................1239
Rework on tyre pressure monitoring system (RDK) control module.........................................1239
Programming tyre pressure monitoring system (RDK) control unit................................................1239
Control units - reading and writing replacement values..............................................................1239
44 38 19 Removing and installing antenna for tyre pressure monitoring system - as of MY 2005......1243
Preliminary work..............................................................................................................................1243
Preliminary work.........................................................................................................................1243
Removing antenna for tyre pressure monitoring system..................................................................1243
Removing antenna of front tyre pressure monitoring system.....................................................1243
Removing antenna of rear tyre pressure monitoring system.......................................................1245
Installing antenna for tyre pressure monitoring system....................................................................1246
Installing antenna of front tyre pressure monitoring system.......................................................1246
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Table of Contents
44 38 19 Removing and installing antenna for tyre pressure monitoring system - as of MY 2005
Installing antenna of rear tyre pressure monitoring system........................................................1246
Subsequent work...............................................................................................................................1248
Subsequent work.........................................................................................................................1248
44 40 19 Tyre mounting (removing and installing tyres) - for vehicle with and without tyre
pressure monitoring system - as of MY 2005............................................................................................1250
Notes on removing/mounting tyres...................................................................................................1250
Tools............................................................................................................................................1250
Notes on removing/mounting tyres.............................................................................................1251
Special notes for tyre pressure monitoring system (RDK)..........................................................1252
Removal.......................................................................................................................................1253
Installation...................................................................................................................................1255
44 95 03 Suspension alignment, complete - as of MY 2005......................................................................1258
Tools..................................................................................................................................................1258
Information.......................................................................................................................................1258
General procedure for wheel alignment......................................................................................1258
Measuring vehicle at front and rear..................................................................................................1259
Vehicle height (height check)......................................................................................................1259
Wheel alignment..........................................................................................................................1260
Rear axle......................................................................................................................................1260
Front axle.....................................................................................................................................1262
45 01 01 PSM/ABS check using the PIWIS Tester - as of MY 2005.......................................................1267
Tools..................................................................................................................................................1267
..........................................................................................................................................................1267
Test overview..............................................................................................................................1267
PSM check using the PIWIS Tester............................................................................................1268
46 36 02 Checking the thickness of the disc brake pads - as of MY 2005...............................................1271
Test....................................................................................................................................................1271
46 36 19 Removing and installing front brake pads - as of MY 2005.....................................................1275
Preliminary work..............................................................................................................................1275
General warning notes......................................................................................................................1275
Danger of accidents.....................................................................................................................1275
Removal............................................................................................................................................1276
Removing front disc brake pads..................................................................................................1276
Installing...........................................................................................................................................1276
Installing front disc brake pads...................................................................................................1276
Subsequent work...............................................................................................................................1278
46 38 02 Checking the thickness of the rear disc brake pads - as of MY 2005.......................................1280
Preliminary work..............................................................................................................................1280
Checking...........................................................................................................................................1280
Subsequent work...............................................................................................................................1281
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46 38 19 Removing and installing the rear disc brake pads - as of MY 2005.........................................1284
Preliminary work..............................................................................................................................1284
General warning notes......................................................................................................................1284
Danger of accidents.....................................................................................................................1284
Removal............................................................................................................................................1285
Removing rear disc brake pads...................................................................................................1285
Installation........................................................................................................................................1285
Installing rear disc brake pads.....................................................................................................1285
Subsequent work...............................................................................................................................1287
46 50 19 Removing and installing the front brake disc - as of MY 2005................................................1289
Tools..................................................................................................................................................1289
Preliminary work..............................................................................................................................1289
General warning notes......................................................................................................................1289
Removing front brake disc................................................................................................................1290
Installing...........................................................................................................................................1291
Subsequent work...............................................................................................................................1292
46 50 19 Removing and installing the front PCCB brake disc - as of MY 2005.....................................1294
Tools..................................................................................................................................................1294
Preliminary work..............................................................................................................................1294
General warning notes......................................................................................................................1294
Removing front brake disc................................................................................................................1295
Installing...........................................................................................................................................1296
Subsequent work...............................................................................................................................1297
Bedding in the brake pads...........................................................................................................1297
46 51 02 Checking front PCCB brake discs (wear assessment) - as of MY 2005...................................1300
Checking information on PCCB brake discs....................................................................................1300
Basic information........................................................................................................................1300
General information on replacing worn PCCB brake discs........................................................1301
Replacing brake discs (notes/decision-making aid)....................................................................1302
Cracks (stress-relief microstructure) in the brake disc friction surface.......................................1302
Note concerning bores (perforations) in the brake disc friction surface.....................................1303
Coating on the PCCB brake discs (potential causes)..................................................................1304
Note on bedding in the new brake pads......................................................................................1304
Checking PCCB brake discs (wear assessment)...............................................................................1305
Visual inspection of the surfaces of the brake disc friction surfaces (indication of wear)..........1305
Evaluating surface roughness (Sr) (max. 80 micrometre permitted)..........................................1306
Checking brake discs for minimum thickness.............................................................................1310
Checking brake discs for edge damage.......................................................................................1310
46 53 19 Removing and installing rear brake disc - as of MY 2005........................................................1314
Tools..................................................................................................................................................1314
Preliminary work..............................................................................................................................1314
General warning notes......................................................................................................................1314
Removing rear brake disc.................................................................................................................1315
Installing rear brake disc...................................................................................................................1316
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46 53 19 Removing and installing rear brake disc - as of MY 2005
Subsequent work...............................................................................................................................1317
46 53 19 Removing and installing rear brake disc - as of MY 2005........................................................1320
Tools..................................................................................................................................................1320
Preliminary work..............................................................................................................................1320
General warning notes......................................................................................................................1320
Removing rear brake disc.................................................................................................................1321
Installing rear brake disc...................................................................................................................1322
Subsequent work...............................................................................................................................1323
46 53 19 Removing and installing the rear PCCB brake disc - as of MY 2005......................................1326
Tools..................................................................................................................................................1326
Preliminary work..............................................................................................................................1326
General warning notes......................................................................................................................1326
Removing rear brake disc.................................................................................................................1327
Installing rear brake disc...................................................................................................................1328
Subsequent work...............................................................................................................................1330
Bedding in the brake pads...........................................................................................................1330
46 54 02 Checking rear PCCB brake discs (wear assessment) - as of MY 2005....................................1332
Checking information on PCCB brake discs....................................................................................1332
Basic information........................................................................................................................1332
General information on replacing worn PCCB brake discs........................................................1333
Replacing brake discs (notes/decision-making aid)....................................................................1334
Cracks (stress-relief microstructure) in the brake disc friction surface.......................................1334
Note concerning bores (perforations) in the brake disc friction surface.....................................1335
Coating on the PCCB brake discs (potential causes)..................................................................1336
Note on bedding in the new brake pads......................................................................................1336
Checking PCCB brake discs (wear assessment)...............................................................................1337
Visual inspection of the surfaces of the brake disc friction surfaces (indication of wear)..........1337
Evaluating surface roughness (Sr) (max. 80 micrometre permitted)..........................................1338
Checking brake discs for minimum thickness.............................................................................1342
Checking brake discs for edge damage.......................................................................................1342
46 83 16 Adjusting the parking brake shoes - as of MY 2005..................................................................1346
Adjusting the parking brake shoes.....................................................................................................1346
47 01 07 Bleeding brake system - as of MY 2005......................................................................................1349
Notes.................................................................................................................................................1349
Bleeding the brake system................................................................................................................1349
Procedure for bleeding................................................................................................................1349
1. Step: Bleeding (primary circuit)..............................................................................................1349
2nd Step: Bleeding (secondary circuit).......................................................................................1351
47 08 01 Check brake fluid level - as of MY 2005.....................................................................................1354
Check brake fluid level.....................................................................................................................1354
Checking brake fluid level..........................................................................................................1354
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47 08 55 Replacing brake fluid - as of MY 2005........................................................................................1357
Replacing brake fluid........................................................................................................................1357
Changing brake fluid...................................................................................................................1357
48 02 01 Checking the fluid level for the power-assisted steering - as of MY 2005...............................1361
Checking the fluid level for the power-assisted steering..................................................................1361
Notes on power-steering fluid.....................................................................................................1361
Checking fluid level for power-assisted steering........................................................................1361
Checking the steering system for leaks (visual check)................................................................1362
Bleeding the steering system.......................................................................................................1362
48 10 19 Removing and installing steering wheel - as of MY 2005..........................................................1365
Preliminary work..............................................................................................................................1365.....................................................................................................................................................1365
Warning notes for removing and installing steering wheel.........................................................1365
Removal............................................................................................................................................1365
Installation........................................................................................................................................1366
48 15 19 Removing and installing steering column - as of MY 2005.......................................................1369
Preliminary work..............................................................................................................................1369
Preliminary work.........................................................................................................................1369
Removing the steering column.........................................................................................................1370
Installing the steering column...........................................................................................................1372
Subsequent work...............................................................................................................................1375
Subsequent work.........................................................................................................................1375
48 90 19 Removing and installing power-steering gear - as of MY 2005................................................1378
Tools..................................................................................................................................................1378
Preliminary work..............................................................................................................................1378
Preliminary work.........................................................................................................................1378
General warning notes......................................................................................................................1379
General warning notes.................................................................................................................1379
Removal............................................................................................................................................1379
Removing....................................................................................................................................1379
Installation........................................................................................................................................1382
Installing......................................................................................................................................1382
Subsequent work...............................................................................................................................1383
Subsequent work.........................................................................................................................1383
50 10 55 Replacing closing panel - as of MY 2005....................................................................................1386
Tools..................................................................................................................................................1386
General warning notes......................................................................................................................1387
Safety instructions for body repairs.............................................................................................1387
Tools and materials...........................................................................................................................1387
Tools and materials.....................................................................................................................1387
Preliminary work for body repairs with alignment bench................................................................1388
Preliminary work for body repairs with alignment bench...........................................................1388
Preliminary work for body repairs....................................................................................................1388
Preliminary work for body repairs..............................................................................................1388
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Diagnostic system: reading out fault memory and activating systems
Table of Contents
50 10 55 Replacing closing panel - as of MY 2005
Removing closing panel....................................................................................................................1389
Removing end plate.....................................................................................................................1389
Preparing connection areas of body for installing end plate.......................................................1391
Fitting front closing panel and preparing for installation.................................................................1392
Safety instructions for sharp-edged body and unit parts.............................................................1392
Fitting front closing panel and preparing for installation............................................................1392
Installing front closing panel............................................................................................................1394
Danger of injury when welding...................................................................................................1394
Safety instructions for flying sparks during grinding and welding work....................................1394
Installing front closing panel.......................................................................................................1395
Reworking.........................................................................................................................................1396
Subsequent work for body repairs...............................................................................................1396
50 14 55 Replacing front panel - as of MY 2005........................................................................................1399
Tools..................................................................................................................................................1399
General warning notes......................................................................................................................1400
Safety instructions for body repairs.............................................................................................1400
Tools and materials...........................................................................................................................1400
Tools and materials.....................................................................................................................1400
Preliminary work for body repairs with alignment bench................................................................1401
Preliminary work for body repairs with alignment bench...........................................................1401
Preliminary work for body repairs..............................................................................................1401
Removing front panel.......................................................................................................................1402
Removing front panel..................................................................................................................1402
Preparing connection areas of the body for installing the front panel..............................................1404
Safety instructions for flying sparks during grinding and welding work....................................1404
Preparing connection areas of the body for installing the front panel.........................................1404
Preparing front panel for installation................................................................................................1406
Safety instructions for sharp-edged body and unit parts.............................................................1406
Preparing front panel for installation...........................................................................................1406
Installing front panel.........................................................................................................................1408
Danger of injury when welding...................................................................................................1408
Installing front panel...................................................................................................................1409
Subsequent work...............................................................................................................................1411
Subsequent work for body repairs...............................................................................................1411
50 20 55 Replacing front floor panel - as of MY 2005..............................................................................1414
Tools..................................................................................................................................................1414
General warning notes......................................................................................................................1415
Safety instructions for body repairs.............................................................................................1415
Tools and materials...........................................................................................................................1415
Tools and materials.....................................................................................................................1415
Preliminary work for body repairs....................................................................................................1416
Preliminary work for body repairs with alignment bench...........................................................1416
Preliminary work for body repairs..............................................................................................1416
Removing floor front section............................................................................................................1417
Removing floor front section......................................................................................................1417
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50 20 55 Replacing front floor panel - as of MY 2005
Preparing connection areas of the body for installing front floor panel...........................................1419
Safety instructions for flying sparks during grinding and welding work....................................1419
Preparing connection areas of body for installing floor front section.........................................1419
Safety instructions for sharp-edged body and unit parts.............................................................1420
Adjusting floor front section and preparing for installation........................................................1420
Installing front floor panel................................................................................................................1421
Danger of injury when welding...................................................................................................1421
Installing floor front section........................................................................................................1422
Subsequent work...............................................................................................................................1423
Subsequent work for body repairs...............................................................................................1423
50 55 19 Removing and installing wing - as of MY 2005..........................................................................1426
Preliminary work..............................................................................................................................1426
Preliminary work.........................................................................................................................1426
Removing the wing...........................................................................................................................1427
Removing fuel tank cap...............................................................................................................1427
Releasing tank filler neck............................................................................................................1428
Releasing bottom of wing............................................................................................................1428
Releasing top of wing..................................................................................................................1429
Removing retaining strip.............................................................................................................1430
Removing protective film............................................................................................................1431
Releasing wing from A-pillar......................................................................................................1432
Removing masking panel............................................................................................................1433
Installing the wing............................................................................................................................1434
Installing masking panel..............................................................................................................1434
Fastening wing to A-pillar...........................................................................................................1435
Fastening top of wing..................................................................................................................1436
Fastening bottom of wing............................................................................................................1437
Sticking in the protective film.....................................................................................................1438
Installing retaining strip...............................................................................................................1439
Fastening tank filler neck............................................................................................................1440
Installing fuel tank cap................................................................................................................1441
Subsequent work...............................................................................................................................1442
Subsequent work.........................................................................................................................1442
50 56 19 Removing and installing front wheel housing liner. - as of MY 2005......................................1446
Preliminary work..............................................................................................................................1446
Preliminary work.........................................................................................................................1446
Removing front wheel housing liner.................................................................................................1446
Removing front wheel housing liner - rear section.....................................................................1446
Remove front wheel housing liner - front section.......................................................................1447
Installing front wheel housing liner..................................................................................................1448
Install front wheel housing liner - front section..........................................................................1448
Installing front wheel housing liner - rear section.......................................................................1449
Subsequent work...............................................................................................................................1450
Reworking...................................................................................................................................1450
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Table of Contents
50 56 19 Removing and installing front wheel housing liner. - as of MY 2005......................................1453
Preliminary work..............................................................................................................................1453
Preliminary work.........................................................................................................................1453
Removing front wheel housing liner.................................................................................................1453
Remove front wheel housing liner - front section.......................................................................1453
Installing front wheel housing liner..................................................................................................1454
Install front wheel housing liner - front section..........................................................................1454
Installing front wheel housing liner - rear section.......................................................................1455
Subsequent work...............................................................................................................................1456
Reworking...................................................................................................................................1456
50 56 19 Removing and installing front wheel housing liner. - as of MY 2005......................................1459
Preliminary work..............................................................................................................................1459
Preliminary work.........................................................................................................................1459
Removing front wheel housing liner.................................................................................................1459
Removing front wheel housing liner - rear section.....................................................................1459
Remove front wheel housing liner - front section.......................................................................1460
Installing front wheel housing liner..................................................................................................1461
Install front wheel housing liner - front section..........................................................................1461
Installing front wheel housing liner - rear section.......................................................................1462
Subsequent work...............................................................................................................................1463
Reworking...................................................................................................................................1463
50 74 55 Replacing front wheel housing - as of MY 2005.........................................................................1466
Tools..................................................................................................................................................1466
General warning notes......................................................................................................................1467
Safety instructions for body repairs.............................................................................................1467
Tools and materials...........................................................................................................................1467
Tools and materials.....................................................................................................................1467
Preliminary work for body repairs with alignment bench................................................................1468
Preliminary work for body repairs with alignment bench...........................................................1468
Removing front wheel housing.........................................................................................................1468
Removing reinforcement for front wheel housing......................................................................1468
Removing front wheel housing...................................................................................................1469
Preparing connection areas of body for installation of front wheel housing....................................1472
Safety instructions for flying sparks during grinding and welding work....................................1472
Preparing connection areas of body for installing front wheel housing......................................1472
Fitting front wheel housing and preparing for installation...............................................................1473
Safety instructions for sharp-edged body and unit parts.............................................................1473
Fitting front wheel housing and preparing for installation..........................................................1474
Preparing reinforcement for front wheel housing for installation...............................................1475
Installing front wheel housing..........................................................................................................1475
Danger of injury when welding...................................................................................................1475
Installing front wheel housing.....................................................................................................1476
Installing reinforcement for front wheel housing........................................................................1479
Subsequent work...............................................................................................................................1479
Subsequent work for body repairs...............................................................................................1480
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Diagnostic system: reading out fault memory and activating systems
Table of Contents
50 77 55 Replacing front outer side member - as of MY 2005.................................................................1482
Tools..................................................................................................................................................1482
Removing front outer side member..................................................................................................1482
Removing outer front side member.............................................................................................1482
Preparing connection areas of body for installing front outer side member.....................................1485
Preparing connection areas of body for installing outer front side member...............................1485
Fitting front outer side member and preparing for installation.........................................................1486
Fitting outer front side member and preparing for installation...................................................1486
Installing front outer side member....................................................................................................1486
Installing outer front side member..............................................................................................1487
50 79 55 Replacing inner front side member - as of MY 2005.................................................................1492
Tools..................................................................................................................................................1492
General warning notes......................................................................................................................1493
Safety instructions for body repairs.............................................................................................1493
Tools and materials.....................................................................................................................1493
Preliminary work for body repairs with alignment bench................................................................1494
Preliminary work for body repairs with alignment bench...........................................................1494
Removing inner front side member..................................................................................................1494
Removing inner front side member.............................................................................................1494
Preparing connection areas of body for installation of inner front side member..............................1497
Safety instructions for flying sparks during grinding and welding work....................................1497
Preparing connection areas of body for installing inner front side member...............................1497
Fitting inner front side member and preparing for installation.........................................................1498
Safety instructions for sharp-edged body and unit parts.............................................................1498
Fitting inner front side member and preparing for installation...................................................1498
Installing inner front side member....................................................................................................1499
Danger of injury when welding...................................................................................................1499
Installing inner front side member..............................................................................................1499
Subsequent work...............................................................................................................................1501
Subsequent work for body repairs...............................................................................................1501
50 79 55 Replacing front side member (section) - as of MY 2005............................................................1504
Tools..................................................................................................................................................1504
General warning notes......................................................................................................................1505
Safety instructions for body repairs.............................................................................................1505
Tools and materials.....................................................................................................................1505
Preliminary work for body repairs with alignment bench...........................................................1505
Preliminary work for body repairs..............................................................................................1506
Possible separation points...........................................................................................................1506
Removing front side member (section).......................................................................................1507
Preparing connection areas of body for installing front side members............................................1509
Safety instructions for flying sparks during grinding and welding work....................................1509
Preparing connection areas of body for installing front side members.......................................1510
Fitting front side member and preparing for installation..................................................................1510
Safety instructions for sharp-edged body and unit parts.............................................................1510
Fitting front side members and preparing for installation...........................................................1511
Danger of injury when welding...................................................................................................1513
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50 79 55 Replacing front side member (section) - as of MY 2005
Safety instructions for flying sparks during grinding and welding work....................................1513
Installing front side members......................................................................................................1514
Subsequent work...............................................................................................................................1515
Subsequent work for body repairs...............................................................................................1515
50 87 19 Removing and installing cowl panel cover - as of MY 2005......................................................1518
Preliminary work..............................................................................................................................1518
Preliminary work.........................................................................................................................1518
Removing cowl panel cover..............................................................................................................1518
Removing lateral cap...................................................................................................................1518
Removing upper cowl panel cover..............................................................................................1519
Disconnecting plug connection of spray nozzle for windscreen washer system........................1520
Disconnecting water line for windscreen washer system............................................................1521
Disconnecting plug connection for GPS antenna........................................................................1522
Disconnecting plug connection for radio antenna.......................................................................1523
Removing lower cowl panel cover..............................................................................................1525
Installing cowl panel cover...............................................................................................................1526
Installing cowl panel cover..........................................................................................................1526
Locking plug connection for radio antenna.................................................................................1527
Locking plug connection for GPS antenna..................................................................................1528
Locking water line for windscreen washer system.....................................................................1528
Locking plug connection of spray nozzle for windscreen washer system..................................1529
Fastening upper cowl panel cover...............................................................................................1530
Installing lateral cover cap..........................................................................................................1531
Subsequent work...............................................................................................................................1532
Subsequent work.........................................................................................................................1532
51 01 41 Repairing threaded bushing for belt connection - as of MY 2005............................................1535
Tools..................................................................................................................................................1535
General warning notes......................................................................................................................1535
Safety instructions for body repairs.............................................................................................1535
Tools and materials...........................................................................................................................1535
Tools and materials.....................................................................................................................1535
Repairing threaded bushing for belt connection...............................................................................1536
Removing thread for belt fastening.............................................................................................1536
Preparing connection areas of the body for installation of the threaded bushing.............................1537
Safety instructions for flying sparks during grinding and welding work....................................1537
Preparing connection areas of the body for installation of the threaded bushing.......................1537
Fitting in threaded bushing and preparing for installation................................................................1538
Safety instructions for sharp-edged body and unit parts.............................................................1538
Fitting in threaded bushing and preparing for installation..........................................................1538
Installing thread for belt fastening....................................................................................................1540
Danger of injury when welding...................................................................................................1540
Safety instructions for flying sparks during grinding and welding work....................................1540
Installing thread for belt fastening...............................................................................................1541
Subsequent work...............................................................................................................................1541
Subsequent work after repair of threaded bushing for belt fastening..........................................1541
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51 03 55 Replacing roof - as of MY 2004...................................................................................................1544
Tools..................................................................................................................................................1544
General warning notes......................................................................................................................1545
Safety instructions for body repairs.............................................................................................1545
Tools and materials...........................................................................................................................1545
Tools and materials.....................................................................................................................1545
Preliminary work for body repairs..............................................................................................1545
Preliminary work for body repairs with alignment bench...........................................................1546
Removing roof..................................................................................................................................1547
Removing roof.............................................................................................................................1547
Preparing connection areas of the body for installation of the roof..................................................1548
Safety instructions for flying sparks during grinding and welding work....................................1548
Preparing connection areas of the body for installation of the roof............................................1549
Fitting roof and preparing for installation.........................................................................................1549
Safety instructions for sharp-edged body and unit parts.............................................................1549
Fitting roof and preparing for installation...................................................................................1549
Installing roof....................................................................................................................................1550
Installing roof..............................................................................................................................1550
Affixing the roof sound absorber................................................................................................1551
Subsequent work...............................................................................................................................1552
Subsequent work for body repairs...............................................................................................1552
51 05 55 Replacing roof pillar (pipe) - as of MY 2005..............................................................................1554
Tools..................................................................................................................................................1554
General warning notes......................................................................................................................1555
Safety instructions for body repairs.............................................................................................1555
Tools and materials...........................................................................................................................1555
Tools and materials.....................................................................................................................1555
Preliminary work for body repairs with alignment bench................................................................1556
Preliminary work for body repairs with alignment bench...........................................................1556
Removing roof pillar (pipe) and roof frame reinforcement..............................................................1557
Removing roof pillar (pipe).........................................................................................................1557
Removing roof frame reinforcement...........................................................................................1558
Preparing connection areas of the body for installing the roof pillar (pipe) and roof frame
reinforcement....................................................................................................................................1559
Safety instructions for flying sparks during grinding and welding work....................................1559
Preparing connection areas of body for installing roof pillar (pipe)...........................................1559
Preparing connection areas of body for installing roof frame reinforcement.............................1560
Fitting roof pillar (pipe) and roof frame reinforcement and preparing for installation....................1560
Safety instructions for sharp-edged body and unit parts.............................................................1561
Fitting roof pillar (pipe) and preparing for installation...............................................................1561
Fitting roof frame reinforcement and preparing for installation.................................................1561
Installing roof frame reinforcement and roof pillar (pipe)................................................................1562
Danger of injury when welding...................................................................................................1562
Installing roof frame reinforcement............................................................................................1563
Installing roof pillar (pipe)..........................................................................................................1564
Subsequent work...............................................................................................................................1564
Subsequent work for body repairs...............................................................................................1565
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51 09 55 Replacing rear cross member (side impact reinforcement) - as of MY 2005..........................1567
Tools..................................................................................................................................................1567
General warning notes......................................................................................................................1568
Safety instructions for body repairs.............................................................................................1568
Tools and materials...........................................................................................................................1568
Tools and materials.....................................................................................................................1568
Preliminary work for body repairs with alignment bench................................................................1569
Preliminary work for body repairs with alignment bench...........................................................1569
Removing rear cross member (side impact reinforcement)..............................................................1569
Removing rear cross member......................................................................................................1569
Removing reinforcement plate for rear cross member................................................................1571
Preparing connection areas of the body for installing the rear cross member (side impact
reinforcement)...................................................................................................................................1572
Safety instructions for flying sparks during grinding and welding work....................................1572
Preparing connection areas of body for installing the rear cross member..................................1572
Preparing connection areas of body for installing reinforcement plate for rear cross
member................................................................................................................................1573
Fitting rear cross member (side impact reinforcement) and preparing for installation....................1574
Safety instructions for sharp-edged body and unit parts.............................................................1574
Fitting rear cross member and preparing for installation............................................................1574
Fitting reinforcement plate for rear cross member and preparing for installation......................1575
Installing rear cross member (side impact reinforcement)...............................................................1575
Danger of injury when welding...................................................................................................1575
Installing reinforcement plate for rear cross member.................................................................1576
Installing rear cross member.......................................................................................................1577
Subsequent work...............................................................................................................................1578
Subsequent work for body repairs...............................................................................................1578
51 11 55 Replacing windscreen frame - as of MY 2005............................................................................1581
Tools..................................................................................................................................................1581
General warning notes......................................................................................................................1582
Safety instructions for body repairs.............................................................................................1582
Tools and materials...........................................................................................................................1582
Tools and materials.....................................................................................................................1582
Preliminary work for body repairs with alignment bench................................................................1583
Preliminary work for body repairs with alignment bench...........................................................1583
Removing windscreen frame............................................................................................................1583
Removing windscreen frame.......................................................................................................1583
Preparing connection areas of the body for installing the windscreen frame...................................1586
Safety instructions for flying sparks during grinding and welding work....................................1586
Preparing connection areas of body for installing the windscreen frame...................................1586
Fitting in windscreen frame and preparing for installation...............................................................1588
Safety instructions for sharp-edged body and unit parts.............................................................1588
Fitting in windscreen frame and preparing for installation.........................................................1588
Installing windscreen frame..............................................................................................................1590
Danger of injury when welding...................................................................................................1590
Installing windscreen frame........................................................................................................1591
Subsequent work...............................................................................................................................1593
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Diagnostic system: reading out fault memory and activating systems
Table of Contents
51 11 55 Replacing windscreen frame - as of MY 2005
Subsequent work for body repairs...............................................................................................1593
51 21 19 Removing and installing rear centre panel - as of MY 2005.....................................................1596
Preliminary work..............................................................................................................................1596
Preliminary work.........................................................................................................................1596
Removing rear centre panel..............................................................................................................1596
Loosening inner rear centre panel...............................................................................................1596
Loosening outer rear centre panel...............................................................................................1597
Disconnecting electric plug connection for auxiliary stop light..................................................1598
Installing rear centre panel................................................................................................................1599
Locking electric plug connection for auxiliary stop light...........................................................1599
Installing rear centre panel..........................................................................................................1600
Fastening inner rear centre panel.................................................................................................1601
Subsequent work...............................................................................................................................1603
Subsequent work.........................................................................................................................1603
51 21 37 Disassembling and assembling rear centre panel - as of MY 2005...........................................1605
Preliminary work..............................................................................................................................1605
Preliminary work.........................................................................................................................1605
Disassembling rear centre panel.......................................................................................................1605
Removing seal for rear centre panel............................................................................................1605
Assembling rear centre panel............................................................................................................1606
Installing seal for rear centre panel.............................................................................................1606
Subsequent work...............................................................................................................................1606
Subsequent work.........................................................................................................................1606
51 21 55 Replacing rear centre panel reinforcement - as of MY 2005....................................................1609
Tools..................................................................................................................................................1609
General warning notes......................................................................................................................1610
Safety instructions for body repairs.............................................................................................1610
Tools and materials...........................................................................................................................1610
Tools and materials.....................................................................................................................1610
Preliminary work for body repairs....................................................................................................1611
Preliminary work for body repairs..............................................................................................1611
Removing rear centre panel reinforcement.......................................................................................1611
Removing rear centre panel reinforcement.................................................................................1612
Preparing connection areas of the body for installing rear centre panel reinforcement...................1613
Safety instructions for flying sparks during grinding and welding work....................................1613
Preparing connection areas of the body for installing rear centre panel reinforcement..............1614
Preparing rear centre panel reinforcement for installation...............................................................1615
Safety instructions for sharp-edged body and unit parts.............................................................1615
Preparing rear centre panel reinforcement for installation..........................................................1615
Installing rear centre panel reinforcement........................................................................................1616
Danger of injury when welding...................................................................................................1616
Installing rear centre panel reinforcement...................................................................................1616
Subsequent work...............................................................................................................................1618
Subsequent work for body repairs...............................................................................................1618
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Diagnostic system: reading out fault memory and activating systems
Table of Contents
51 48 55 Replacing centre side member - as of MY 2005.........................................................................1620
General warning notes......................................................................................................................1620
Safety instructions for body repairs.............................................................................................1620
Preliminary work for body repairs..............................................................................................1620
Preliminary work for body repairs with alignment bench...........................................................1621
Removing centre side member..........................................................................................................1621
Removing centre side member....................................................................................................1621
Length offset for part replacement..............................................................................................1622
Removing centre side member....................................................................................................1622
Preparing connection areas of body for installing centre side member............................................1625
Safety instructions for flying sparks during grinding and welding work....................................1625
Preparing connection areas of body for installing centre side member......................................1625
Fitting in centre side member and preparing for installation............................................................1626
Safety instructions for sharp-edged body and unit parts.............................................................1626
Fitting in centre side member and preparing for installation......................................................1627
Installing centre side member...........................................................................................................1628
Danger of injury when welding...................................................................................................1628
Installing centre side member......................................................................................................1629
Safety instructions for flying sparks during grinding and welding work....................................1630
Subsequent work...............................................................................................................................1631
Subsequent work for body repairs...............................................................................................1631
51 49 55 Replacing lower side member reinforcement (support tube) - as of MY 2005.......................1634
Tools..................................................................................................................................................1634
General warning notes......................................................................................................................1635
Safety instructions for body repairs.............................................................................................1635
Tools and materials...........................................................................................................................1635
Tools and materials.....................................................................................................................1635
Preliminary work for body repairs with alignment bench................................................................1636
Preliminary work for body repairs with alignment bench...........................................................1636
Removing lower side member reinforcement...................................................................................1636
Removing lower side member reinforcement.............................................................................1637
Preparing connection areas of the body for installing lower side member reinforcement...............1639
Safety instructions for flying sparks during grinding and welding work....................................1639
Preparing connection area of body for installing lower side member reinforcement.................1639
Fitting lower side member reinforcement and preparing for installation.........................................1640
Safety instructions for sharp-edged body and unit parts.............................................................1640
Fitting in retaining bracket and preparing for installation...........................................................1641
Fitting in support tube and preparing for installation..................................................................1642
Installing lower side member reinforcement....................................................................................1642
Danger of injury when welding...................................................................................................1643
Installing lower side member reinforcement...............................................................................1643
Subsequent work...............................................................................................................................1647
Subsequent work for body repairs...............................................................................................1647
51 63 19 Removing and installing deformation element - as of MY 2005...............................................1650
Preliminary work..............................................................................................................................1650
Preliminary work.........................................................................................................................1650
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Diagnostic system: reading out fault memory and activating systems
Table of Contents
51 63 19 Removing and installing deformation element - as of MY 2005
Removing deformation element........................................................................................................1650
Removing deformation element..................................................................................................1650
Installing deformation element.........................................................................................................1651
Installing deformation element....................................................................................................1651
Subsequent work...............................................................................................................................1652
Reworking...................................................................................................................................1652
51 92 19 Removing and installing cover for front underbody - as of MY 2005.....................................1654
Preliminary work..............................................................................................................................1654
Preliminary work.........................................................................................................................1654
Removing cover for front underbody...............................................................................................1654
Removing cover for front underbody..........................................................................................1654
Installing cover for front underbody.................................................................................................1655
Installing cover for front underbody...........................................................................................1655
Subsequent work...............................................................................................................................1656
Reworking...................................................................................................................................1656
51 93 19 Removing and installing cover for centre underbody - as of MY 2005...................................1659
Preliminary work..............................................................................................................................1659
Preliminary work.........................................................................................................................1659
Removing cover for centre underbody.............................................................................................1659
Removing cover for side underbody...........................................................................................1659
Removing cover for centre underbody........................................................................................1660
Installing cover for centre underbody...............................................................................................1661
Installing cover for centre underbody.........................................................................................1661
Installing cover for side underbody.............................................................................................1662
Subsequent work...............................................................................................................................1663
Reworking...................................................................................................................................1663
51 94 19 Removing and installing cover for rear underbody - as of MY 2005.......................................1666
Preliminary work..............................................................................................................................1666
Preliminary work.........................................................................................................................1666
Removing cover for rear underbody.................................................................................................1666
Removing cover for rear underbody- rear section.......................................................................1666
Removing cover for rear underbody - front section....................................................................1667
Installing cover for rear underbody...................................................................................................1668
Installing cover for rear underbody- front section.......................................................................1668
Installing cover for rear underbody- rear section........................................................................1669
Subsequent work...............................................................................................................................1670
Reworking...................................................................................................................................1670
53 48 55 Replacing rear side member (section) - as of MY 2005.............................................................1673
Tools..................................................................................................................................................1673
General warning notes......................................................................................................................1674
Safety instructions for body repairs.............................................................................................1674
Tools and materials...........................................................................................................................1674
Tools and materials.....................................................................................................................1674
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Diagnostic system: reading out fault memory and activating systems
Table of Contents
53 48 55 Replacing rear side member (section) - as of MY 2005
Preliminary work for body repairs with alignment bench................................................................1675
Preliminary work for body repairs with alignment bench...........................................................1675
Removing side member....................................................................................................................1675
Removing side member...............................................................................................................1675
Preparing connection area of body for installing rear side member.................................................1681
Safety instructions for flying sparks during grinding and welding work....................................1681
Preparing connection areas of body for installing rear side members........................................1682
Fitting rear side member and preparing for installation....................................................................1682
Adjusting rear side members and preparing for installation.......................................................1682
Installing rear side member...............................................................................................................1684
Danger of injury when welding...................................................................................................1684
Safety instructions for flying sparks during grinding and welding work....................................1685
Installing side member................................................................................................................1685
Subsequent work...............................................................................................................................1689
Subsequent work for body repairs...............................................................................................1689
53 55 55 Replacing side section - as of MY 2005.......................................................................................1692
Tools..................................................................................................................................................1692
General warning notes......................................................................................................................1693
Safety instructions for body repairs.............................................................................................1693
Tools and materials...........................................................................................................................1693
Tools and materials.....................................................................................................................1693
Preliminary work for body repairs..............................................................................................1694
Preliminary work for body repairs with alignment bench...........................................................1694
Removing side section......................................................................................................................1695
Removing side section.................................................................................................................1695
Preparing connection areas of the body for installation of the side section......................................1697
Safety instructions for flying sparks during grinding and welding work....................................1697
Preparing connection areas of the body for installation of the side section................................1698
Fitting side section and preparing for installation.............................................................................1698
Safety instructions for sharp-edged body and unit parts.............................................................1698
Fitting in side section and preparing for installation...................................................................1699
Installing side section........................................................................................................................1700
Installing side section..................................................................................................................1700
Subsequent work...............................................................................................................................1703
Subsequent work for body repairs...............................................................................................1703
53 55 55 Replacing side section - as of MY 2005.......................................................................................1706
Tools..................................................................................................................................................1706
General warning notes......................................................................................................................1707
Safety instructions for body repairs.............................................................................................1707
Tools and materials...........................................................................................................................1707
Tools and materials.....................................................................................................................1707
Preliminary work for body repairs..............................................................................................1708
Preliminary work for body repairs with alignment bench...........................................................1708
Removing side section......................................................................................................................1709
Removing side section.................................................................................................................1709
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Diagnostic system: reading out fault memory and activating systems
Table of Contents
53 55 55 Replacing side section - as of MY 2005
Preparing connection areas of the body for installing the side section.............................................1711
Safety instructions for flying sparks during grinding and welding work....................................1711
Preparing connection areas of the body for installing the side section.......................................1712
Safety instructions for sharp-edged body and unit parts.............................................................1712
Fitting side section and preparing for installation.......................................................................1712
Installing side section........................................................................................................................1714
Installing side section..................................................................................................................1714
Subsequent work...............................................................................................................................1719
Subsequent work for body repairs...............................................................................................1719
53 55 55 Replacing side section - as of MY 2005.......................................................................................1722
General warning notes......................................................................................................................1722
Safety instructions for body repairs.............................................................................................1722
Tools and materials...........................................................................................................................1722
Preliminary work for body repairs..............................................................................................1722
Preliminary work for body repairs with alignment bench...........................................................1723
Removing side section......................................................................................................................1723
Removing side section.................................................................................................................1723
Preparing connection areas of the body for installing the side section.............................................1726
Safety instructions for flying sparks during grinding and welding work....................................1726
Preparing connection areas of the body for installing the side section.......................................1726
Safety instructions for sharp-edged body and unit parts.............................................................1727
Fitting side section and preparing for installation.......................................................................1727
Installing side section........................................................................................................................1728
Installing side section..................................................................................................................1728
53 68 55 Replacing rear wheel housing - as of MY 2005..........................................................................1736
Tools..................................................................................................................................................1736
General warning notes......................................................................................................................1737
Safety instructions for body repairs.............................................................................................1737
Tools and materials...........................................................................................................................1737
Tools and materials.....................................................................................................................1737
Preliminary work for body repairs with alignment bench................................................................1738
Preliminary work for body repairs with alignment bench...........................................................1738
Removing rear wheel housing..........................................................................................................1738
Removing outer rear wheel housing............................................................................................1738
Removing inner rear wheel housing............................................................................................1739
Preparing connection areas of the body for installing the rear wheel housing.................................1742
Safety instructions for flying sparks during grinding and welding work....................................1742
Preparing connection areas of the body for installing the inner rear wheel housing..................1742
Preparing connection areas of the body for installing the outer rear wheel housing..................1742
Preparing rear wheel housing for installation...................................................................................1743
Safety instructions for sharp-edged body and unit parts.............................................................1743
Preparing inner rear wheel housing for installation....................................................................1743
Preparing outer rear wheel housing for installation....................................................................1745
Installing rear wheel housing............................................................................................................1745
Danger of injury when welding...................................................................................................1745
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Diagnostic system: reading out fault memory and activating systems
Table of Contents
53 68 55 Replacing rear wheel housing - as of MY 2005
Installing inner rear wheel housing.............................................................................................1746
Installing outer rear wheel housing.............................................................................................1748
Subsequent work...............................................................................................................................1748
Subsequent work for body repairs...............................................................................................1748
53 69 19 Removing and installing rear wheel housing liner - as of MY 2005.........................................1751
Preliminary work..............................................................................................................................1751
Preliminary work.........................................................................................................................1751
Removing rear wheel housing liner..................................................................................................1751
Removing rear wheel housing liner.............................................................................................1751
Installing rear wheel housing liner....................................................................................................1752
Installing rear wheel housing liner..............................................................................................1752
Subsequent work...............................................................................................................................1753
Reworking...................................................................................................................................1753
53 69 19 Removing and installing rear wheel housing liner - as of MY 2005.........................................1756
Preliminary work..............................................................................................................................1756
Preliminary work.........................................................................................................................1756
Removing rear wheel housing liner..................................................................................................1756
Removing rear wheel housing liners...........................................................................................1756
Installing rear wheel housing liner....................................................................................................1757
Installing rear wheel housing liner..............................................................................................1757
Subsequent work...............................................................................................................................1758
Reworking...................................................................................................................................1759
55 10 19 Removing and installing release for front lid - as of MY 2005.................................................1761
Preliminary work..............................................................................................................................1761
Preliminary work.........................................................................................................................1761
Removing release for front lid..........................................................................................................1761
Removing release for front lid.....................................................................................................1761
Installing release for front lid............................................................................................................1762
Installing release for front lid......................................................................................................1762
Subsequent work...............................................................................................................................1763
Subsequent work.........................................................................................................................1763
55 13 19 Removing and installing servo motor for front lid release - as of MY 2005............................1766
Preliminary work..............................................................................................................................1766
Preliminary work for servo motor for hood release....................................................................1766
Removing servo motor for front lid release......................................................................................1766
Removing the servo motor for front lid release..........................................................................1766
Installing servo motor for front lid release.......................................................................................1768
Installing the servo motor for front lid release............................................................................1768
Subsequent work...............................................................................................................................1769
Subsequent work for servo motor for hood release.....................................................................1769
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Diagnostic system: reading out fault memory and activating systems
Table of Contents
55 17 19 Removing and installing front lower part of lid lock - as of MY 2005.....................................1772
Preliminary work..............................................................................................................................1772
Preliminary work.........................................................................................................................1772
Removing front lower part of lid lock..............................................................................................1772
Removing bowden cable for emergency release.........................................................................1772
Pressing out bowden cable for emergency release......................................................................1773
Disconnect electrical plug connection.........................................................................................1774
Removing lower part of lid lock..................................................................................................1774
Removing lid-release cable.........................................................................................................1775
Installing front lower part of lid lock................................................................................................1776
Inserting lid-release cable............................................................................................................1776
Installing lower part of lid lock...................................................................................................1777
Locking electrical plug connection.............................................................................................1778
Installing bowden cable for emergency release..........................................................................1779
Inserting bowden cable for emergency release...........................................................................1780
Subsequent work...............................................................................................................................1781
Reworking...................................................................................................................................1781
55 18 19 Removing and installing front upper part of lid lock - as of MY 2005....................................1784
Removing front upper part of lid lock..............................................................................................1784
Removing upper part of front lid lock.........................................................................................1784
Installing front upper part of lid lock................................................................................................1785
Installing upper part of front lid lock..........................................................................................1785
Checking lid functions.................................................................................................................1786
55 22 15 Adjusting front lid - as of MY 2005.............................................................................................1789
Tools..................................................................................................................................................1789
Adjusting front lid.............................................................................................................................1789
Adjusting lid in X and Y direction..............................................................................................1789
Adjusting lid in Z direction.........................................................................................................1790
Adjusting front lid.......................................................................................................................1791
55 22 19 Removing and installing front cover - as of MY 2005...............................................................1794
Removing front lid............................................................................................................................1794
Removing front lid......................................................................................................................1794
Installing front lid.............................................................................................................................1795
Installing front lid........................................................................................................................1795
Reworking.........................................................................................................................................1796
Reworking...................................................................................................................................1796
55 22 37 Disassembling and assembling front lid - as of MY 2005..........................................................1798
Preliminary work..............................................................................................................................1798
Preliminary work.........................................................................................................................1798
Disassembling front lid.....................................................................................................................1798
Removing rubber pad..................................................................................................................1798
Removing self-adhesive label.....................................................................................................1799
Assembling front lid.........................................................................................................................1800
Installing rubber pad....................................................................................................................1800
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Diagnostic system: reading out fault memory and activating systems
Table of Contents
55 22 37 Disassembling and assembling front lid - as of MY 2005
Installing self-adhesive label.......................................................................................................1801
Subsequent work...............................................................................................................................1802
Reworking...................................................................................................................................1802
55 25 19 Removing and installing front lid hinge - as of MY 2005..........................................................1805
Preliminary work..............................................................................................................................1805
Preliminary work.........................................................................................................................1805
Removing front lid hinge..................................................................................................................1805
Removing front lid hinge............................................................................................................1805
Install front lid hinge.........................................................................................................................1806
Installing front lid hinge..............................................................................................................1806
Reworking.........................................................................................................................................1807
Reworking...................................................................................................................................1807
55 31 19 Removing and installing front pneumatic spring - as of MY 2005...........................................1810
Removing front pneumatic spring....................................................................................................1810
Removing front pneumatic spring at lid end...............................................................................1810
Removing front pneumatic spring on body.................................................................................1811
Installing front pneumatic spring......................................................................................................1812
Installing front pneumatic spring on the body.............................................................................1812
Installing front pneumatic spring at lid end.................................................................................1813
Function test on pneumatic spring...............................................................................................1814
55 33 19 Removing and installing front lid seal - as of MY 2005.............................................................1817
Removing front lid seal.....................................................................................................................1817
Removing front lid seal...............................................................................................................1817
Removing front lid seal...............................................................................................................1818
Installing front lid seal......................................................................................................................1818
Mounting front lid seal................................................................................................................1819
Installing front lid seal.................................................................................................................1819
55 37 19 Removing and installing filler flap - as of MY 2005..................................................................1823
Tools..................................................................................................................................................1823
Removing filler flap..........................................................................................................................1823
Removing filler flap....................................................................................................................1823
Removing plastic hinge...............................................................................................................1824
Installing filler flap...........................................................................................................................1825
Installing plastic hinge.................................................................................................................1825
Installing filler flap......................................................................................................................1826
55 38 19 Removing and installing switching element for filler flap - as of MY 2005.............................1830
Preliminary work..............................................................................................................................1830
Preliminary work.........................................................................................................................1830
Removing switching element for filler flap......................................................................................1830
Removing switching element for filler flap................................................................................1830
Installing switching element for filler flap........................................................................................1832
Installing switching element for filler flap..................................................................................1832
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Table of Contents
55 38 19 Removing and installing switching element for filler flap - as of MY 2005
Subsequent work...............................................................................................................................1833
Subsequent work.........................................................................................................................1833
55 57 19 Removing and installing release for rear lid - as of MY 2005..................................................1836
Preliminary work..............................................................................................................................1836
Preliminary work.........................................................................................................................1836
Removing release for rear lid............................................................................................................1836
Removing release for rear lid......................................................................................................1836
Installing release for rear lid.............................................................................................................1837
Installing release for rear lid........................................................................................................1837
Subsequent work...............................................................................................................................1838
Subsequent work.........................................................................................................................1838
55 61 19 Removing and installing servo motor for emergency release - as of MY 2005.......................1841
Preliminary work..............................................................................................................................1841
Preliminary work on servo motor for emergency release...........................................................1841
Removing servo motor for emergency release.................................................................................1841
Removing servo motor for emergency release............................................................................1841
Installing servo motor for emergency release...................................................................................1843
Installing servo motor for emergency release.............................................................................1843
Subsequent work...............................................................................................................................1844
Subsequent work on servo motor for emergency release............................................................1844
55 62 19 Removing and installing front emergency release - as of MY 2005.........................................1846
Removing front emergency release..................................................................................................1846
Removing front emergency release.............................................................................................1846
Installing front emergency release....................................................................................................1847
Installing support for release handle...........................................................................................1847
Installing front emergency release..............................................................................................1849
Checking inner release of luggage compartment (Trunk Entrapment).............................................1850
Checking inner release of luggage compartment (Trunk Entrapment).......................................1850
55 62 19 Removing and installing front emergency release - as of MY 2005.........................................1853
Removing front emergency release..................................................................................................1853
Removing front emergency release.............................................................................................1853
Removing front emergency release.............................................................................................1854
Installing front emergency release....................................................................................................1856
Installing front emergency release..............................................................................................1856
Installing support for release handle...........................................................................................1857
Installing front emergency release..............................................................................................1858
Checking inner release of luggage compartment (Trunk Entrapment).............................................1860
Checking inner release of luggage compartment (Trunk Entrapment).......................................1860
55 84 19 Removing and installing motor for rear lid release - as of MY 2005.......................................1863
Preliminary work..............................................................................................................................1863
Preliminary work.........................................................................................................................1863
Removing motor for rear lid release.................................................................................................1863
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Diagnostic system: reading out fault memory and activating systems
Table of Contents
55 84 19 Removing and installing motor for rear lid release - as of MY 2005
Removing rear lid release motor.................................................................................................1863
Installing motor for rear lid release...................................................................................................1864
Installing rear-lid release motor..................................................................................................1864
Subsequent work...............................................................................................................................1865
Subsequent work.........................................................................................................................1865
55 86 19 Removing and installing lower part of lid lock at rear - as of MY 2005..................................1868
Preliminary work..............................................................................................................................1868
Preliminary work.........................................................................................................................1868
Removing lower part of lid lock at rear............................................................................................1868
Disconnecting electrical plug connection....................................................................................1868
Removing lower part of lid lock at rear......................................................................................1869
Disconnecting the emergency release cable................................................................................1870
Installing lower part of lid lock at rear..............................................................................................1871
Installing the emergency release cable........................................................................................1871
Installing lower part of lid lock at rear........................................................................................1871
Locking electrical plug connection.............................................................................................1872
Subsequent work...............................................................................................................................1873
Subsequent work.........................................................................................................................1873
55 87 19 Removing and installing rear upper part of lid lock - as of MY 2005.....................................1876
Removing rear upper part of lid lock................................................................................................1876
Removing rear upper part of lid lock..........................................................................................1876
Installing rear upper part of lid lock.................................................................................................1877
Installing rear upper part of lid lock............................................................................................1877
Checking lid functions.................................................................................................................1878
55 90 15 Adjusting rear lid - as of MY 2005..............................................................................................1881
Tools..................................................................................................................................................1881
Adjusting rear lid..............................................................................................................................1881
Adjusting lid in X and Y direction..............................................................................................1881
Adjusting lid in Z direction.........................................................................................................1882
Adjusting rear lid.........................................................................................................................1883
Subsequent work...............................................................................................................................1884
Reworking...................................................................................................................................1884
55 90 19 Removing and installing rear lid - as of MY 2005.....................................................................1886
Removing rear lid.............................................................................................................................1886
Disconnecting wiring harness on rear lid....................................................................................1886
Removing rear lid........................................................................................................................1887
Installing rear lid...............................................................................................................................1888
Installing rear lid.........................................................................................................................1888
Locking wiring harness on rear lid..............................................................................................1889
55 90 37 Disassembling and assembling rear lid - as of MY 2005...........................................................1892
Preliminary work..............................................................................................................................1892
Preliminary work.........................................................................................................................1892
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Table of Contents
55 90 37 Disassembling and assembling rear lid - as of MY 2005
Disassembling rear lid.......................................................................................................................1892
Removing fan with fan housing..................................................................................................1892
Removing air guide.....................................................................................................................1893
Remove adjusting element..........................................................................................................1894
Remove rubber cover..................................................................................................................1895
Removing upper part of spoiler...................................................................................................1896
Removing the folding wall from the upper part of the spoiler....................................................1897
Removing the folding wall from the cover.................................................................................1898
Removing the lower part of the spoiler.......................................................................................1899
Removing hinge..........................................................................................................................1900
Removing the mount...................................................................................................................1901
Assembling rear lid...........................................................................................................................1902
Fitting mount...............................................................................................................................1902
Fitting hinge................................................................................................................................1903
Mounting the lower part of the spoiler........................................................................................1904
Mounting the folding wall on the lid...........................................................................................1905
Mounting the folding wall on the upper part of the spoiler.........................................................1906
Mounting upper part of spoiler....................................................................................................1907
Fitting rubber cover.....................................................................................................................1909
Installing adjusting element.........................................................................................................1909
Installing air guide.......................................................................................................................1910
Fitting fan with fan housing........................................................................................................1911
Reworking.........................................................................................................................................1912
Reworking...................................................................................................................................1912
55 91 19 Removing and installing rear lid hinge - as of MY 2005...........................................................1915
Preliminary work..............................................................................................................................1915
Preliminary work.........................................................................................................................1915
Removing rear lid hinge....................................................................................................................1915
Removing rear lid hinge..............................................................................................................1915
Installing rear lid hinge.....................................................................................................................1916
Installing rear lid hinge................................................................................................................1917
Subsequent work...............................................................................................................................1917
Reworking...................................................................................................................................1917
55 93 19 Removing and installing rear pneumatic spring - as of MY 2005............................................1920
Removing rear pneumatic spring......................................................................................................1920
Removing rear pneumatic spring at lid end.................................................................................1920
Removing rear pneumatic spring at the body..............................................................................1921
Installing rear pneumatic spring........................................................................................................1922
Installing rear pneumatic spring on the body..............................................................................1922
Installing rear pneumatic spring at lid end..................................................................................1923
Function test on pneumatic spring...............................................................................................1924
57 08 37 Disassembling and assembling key - as of MY 2005..................................................................1927
Disassembling key............................................................................................................................1927
Removing cover of hand-held transmitter...................................................................................1927
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Table of Contents
57 08 37 Disassembling and assembling key - as of MY 2005
Removing hand-held transmitter key..........................................................................................1927
Assembling key.................................................................................................................................1928
Installing hand-held transmitter key............................................................................................1928
Installing cover of hand-held transmitter....................................................................................1928
57 11 19 Removing and installing door handle - as of MY 2005..............................................................1931
Tools..................................................................................................................................................1931
Preliminary work..............................................................................................................................1931
Preliminary work.........................................................................................................................1931
Removing door handle......................................................................................................................1931
Unclipping electric wire for micro switches...............................................................................1931
Disconnect connection piece.......................................................................................................1932
Removing door handle and bottom part of door handle..............................................................1933
Additional assembly instructions......................................................................................................1935
Locking lock actuation................................................................................................................1935
Installing door handle.......................................................................................................................1937
Fitting door handle and bottom part of door handle....................................................................1937
Fit connection piece.....................................................................................................................1938
Clipping in the electric wire for micro switches.........................................................................1939
Subsequent work...............................................................................................................................1940
Subsequent work.........................................................................................................................1940
Function test following assembly work.......................................................................................1940
57 11 37 Disassembling and assembling door handle - as of MY 2005...................................................1944
Preliminary work..............................................................................................................................1944
Preliminary work.........................................................................................................................1944
Disassembling door handle...............................................................................................................1944
Disassembling door handle.........................................................................................................1944
Assembling door handle...................................................................................................................1945
Assembling door handle..............................................................................................................1945
Subsequent work...............................................................................................................................1945
Subsequent work.........................................................................................................................1946
57 17 19 Removing and installing door lock - as of MY 2005..................................................................1948
Tools..................................................................................................................................................1948
Preliminary work..............................................................................................................................1948
Preliminary work.........................................................................................................................1948
Removing door lock..........................................................................................................................1948
Disconnect connection piece.......................................................................................................1948
Removing door lock....................................................................................................................1949
Unclipping and disengaging the bowden cable...........................................................................1950
Additional assembly instructions......................................................................................................1951
Locking lock actuation................................................................................................................1951
Installing door lock...........................................................................................................................1953
Fitting the bowden cable.............................................................................................................1953
Installing door lock......................................................................................................................1954
Fit connection piece.....................................................................................................................1955
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57 17 19 Removing and installing door lock - as of MY 2005
Subsequent work...............................................................................................................................1956
Subsequent work.........................................................................................................................1957
Function test following assembly work.......................................................................................1957
57 26 19 Removing and installing striker pin - as of MY 2005................................................................1960
Removing striker pin........................................................................................................................1960
Removing striker pin...................................................................................................................1960
Installing striker pin..........................................................................................................................1961
Installing striker pin.....................................................................................................................1961
57 30 19 Removing and installing door unit carrier - as of MY 2005.....................................................1964
Preliminary work..............................................................................................................................1964
Preliminary work.........................................................................................................................1964
Removing door unit carrier...............................................................................................................1964
Covering door with adhesive tape...............................................................................................1964
Removing seal for mirror triangle...............................................................................................1965
Disconnecting electrical plug connection....................................................................................1966
Releasing door unit carrier..........................................................................................................1967
Disconnecting electrical plug connection on microswitch..........................................................1969
Disconnecting the door lock electrical plug connection.............................................................1970
Installing door unit carrier................................................................................................................1971
Locking electrical plug connection for door lock.......................................................................1971
Locking electrical plug connection for microswitch...................................................................1972
Fastening door unit carrier..........................................................................................................1972
Locking electrical plug connection.............................................................................................1974
Fitting seal for mirror triangle.....................................................................................................1975
Removing adhesive tape..............................................................................................................1976
Subsequent work...............................................................................................................................1976
Subsequent work.........................................................................................................................1976
57 30 37 Disassembling and assembling door unit carrier - as of MY 2005...........................................1979
Preliminary work..............................................................................................................................1979
Preliminary work.........................................................................................................................1979
Disassembling door unit carrier........................................................................................................1979
Disassembling door unit carrier..................................................................................................1979
Assembling door unit carrier............................................................................................................1980
Assembling door unit carrier.......................................................................................................1980
Subsequent work...............................................................................................................................1981
Subsequent work.........................................................................................................................1981
57 45 19 Removing and installing door handle - as of MY 2005..............................................................1984
Preliminary work..............................................................................................................................1984
Preliminary work.........................................................................................................................1984
Removing door handle......................................................................................................................1984
Removing door handle................................................................................................................1984
Installing door handle.......................................................................................................................1985
Installing door handle..................................................................................................................1985
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57 45 19 Removing and installing door handle - as of MY 2005
Subsequent work...............................................................................................................................1987
Subsequent work.........................................................................................................................1987
57 48 19 Removing and installing crash support - as of MY 2005..........................................................1989
Removing crash support...................................................................................................................1989
Removing crash support..............................................................................................................1989
Installing crash support.....................................................................................................................1990
Installing crash support...............................................................................................................1990
57 51 15 Adjusting front door - as of MY 2005.........................................................................................1993
Tools..................................................................................................................................................1993
Adjusting front door..........................................................................................................................1993
Setting the front door...................................................................................................................1993
Setting the rear door....................................................................................................................1994
57 51 19 Removing and installing door - as of MY 2005..........................................................................1997
General warning notes......................................................................................................................1997
General warning notes.................................................................................................................1997
Preliminary work..............................................................................................................................1997
Preliminary work.........................................................................................................................1997
Removing door.................................................................................................................................1997
Releasing hinge joint...................................................................................................................1997
Releasing door latch snib on body side.......................................................................................1998
Removing door............................................................................................................................1999
Installing door...................................................................................................................................2000
Installing door..............................................................................................................................2000
Fastening the hinge joint.............................................................................................................2001
Fastening door latch snib on body side.......................................................................................2002
Subsequent work...............................................................................................................................2003
Reworking...................................................................................................................................2003
57 51 37 Disassembling and assembling door - as of MY 2005................................................................2006
Tools..................................................................................................................................................2006
Preliminary work..............................................................................................................................2006
Preliminary work.........................................................................................................................2006
General warning notes......................................................................................................................2007
Safety instructions for door.........................................................................................................2007
Tools and materials...........................................................................................................................2008
Tools and materials.....................................................................................................................2008
Disassembling door...........................................................................................................................2008
Removing lid and rubber sleeve..................................................................................................2009
Removing retaining clips.............................................................................................................2009
Removing rubber pad..................................................................................................................2010
Assembling door...............................................................................................................................2011
Installing rubber buffer................................................................................................................2011
Installing retaining clips..............................................................................................................2012
Fitting lid and rubber sleeves......................................................................................................2013
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57 51 37 Disassembling and assembling door - as of MY 2005
Subsequent work...............................................................................................................................2014
Subsequent work.........................................................................................................................2014
57 53 55 Replacing door hinge (on body side) - as of MY 2005...............................................................2017
Tools..................................................................................................................................................2017
General warning notes......................................................................................................................2018
Safety instructions for body repairs.............................................................................................2018
Tools and materials...........................................................................................................................2018
Tools and materials.....................................................................................................................2018
Preliminary work for body repairs with alignment bench................................................................2019
Preliminary work for body repairs..............................................................................................2019
Removing door hinge (on body side)................................................................................................2019
Removing door hinge (on body side)..........................................................................................2020
Preparing connection areas of the body for installing the door hinge (on body side)......................2021
Safety instructions for flying sparks during grinding and welding work....................................2021
Preparing connection areas of the body for installing the door hinge (on body side).................2021
Preparing door hinge (on body side) for installation........................................................................2022
Safety instructions for sharp-edged body and unit parts.............................................................2022
Preparing door hinge (on body side) for installation...................................................................2022
Installing door hinge (on body side).................................................................................................2023
Danger of injury when welding...................................................................................................2023
Installing door hinge (on body side)............................................................................................2023
Subsequent work...............................................................................................................................2026
Subsequent work for body repairs...............................................................................................2027
57 59 19 Removing and installing door latch snib - as of MY 2005.........................................................2029
Preliminary work..............................................................................................................................2029
Preliminary work.........................................................................................................................2029
Removing door latch snib.................................................................................................................2029
Releasing door latch snib on body side.......................................................................................2029
Removing door latch snib............................................................................................................2030
Installing door latch snib...................................................................................................................2032
Installing door latch snib.............................................................................................................2032
Fastening door latch snib on body side.......................................................................................2033
Subsequent work...............................................................................................................................2033
Subsequent work.........................................................................................................................2033
57 63 19 Removing and installing rubber seal for door - as of MY 2005................................................2036
Preliminary work..............................................................................................................................2036
Preliminary work.........................................................................................................................2036
Removing rubber seal for door.........................................................................................................2036
Removing rubber seal for door....................................................................................................2036
Installing rubber seal for door...........................................................................................................2037
Installing rubber seal for door.....................................................................................................2037
Subsequent work...............................................................................................................................2038
Subsequent work.........................................................................................................................2038
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57 63 19 Removing and installing rubber seal for door - Cabriolet - as of MY 2005............................2041
Preliminary work..............................................................................................................................2041
Preliminary work.........................................................................................................................2041
Removing rubber seal for door.........................................................................................................2041
Removing cover of three-point seat belt.....................................................................................2041
Removing rubber seal for door....................................................................................................2042
Installing rubber seal for door...........................................................................................................2043
Installing rubber seal for door.....................................................................................................2043
Installing cover of three-point seat belt.......................................................................................2045
Subsequent work...............................................................................................................................2045
Subsequent work.........................................................................................................................2045
57 65 19 Removing and installing rubber seal for door - as of MY 2005................................................2048
Preliminary work..............................................................................................................................2048
Preliminary work.........................................................................................................................2048
Removing rubber seal for door.........................................................................................................2048
Removing rubber seal for door....................................................................................................2048
Installing rubber seal for door...........................................................................................................2050
Installing rubber seal for door.....................................................................................................2050
Subsequent work...............................................................................................................................2052
Subsequent work.........................................................................................................................2052
57 78 19 Removing and installing central locking switch - as of MY 2005.............................................2054
Removing central locking switch......................................................................................................2054
Removing central locking switch................................................................................................2054
Installing central locking switch.......................................................................................................2055
Installing central locking switch..................................................................................................2055
57 89 19 Removing and installing control unit for rear convenience systems - as of MY 2005............2058
Tools..................................................................................................................................................2058
Preliminary work..............................................................................................................................2058
Preparing control unit for comfort system rear...........................................................................2058
General warning notes......................................................................................................................2058
General warnings for rear convenience systems control unit......................................................2058
Removing control unit for rear convenience systems.......................................................................2059
Removing control unit for rear convenience systems.................................................................2059
Installing control unit for rear convenience systems........................................................................2061
Installing control unit for rear convenience systems...................................................................2061
Subsequent work...............................................................................................................................2062
Subsequent work on control unit for rear convenience comfort systems....................................2062
Programming control unit for rear convenience systems.................................................................2063
Reading from and writing to the rear convenience system control unit......................................2063
Coding control unit for rear convenience systems............................................................................2064
Coding the control unit for rear convenience systems................................................................2064
60 12 19 Removing and installing switch for sliding roof - as of MY 2005.............................................2068
Removing switch for sliding roof.....................................................................................................2068
Removing cover for motor for sliding roof.................................................................................2068
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Table of Contents
60 12 19 Removing and installing switch for sliding roof - as of MY 2005
Removing switch for sliding roof................................................................................................2069
Installing switch for sliding roof.......................................................................................................2069
Installing switch for sliding roof.................................................................................................2069
Installing cover for sunroof motor...............................................................................................2070
60 14 19 Removing and installing motor for sliding roof - as of MY 2005.............................................2073
Removing motor for sliding roof......................................................................................................2073
Removing cover for motor for sliding roof.................................................................................2073
Removing motor for sunroof.......................................................................................................2074
Installing motor for sliding roof........................................................................................................2075
Installing motor for sunroof........................................................................................................2075
Installing cover for sunroof motor...............................................................................................2077
Information.......................................................................................................................................2078
Emergency operation on motor for sliding roof..........................................................................2078
Storing end positions of motor for sliding roof...........................................................................2078
60 28 19 Removing and installing frame for sliding roof - as of MY 2005.............................................2081
Preliminary work..............................................................................................................................2081
Preliminary work.........................................................................................................................2081
Removing frame for sliding roof......................................................................................................2081
Removing frame for sliding roof.................................................................................................2081
Installing frame for sliding roof........................................................................................................2083
Installing frame for sliding roof..................................................................................................2083
Subsequent work...............................................................................................................................2084
Subsequent work.........................................................................................................................2084
60 28 37 Disassembling and assembling frame for sliding roof - as of MY 2005...................................2087
Preliminary work..............................................................................................................................2087
Preliminary work.........................................................................................................................2087
Disassembling frame for sliding roof...............................................................................................2087
Disassembling frame for sliding roof..........................................................................................2087
Converting frame for sliding roof.....................................................................................................2089
Converting frame for sliding roof...............................................................................................2089
Assembling frame for sliding roof....................................................................................................2092
Assembling frame for sliding roof..............................................................................................2092
Subsequent work...............................................................................................................................2093
Subsequent work.........................................................................................................................2093
60 33 19 Removing and installing air deflector - as of MY 2005.............................................................2096
Preliminary work..............................................................................................................................2096
Preliminary work.........................................................................................................................2096
Removing air deflector.....................................................................................................................2096
Removing air deflector................................................................................................................2096
Installing air deflector.......................................................................................................................2097
Installing air deflector.................................................................................................................2097
Subsequent work...............................................................................................................................2098
Subsequent work.........................................................................................................................2098
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60 40 19 Removing and installing cover for sliding roof - as of MY 2005..............................................2101
Removing cover for sliding roof.......................................................................................................2101
Removing cover for sliding roof.................................................................................................2101
Installing cover for sliding roof........................................................................................................2103
Installing cover for sliding roof...................................................................................................2103
60 42 19 Removing and installing seal for sliding roof - as of MY 2005.................................................2109
Preliminary work..............................................................................................................................2109
Preliminary work.........................................................................................................................2109
Removing seal for sliding roof.........................................................................................................2109
Removing seal for sliding roof....................................................................................................2109
Installing seal for sliding roof...........................................................................................................2110
Installing seal for sliding roof.....................................................................................................2110
Subsequent work...............................................................................................................................2110
Subsequent work.........................................................................................................................2110
61 01 15 Adjusting convertible top - as of MY 2005.................................................................................2113
Adjusting convertible top..................................................................................................................2113
Adjusting assembly aids..............................................................................................................2113
Adjusting convertible-top peg housing.......................................................................................2114
Checking diagonal dimension of styling edge............................................................................2114
Adjusting tension cable on adjusting piece.................................................................................2115
Adjusting end setting for convertible-top resting position..........................................................2115
61 01 19 Removing and installing convertible top - as of MY 2005........................................................2118
Tools..................................................................................................................................................2118
Preliminary work..............................................................................................................................2118
Preliminary work.........................................................................................................................2118
Tools and materials...........................................................................................................................2118
Tools............................................................................................................................................2118
Removing convertible top.................................................................................................................2119
Removing convertible top...........................................................................................................2119
Installing convertible top..................................................................................................................2121
Installing convertible top.............................................................................................................2121
Subsequent work...............................................................................................................................2124
Subsequent work.........................................................................................................................2124
61 01 41 Convertible top repair - after emergency operation - as of MY 2005......................................2127
Preliminary work..............................................................................................................................2127
Preliminary work.........................................................................................................................2127
Convertible top repair - after emergency operation..........................................................................2128
Repairing convertible-top compartment lid drive.......................................................................2128
Subsequent work...............................................................................................................................2129
Subsequent work.........................................................................................................................2129
61 02 15 Adjusting the hardtop - as of MY 2005.......................................................................................2132
Tools..................................................................................................................................................2132
Adjusting the hardtop........................................................................................................................2132
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61 02 15 Adjusting the hardtop - as of MY 2005
Adjusting the hardtop..................................................................................................................2132
61 02 19 Removing and installing hardtop - as of MY 2005....................................................................2138
Removing hardtop.............................................................................................................................2138
Removing hardtop.......................................................................................................................2138
Installing hardtop..............................................................................................................................2140
Installing hardtop.........................................................................................................................2140
61 02 37 Disassembling and assembling hardtop - as of MY 2005..........................................................2146
Preliminary work..............................................................................................................................2146
Preliminary work.........................................................................................................................2146
Disassembling hardtop......................................................................................................................2146
Disassembling hardtop................................................................................................................2146
Assembling hardtop..........................................................................................................................2150
Assembling hardtop.....................................................................................................................2150
Subsequent work...............................................................................................................................2156
Subsequent work.........................................................................................................................2156
61 05 19 Removing and installing latch at front - as of MY 2005............................................................2159
Preliminary work..............................................................................................................................2159
Preliminary work.........................................................................................................................2159
Removing latch at front....................................................................................................................2159
Removing front lock....................................................................................................................2159
Installing latch at front......................................................................................................................2161
Installing front lock.....................................................................................................................2161
Subsequent work...............................................................................................................................2161
Subsequent work.........................................................................................................................2162
61 09 19 Removing and installing convertible-top inner lining - as of MY 2005...................................2164
Preliminary work..............................................................................................................................2164
Preliminary work.........................................................................................................................2164
Removing convertible-top inner lining.............................................................................................2164
Removing front inner lining of convertible top...........................................................................2164
Removing inner lining of convertible top at rear........................................................................2168
Removing convertible-top inner lining at sides..........................................................................2172
Installing convertible-top inner lining..............................................................................................2173
Installing convertible-top inner lining at front............................................................................2173
Installing convertible-top inner lining at rear..............................................................................2177
Installing convertible-top inner lining at sides............................................................................2180
61 10 19 Removing and installing front convertible-top mount - as of MY 2005..................................2184
Preliminary work..............................................................................................................................2184
Preliminary work.........................................................................................................................2184
Preliminary work.........................................................................................................................2184
Removing front convertible-top mount............................................................................................2184
Removing centring journal..........................................................................................................2184
Removing centring journal (hardtop)..........................................................................................2185
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61 10 19 Removing and installing front convertible-top mount - as of MY 2005
Removing convertible-top peg mount.........................................................................................2186
Installing front convertible-top mount..............................................................................................2187
Installing centring journal...........................................................................................................2187
Installing centring journal (hardtop)............................................................................................2188
Installing convertible-top peg mount..........................................................................................2189
Subsequent work...............................................................................................................................2190
Subsequent work.........................................................................................................................2190
Subsequent work...............................................................................................................................2191
Subsequent work.........................................................................................................................2191
61 11 19 Removing and installing the rear hardtop locking element - as of MY 2005..........................2194
Preliminary work..............................................................................................................................2194
Preliminary work.........................................................................................................................2194
Removing the rear hardtop locking element.....................................................................................2194
Removing rear hardtop locking mechanism................................................................................2194
Installing the rear hardtop locking element......................................................................................2197
Installing rear hardtop locking mechanism.................................................................................2197
Subsequent work...............................................................................................................................2199
Subsequent work.........................................................................................................................2199
61 14 19 Removing and installing water drip pan - as of MY 2005.........................................................2202
Preliminary work..............................................................................................................................2202
Preliminary work.........................................................................................................................2202
Removing water drip pan..................................................................................................................2202
Removing water drip pan............................................................................................................2202
Removing water channel.............................................................................................................2203
Installing water drip pan...................................................................................................................2205
Installing water channel...............................................................................................................2205
Installing water drip pan..............................................................................................................2207
Subsequent work...............................................................................................................................2208
Subsequent work.........................................................................................................................2208
61 17 19 Removing and installing hardtop fastening - as of MY 2005....................................................2210
Preliminary work..............................................................................................................................2210
Preliminary work.........................................................................................................................2210
Removing hardtop fastening.............................................................................................................2210
Removing bracket for hardtop mount.........................................................................................2210
Installing hardtop fastening...............................................................................................................2211
Installing bracket for hardtop mount...........................................................................................2212
Subsequent work...............................................................................................................................2213
Subsequent work.........................................................................................................................2213
61 19 19 Removing and installing convertible top lock - as of MY 2005................................................2215
Removing convertible top lock.........................................................................................................2215
Removing cover for convertible top lock....................................................................................2215
Removing convertible top lock...................................................................................................2216
Installing convertible top lock..........................................................................................................2216
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61 19 19 Removing and installing convertible top lock - as of MY 2005
Installing convertible top lock.....................................................................................................2216
Installing cover for convertible top lock.....................................................................................2217
61 28 19 Removing and installing convertible top covering - as of MY 2005.........................................2220
Tools..................................................................................................................................................2220
Preliminary work..............................................................................................................................2220
Preliminary work.........................................................................................................................2220
Removing convertible-top covering.................................................................................................2220
Removing convertible-top covering............................................................................................2220
Installing convertible-top covering...................................................................................................2225
Installing convertible-top covering.............................................................................................2225
Subsequent work...............................................................................................................................2231
Subsequent work.........................................................................................................................2231
61 30 55 Replacing convertible-top frame - as of MY 2005.....................................................................2234
Replacing convertible-top frame.......................................................................................................2234
Installing convertible top frame..................................................................................................2234
Installing tension strap.................................................................................................................2239
Installing plastic panel.................................................................................................................2240
Installing styling frame................................................................................................................2241
61 40 19 Removing and installing flap motor - as of MY 2005................................................................2245
Tools..................................................................................................................................................2245
Preliminary work..............................................................................................................................2245
Preliminary work.........................................................................................................................2245
Removing flap motor........................................................................................................................2245
Removing flap motor...................................................................................................................2245
Installing flap motor..........................................................................................................................2247
Installing flap motor....................................................................................................................2247
Subsequent work...............................................................................................................................2248
Subsequent work.........................................................................................................................2248
61 41 19 Removing and installing microswitch for flap - as of MY 2005...............................................2251
Tools..................................................................................................................................................2251
Preliminary work.........................................................................................................................2251
Removing microswitch for flap........................................................................................................2251
Removing microswitch for flap...................................................................................................2251
Installing microswitch for flap..........................................................................................................2255
Installing microswitch for flap....................................................................................................2255
Subsequent work...............................................................................................................................2259
Subsequent work.........................................................................................................................2259
61 42 19 Removing and installing rear side section flap - as of MY 2005...............................................2262
Tools..................................................................................................................................................2262
Preliminary work..............................................................................................................................2262
Preliminary work.........................................................................................................................2262
Removing rear side section flap........................................................................................................2262
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61 42 19 Removing and installing rear side section flap - as of MY 2005
Removing rear side panel flap.....................................................................................................2262
Installing rear side section flap.........................................................................................................2264
Installing rear side section flap....................................................................................................2264
Subsequent work...............................................................................................................................2266
Subsequent work.........................................................................................................................2266
61 43 19 Removing and installing tension cable - as of MY 2005............................................................2269
Preliminary work..............................................................................................................................2269
Preliminary work.........................................................................................................................2269
Removing tension cable....................................................................................................................2269
Removing tension cable..............................................................................................................2269
Installing tension cable.....................................................................................................................2270
Installing tension cable................................................................................................................2270
Subsequent work...............................................................................................................................2272
Subsequent work.........................................................................................................................2272
61 64 19 Removing and installing microswitch for roof - as of MY 2005...............................................2275
Preliminary work..............................................................................................................................2275
Preliminary work.........................................................................................................................2275
Removing microswitch for roof........................................................................................................2275
Removing microswitch for roof..................................................................................................2275
Installing microswitch for roof.........................................................................................................2276
Installing microswitch for roof....................................................................................................2276
Subsequent work...............................................................................................................................2277
Subsequent work.........................................................................................................................2277
61 66 19 Removing and installing potentiometer - as of MY 2006..........................................................2280
Tools..................................................................................................................................................2280
Preliminary work..............................................................................................................................2280
Preliminary work for potentiometer............................................................................................2280
Removing potentiometer...................................................................................................................2280
Removing potentiometer.............................................................................................................2280
Installing potentiometer....................................................................................................................2281
Installing potentiometer...............................................................................................................2281
Subsequent work...............................................................................................................................2282
Subsequent work on potentiometer.............................................................................................2282
61 70 19 Removing and installing convertible-top compartment lid drive - as of MY 2006.................2285
Tools..................................................................................................................................................2285
Preliminary work..............................................................................................................................2285
Preliminary work.........................................................................................................................2285
Removing motor for convertible-top compartment lid drive............................................................2286
Removing motor for convertible-top compartment lid drive......................................................2286
Installing motor for convertible-top compartment lid drive.............................................................2287
Installing motor for convertible-top compartment lid drive........................................................2287
Subsequent work...............................................................................................................................2289
Subsequent work.........................................................................................................................2289
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61 72 19 Removing and installing convertible-top compartment lid drive gear - as of MY 2005........2292
Tools..................................................................................................................................................2292
Preliminary work..............................................................................................................................2292
Preliminary work.........................................................................................................................2292
Removing convertible-top compartment lid drive gear....................................................................2292
Disengaging cable for locking hook............................................................................................2292
Removing convertible-top compartment lid drive gear..............................................................2293
Installing convertible-top compartment lid drive gear......................................................................2295
Installing convertible-top compartment lid drive gear................................................................2295
Engaging cable for locking hook.................................................................................................2296
Subsequent work...............................................................................................................................2297
Subsequent work.........................................................................................................................2297
61 74 19 Removing and installing cable for locking hook - as of MY 2005............................................2300
Preliminary work..............................................................................................................................2300
Preliminary work.........................................................................................................................2300
Removing cable for locking hook.....................................................................................................2300
Disengaging cable for locking hook............................................................................................2300
Removing cable for locking hook...............................................................................................2301
Installing cable for locking hook......................................................................................................2303
Installing cable for locking hook.................................................................................................2303
Engaging cable for locking hook.................................................................................................2304
Subsequent work...............................................................................................................................2305
Subsequent work.........................................................................................................................2305
61 81 19 Removing and installing microswitch for convertible-top compartment lid drive - as of
MY 2006........................................................................................................................................................2307
Preliminary work..............................................................................................................................2307
Preliminary work.........................................................................................................................2307
Removing microswitch for convertible-top compartment lid drive.................................................2307
Removing microswitch for convertible-top compartment lid drive............................................2307
Installing microswitch for convertible-top compartment lid drive...................................................2308
Installing microswitch for convertible-top compartment lid drive.............................................2308
Subsequent work...............................................................................................................................2308
Subsequent work.........................................................................................................................2308
61 84 19 Removing and installing hydraulic pump - as of MY 2005.......................................................2311
Preliminary work..............................................................................................................................2311
Preliminary work.........................................................................................................................2311
Removing hydraulic mount..............................................................................................................2311
Disconnecting electric plug connection for hydraulic pump.......................................................2311
Removing hydraulic pump..........................................................................................................2312
Removing support for hydraulic pump.......................................................................................2314
Installing hydraulic pump.................................................................................................................2315
Installing support for hydraulic pump.........................................................................................2315
Installing hydraulic pump............................................................................................................2315
Locking electric plug connection for hydraulic pump................................................................2317
General information on the hydraulic system...................................................................................2318
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61 84 19 Removing and installing hydraulic pump - as of MY 2005
Opening and closing hydraulic valve of the hydraulic pump...........................................................2318
Access for opening and closing the hydraulic valve...................................................................2318
Filling and bleeding the hydraulic system........................................................................................2319
Filling the hydraulic system........................................................................................................2319
Bleeding the hydraulic system....................................................................................................2320
Subsequent work...............................................................................................................................2321
Subsequent work.........................................................................................................................2321
61 86 19 Removing and installing hydraulic cylinder - as of MY 2005...................................................2323
Tools..................................................................................................................................................2323
Preliminary work..............................................................................................................................2323
Preliminary work.........................................................................................................................2323
Tools and materials...........................................................................................................................2323
Tools............................................................................................................................................2324
Removing hydraulic cylinder............................................................................................................2324
Loosening hydraulic cylinder......................................................................................................2324
Disconnecting electric plug connection for hydraulic pump.......................................................2325
Removing hydraulic pump..........................................................................................................2326
Installing hydraulic cylinder.............................................................................................................2328
Installing hydraulic cylinder........................................................................................................2328
Installing hydraulic pump............................................................................................................2329
Locking electric plug connection for hydraulic pump................................................................2331
Opening and closing hydraulic valve of the hydraulic pump...........................................................2332
Access for opening and closing the hydraulic valve...................................................................2332
Bleeding the hydraulic system....................................................................................................2333
Subsequent work...............................................................................................................................2333
Subsequent work.........................................................................................................................2333
61 90 19 Removing and installing convertible-top compartment lid - as of MY 2005...........................2336
Preliminary work..............................................................................................................................2336
Preliminary work.........................................................................................................................2336
Removing convertible-top compartment lid.....................................................................................2336
Loosening the wire harness for auxiliary stop light on the convertible top compartment lid.....2336
Removing convertible top compartment lid................................................................................2337
Installing convertible-top compartment lid.......................................................................................2338
Installing convertible top compartment lid.................................................................................2338
Locking the wire harness for auxiliary stop light on the convertible top compartment lid........2339
Subsequent work...............................................................................................................................2340
Subsequent work.........................................................................................................................2340
61 90 37 Disassembling and assembling convertible top compartment lid - as of MY 2005.................2343
Preliminary work..............................................................................................................................2343
Preliminary work.........................................................................................................................2343
Disassembling convertible top compartment lid...............................................................................2343
Disassembling convertible-top compartment lid.........................................................................2343
Assembling convertible top compartment lid...................................................................................2345
Assembling convertible-top compartment lid.............................................................................2345
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61 90 37 Disassembling and assembling convertible top compartment lid - as of MY 2005
Subsequent work...............................................................................................................................2347
Subsequent work.........................................................................................................................2347
61 91 19 Removing and installing additional flap - as of MY 2005.........................................................2350
Preliminary work..............................................................................................................................2350
Preliminary work.........................................................................................................................2350
Removing additional flap..................................................................................................................2350
Removing additional flap............................................................................................................2350
Installing additional flap...................................................................................................................2351
Installing additional flap..............................................................................................................2351
61 92 19 Removing and installing hinge for top box cover - as of MY 2005...........................................2355
Preliminary work..............................................................................................................................2355
Preliminary work.........................................................................................................................2355
Removing hinge for top box cover...................................................................................................2355
Removing hinge for top box cover..............................................................................................2355
Installing hinge for top box cover.....................................................................................................2356
Installing hinge for top box cover...............................................................................................2356
Subsequent work...............................................................................................................................2359
Subsequent work.........................................................................................................................2359
61 96 19 Removing and installing control unit for convertible-top - as of MY 2006.............................2361
Tools..................................................................................................................................................2361
Preliminary work..............................................................................................................................2361
Preliminary work.........................................................................................................................2361
Removing control unit for convertible top........................................................................................2362
Removing control unit for convertible top..................................................................................2362
Installing control unit for convertible top.........................................................................................2363
Installing control unit for convertible top....................................................................................2363
Subsequent work...............................................................................................................................2364
Subsequent work.........................................................................................................................2364
Programming control unit for convertible top..................................................................................2364
Reading out and writing values for convertible top control unit.................................................2364
Coding control unit for convertible top............................................................................................2365
Coding control unit for convertible top.......................................................................................2365
Calibrating the convertible top..........................................................................................................2366
Calibrating the convertible top....................................................................................................2366
63 10 19 Removing and installing front bumper - as of MY 2005...........................................................2369
Preliminary work..............................................................................................................................2369
Preliminary work.........................................................................................................................2369
Removing front bumper....................................................................................................................2369
Removing the front bumper........................................................................................................2369
Installing front bumper.....................................................................................................................2370
Installing the front bumper..........................................................................................................2370
Subsequent work...............................................................................................................................2371
Reworking...................................................................................................................................2371
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63 15 19 Removing and installing front spoiler - as of MY 2005.............................................................2374
Tools..................................................................................................................................................2374
Preliminary work..............................................................................................................................2374
Preliminary work.........................................................................................................................2374
Removing front apron.......................................................................................................................2374
Undoing front spoiler underneath................................................................................................2374
Undoing front spoiler at the sides................................................................................................2375
Disconnecting electrical plug connection....................................................................................2376
Removing hose for headlight cleaning system............................................................................2377
Undoing front spoiler at the top..................................................................................................2378
Installing front apron.........................................................................................................................2380
Securing front spoiler at the top..................................................................................................2380
Securing front spoiler at the sides...............................................................................................2381
Locking hose for headlight cleaning system...............................................................................2382
Locking electrical plug connection.............................................................................................2383
Securing front spoiler underneath...............................................................................................2383
Reworking.........................................................................................................................................2384
Reworking...................................................................................................................................2384
63 15 37 Disassembling and assembling front apron - as of MY 2005....................................................2387
Preliminary work..............................................................................................................................2387
Preliminary work.........................................................................................................................2387
Disassembling front spoiler..............................................................................................................2388
Removing cover cap....................................................................................................................2388
Removing side covering frame....................................................................................................2388
Removing fastening clip for wiring harness................................................................................2389
Removing expanding nut for licence plate holder.......................................................................2390
Pulling off joining latch...............................................................................................................2391
Assembling front spoiler...................................................................................................................2392
Affixing joining latch..................................................................................................................2392
Installing expanding nut for licence plate holder........................................................................2393
Installing fastening clip for wiring harness.................................................................................2394
Installing side covering frame.....................................................................................................2395
Installing cover cap.....................................................................................................................2396
Reworking.........................................................................................................................................2397
Subsequent work.........................................................................................................................2397
63 17 19 Removing and installing front disc brake pad - as of MY 2005...............................................2400
Preliminary work..............................................................................................................................2400
Preliminary work.........................................................................................................................2400
Removing front retaining strip..........................................................................................................2400
Removing front retaining strip....................................................................................................2400
Installing front retaining strip...........................................................................................................2401
Installing front retaining strip......................................................................................................2401
Adjusting front retaining strip.....................................................................................................2402
Subsequent work...............................................................................................................................2403
Subsequent work.........................................................................................................................2403
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63 33 19 Removing and installing front bracket (impact pipe) - as of MY 2005....................................2406
Preliminary work..............................................................................................................................2406
Preliminary work.........................................................................................................................2406
Removing front bracket (impact pipe)..............................................................................................2406
Removing front impact pipe........................................................................................................2406
Installing front bracket (impact pipe)...............................................................................................2407
Install front impact pipe..............................................................................................................2407
Subsequent work...............................................................................................................................2408
Subsequent work.........................................................................................................................2408
63 50 19 Removing and installing rear bumper - as of MY 2005............................................................2411
Preliminary work..............................................................................................................................2411
Preliminary work.........................................................................................................................2411
General warning notes......................................................................................................................2411
Safety instructions for the heat shield.........................................................................................2411
Removing rear bumper.....................................................................................................................2412
Removing rear bumper................................................................................................................2412
Removing centre retaining strip..................................................................................................2413
Removing centre heat shield.......................................................................................................2413
Removing heat shield at the sides...............................................................................................2414
Checking anti-chafing film..........................................................................................................2415
Installing rear bumper.......................................................................................................................2416
Installing heat shield at the sides.................................................................................................2416
Installing centre heat shield.........................................................................................................2417
Installing centre retaining strip....................................................................................................2418
Installing rear bumper.................................................................................................................2419
Additional assembly instructions for installation of the bumper......................................................2421
Adjustment dimensions of the bumper........................................................................................2421
Correct assembly of the heat shields...........................................................................................2422
Subsequent work...............................................................................................................................2423
Subsequent work.........................................................................................................................2423
63 55 19 Removing and installing rear spoiler - as of MY 2005..............................................................2425
General warning notes......................................................................................................................2425
General warning notes.................................................................................................................2425
Removing rear spoiler.......................................................................................................................2425
Removing rear spoiler.................................................................................................................2425
Installing rear spoiler........................................................................................................................2427
Safety instructions for the heat shield.........................................................................................2427
Removing and installing strut for rear apron...............................................................................2427
Installing rear spoiler...................................................................................................................2428
Dimensions of tailpipes....................................................................................................................2430
Gap dimensions of tailpipe..........................................................................................................2430
Subsequent work...............................................................................................................................2430
Subsequent work.........................................................................................................................2431
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63 55 19 Removing and installing rear spoiler - as of MY 2005..............................................................2433
General warning notes......................................................................................................................2433
General warning notes.................................................................................................................2433
Removing rear spoiler.......................................................................................................................2433
Removing rear spoiler.................................................................................................................2433
Installing rear spoiler........................................................................................................................2435
Safety instructions for the heat shield.........................................................................................2435
Removing and installing strut for rear apron...............................................................................2435
Installing rear spoiler...................................................................................................................2436
Dimensions of tailpipes....................................................................................................................2438
Gap dimensions of tailpipe..........................................................................................................2438
Subsequent work...............................................................................................................................2438
Subsequent work.........................................................................................................................2439
63 55 37 Disassembling and assembling rear spoiler - as of MY 2005....................................................2441
Preliminary work..............................................................................................................................2441
Preliminary work.........................................................................................................................2441
Disassembling rear spoiler................................................................................................................2441
Removing the lower retaining strip.............................................................................................2442
Removing cover cap....................................................................................................................2442
Assembling rear spoiler....................................................................................................................2443
Installing cover cap.....................................................................................................................2443
Installing the lower retaining strip...............................................................................................2444
Subsequent work...............................................................................................................................2445
Subsequent work.........................................................................................................................2445
63 65 19 Removing and installing rear bumper overrider - as of MY 2005...........................................2448
Preliminary work..............................................................................................................................2448
Preliminary work.........................................................................................................................2448
Removing rear bumper overrider......................................................................................................2448
Removing rear bumper horn........................................................................................................2448
Installing rear bumper overrider.......................................................................................................2450
Installing the rear bumper horn...................................................................................................2450
Subsequent work...............................................................................................................................2451
Subsequent work.........................................................................................................................2451
63 73 19 Removing and installing rear bracket (impact pipe, impact absorber) - as of MY 2005.......2454
Preliminary work..............................................................................................................................2454
Preliminary work.........................................................................................................................2454
Removing rear bracket (impact pipe, impact absorber)....................................................................2454
Removing rear impact pipe.........................................................................................................2454
Removing impact absorber..........................................................................................................2455
Installing rear bracket (impact pipe, impact absorber).....................................................................2456
Install rear impact pipe................................................................................................................2456
Installing impact absorber...........................................................................................................2457
Subsequent work...............................................................................................................................2458
Subsequent work.........................................................................................................................2458
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63 73 19 Removing and installing rear bracket (impact pipe, impact absorber) - as of MY 2005.......2461
Preliminary work..............................................................................................................................2461
Preliminary work.........................................................................................................................2461
Removing rear bracket (impact pipe, impact absorber)....................................................................2461
Removing rear impact pipe.........................................................................................................2461
Installing rear bracket (impact pipe, impact absorber).....................................................................2462
Install rear impact pipe................................................................................................................2462
Subsequent work...............................................................................................................................2463
Subsequent work.........................................................................................................................2463
64 12 19 Removing and installing windscreen - as of MY 2005...............................................................2466
Tools..................................................................................................................................................2466
Preliminary work..............................................................................................................................2467
Preliminary work.........................................................................................................................2467
General warning notes......................................................................................................................2468
General warning notes.................................................................................................................2468
Tools and materials...........................................................................................................................2468
Tools and materials.....................................................................................................................2468
Removing windscreen.......................................................................................................................2470
Removing spacer blocks..............................................................................................................2470
Removing windscreen.................................................................................................................2470
Preparing window frame for installation..........................................................................................2471
Removing adhesive from the body..............................................................................................2471
Cleaning and priming areas that are free of adhesive residue or have paint damage or
where there is newly built-up paint in the window aperture of the body............................2471
Preparing windscreen for installation...............................................................................................2472
Removing windscreen seal..........................................................................................................2472
Removing adhesive from the windscreen...................................................................................2473
Fitting windscreen seal................................................................................................................2473
Marking the bonding area............................................................................................................2474
Activating the bonding section of the windscreen......................................................................2474
Priming the windscreen...............................................................................................................2475
Installing windscreen........................................................................................................................2475
Preliminary work before windscreen installation........................................................................2475
Fitting windscreen into the body.................................................................................................2476
Preparing 2-component adhesive for processing.........................................................................2476
Applying adhesive to the windscreen..........................................................................................2477
Pulling off protective film...........................................................................................................2477
Inserting windscreen into the body.............................................................................................2478
Cleaning fields of vision..............................................................................................................2479
Subsequent work...............................................................................................................................2479
Reworking...................................................................................................................................2479
64 16 23 Installing seal for windscreen - as of MY 2005...........................................................................2482
Installing seal for windscreen...........................................................................................................2482
Fitting seal for windscreen..........................................................................................................2482
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64 37 19 Removing and installing microswitch for window opening controls - as of MY 2005...........2485
Preliminary work..............................................................................................................................2485
Preliminary work.........................................................................................................................2485
Removing microswitch for window opening controls......................................................................2485
Unclipping electric wire for micro switches...............................................................................2485
Removing microswitch for window opening controls................................................................2486
Installing microswitch for window opening controls.......................................................................2487
Installing microswitch for window opening controls..................................................................2487
Clipping in the electric wire for micro switches.........................................................................2488
Subsequent work...............................................................................................................................2489
Subsequent work.........................................................................................................................2489
64 40 19 Removing and installing front door window - as of MY 2005..................................................2492
Preliminary work..............................................................................................................................2492
Preliminary work.........................................................................................................................2492
Removing front door window...........................................................................................................2492
Removing front door window.....................................................................................................2492
Installing front door window............................................................................................................2494
Installing front door window.......................................................................................................2494
Securing front door window........................................................................................................2495
Inserting door trim panel.............................................................................................................2497
Standardising the power windows...............................................................................................2498
Blockage detection function........................................................................................................2498
Precondition for operation of the power windows......................................................................2498
Adjusting the door window angle in the vehicle's longitudinal direction...................................2498
Adjusting the door window height..............................................................................................2499
Adjustment of the door window pressing force on the door seal at the top and sides................2501
Subsequent work...............................................................................................................................2503
Subsequent work.........................................................................................................................2503
64 40 49 Reworking (coating) front door window - as of MY 2005.........................................................2505
General warning notes......................................................................................................................2505
Warning note on hydrophobic window.......................................................................................2505
Checking front door window.......................................................................................................2505
Preliminary work..............................................................................................................................2506
Mixing the components...............................................................................................................2506
Cleaning the surface....................................................................................................................2507
Reworking (coating) front door window.....................................................................................2507
64 48 19 Removing and installing the front window shaft seal - as of MY 2005....................................2510
Removing the front window shaft seal.............................................................................................2510
Removing the front window shaft seal........................................................................................2510
Installing the front window shaft seal...............................................................................................2511
Installing the front window shaft seal.........................................................................................2511
64 52 19 Removing and installing front power windows - as of MY 2005..............................................2515
Preliminary work..............................................................................................................................2515
Preliminary work.........................................................................................................................2515
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64 52 19 Removing and installing front power windows - as of MY 2005
Removing front power windows.......................................................................................................2515
Removing front power windows.................................................................................................2515
Installing front power windows........................................................................................................2517
Adjusting the lower stop of the power window unit...................................................................2517
Installing front power windows...................................................................................................2518
Subsequent work...............................................................................................................................2521
Subsequent work.........................................................................................................................2521
64 54 19 Removing and installing power window motor - as of MY 2005..............................................2523
Tools..................................................................................................................................................2523
Preliminary work..............................................................................................................................2523
Preliminary work for power window motor................................................................................2523
Removing power window motor......................................................................................................2523
Removing power window motor.................................................................................................2523
Installing power window motor........................................................................................................2525
Installing power window motor..................................................................................................2525
Subsequent work...............................................................................................................................2526
Subsequent work for window power motor................................................................................2526
Programming power window motor (door control unit)...................................................................2526
Reading from and writing to the power windows motor (door control unit)..............................2526
Coding power window motor (door control unit).............................................................................2527
Coding the power windows motor (door control unit)................................................................2527
64 58 19 Removing and installing switch for power windows - as of MY 2005......................................2532
Preliminary work..............................................................................................................................2532
Preliminary work.........................................................................................................................2532
Removing switch for power windows..............................................................................................2532
Removing switch for power windows.........................................................................................2532
Installing switch for power windows................................................................................................2533
Installing switch for power windows..........................................................................................2533
Subsequent work...............................................................................................................................2534
Subsequent work.........................................................................................................................2534
64 61 19 Removing and installing rear power window motor - as of MY 2005.....................................2537
Preliminary work..............................................................................................................................2537
Preliminary work.........................................................................................................................2537
Removing rear power window motor...............................................................................................2537
Removing rear power window motor..........................................................................................2537
Installing rear power window motor.................................................................................................2538
Installing rear power window motor...........................................................................................2539
Subsequent work...............................................................................................................................2539
Subsequent work.........................................................................................................................2539
64 71 19 Removing and installing rear window lifter - as of MY 2005...................................................2542
Tools..................................................................................................................................................2542
Preliminary work..............................................................................................................................2542
Preliminary work.........................................................................................................................2543
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64 71 19 Removing and installing rear window lifter - as of MY 2005
Removing rear window lifter............................................................................................................2543
Loosening hydraulic cylinder......................................................................................................2543
Removing rear window lifter......................................................................................................2545
Installing rear window lifter..............................................................................................................2548
Installing rear window lifter........................................................................................................2548
Installing hydraulic cylinder........................................................................................................2549
Adjusting rear window lifter.............................................................................................................2551
Adjusting rear window lifter.......................................................................................................2551
Additional instructions for adjusting or replacing the rear window lifter........................................2552
Additional instructions for adjusting or replacing the rear window lifter...................................2552
Subsequent work...............................................................................................................................2553
Subsequent work.........................................................................................................................2553
64 75 19 Removing and installing rear side window - as of MY 2005.....................................................2556
Preliminary work..............................................................................................................................2556
Preliminary work.........................................................................................................................2556
Removing rear side window.............................................................................................................2556
Removing side window...............................................................................................................2556
Installing rear side window...............................................................................................................2557
Installing side window.................................................................................................................2557
Subsequent work...............................................................................................................................2560
Subsequent work.........................................................................................................................2560
64 75 19 Removing and installing rear side window - as of MY 2005.....................................................2563
Tools..................................................................................................................................................2563
Preliminary work..............................................................................................................................2563
Preliminary work.........................................................................................................................2563
Removing rear side window.............................................................................................................2563
Removing rear side window........................................................................................................2564
Installing rear side window.........................................................................................................2565
Adjusting rear side window.........................................................................................................2566
Subsequent work...............................................................................................................................2568
Subsequent work.........................................................................................................................2568
64 76 19 Removing and installing side window seal - as of MY 2005......................................................2571
Preliminary work..............................................................................................................................2571
Preliminary work.........................................................................................................................2571
Removing side window seal.............................................................................................................2571
Removing side window seal........................................................................................................2571
Loosening sound absorber...........................................................................................................2572
Removing seal for roof frame.....................................................................................................2573
Installing side window seal...............................................................................................................2573
Installing seal for roof frame.......................................................................................................2574
Fastening sound absorber............................................................................................................2574
Installing side window seal.........................................................................................................2575
Subsequent work...............................................................................................................................2576
Subsequent work.........................................................................................................................2576
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Table of Contents
64 86 19 Removing and installing rear window - as of MY 2005............................................................2578
Tools..................................................................................................................................................2578
Preliminary work..............................................................................................................................2579
Preliminary work.........................................................................................................................2579
General warning notes......................................................................................................................2580
General warning notes.................................................................................................................2580
Tools and materials...........................................................................................................................2580
Tools and materials.....................................................................................................................2580
Removing rear window.....................................................................................................................2581
Removing rear window...............................................................................................................2581
Preparing window frame for installation..........................................................................................2582
Removing adhesive from the body..............................................................................................2582
Cleaning and priming paint damage or newly built-up paint areas in the window aperture
of the body...........................................................................................................................2583
Preparing rear window for installation.............................................................................................2583
Removing seal for rear window..................................................................................................2583
Removing adhesive from the rear window..................................................................................2584
Fitting seal for rear window........................................................................................................2585
Applying activator to the bonding section of the rear window...................................................2585
Installing rear window......................................................................................................................2586
Aligning rear window..................................................................................................................2586
Preparing 2-component adhesive for processing.........................................................................2586
Applying adhesive on the rear window.......................................................................................2587
Pulling off protective film...........................................................................................................2587
Inserting rear window into the body............................................................................................2588
Cleaning fields of vision..............................................................................................................2589
Subsequent work...............................................................................................................................2589
Subsequent work.........................................................................................................................2589
64 86 19 Removing and installing rear window - as of MY 2005............................................................2592
Tools..................................................................................................................................................2592
Preliminary work..............................................................................................................................2593
Preliminary work.........................................................................................................................2593
General warning notes......................................................................................................................2593
General warning notes.................................................................................................................2594
Tools and materials...........................................................................................................................2594
Tools and materials.....................................................................................................................2594
Removing rear window.....................................................................................................................2595
Preparing the rear window (hardtop) for removal.......................................................................2595
Removing rear window...............................................................................................................2598
Preparing window frame for installation..........................................................................................2598
Removing adhesive on the hardtop body....................................................................................2598
Cleaning and priming paint damage or newly built-up paint areas in the window aperture
of the hardtop body..............................................................................................................2599
Preparing rear window for installation.............................................................................................2599
Removing adhesive from the rear window..................................................................................2600
Applying activator to the bonding section of the rear window...................................................2600
Fitting cover section....................................................................................................................2601
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64 86 19 Removing and installing rear window - as of MY 2005
Installing rear window......................................................................................................................2602
Preparing 2-component adhesive for processing.........................................................................2602
Applying adhesive on the rear window.......................................................................................2602
Inserting rear window into the hardtop body..............................................................................2603
Cleaning fields of vision..............................................................................................................2604
Completing the rear window (hardtop) after installation............................................................2604
Subsequent work...............................................................................................................................2606
Subsequent work.........................................................................................................................2606
64 90 23 Installing seal for rear window - as of MY 2005........................................................................2608
Installing seal for rear window.........................................................................................................2608
Fitting seal for rear window........................................................................................................2608
66 07 19 Removing and installing front logo - as of MY 2005.................................................................2611
Removing front logo.........................................................................................................................2611
Removing front logo...................................................................................................................2611
Installing front logo..........................................................................................................................2612
Installing front logo.....................................................................................................................2612
66 31 19 Removing and installing sill cover - as of MY 2006...................................................................2615
Preliminary work..............................................................................................................................2615
Preliminary work.........................................................................................................................2615
Removing sill cover..........................................................................................................................2615
Removing sill cover.....................................................................................................................2615
Disassembling and assembling sill cover....................................................................................2617
Installing sill cover............................................................................................................................2618
Installing sill cover......................................................................................................................2618
Gap dimensions of sill cover.............................................................................................................2620
Gap dimensions of sill cover.......................................................................................................2621
Subsequent work...............................................................................................................................2622
Reworking...................................................................................................................................2622
66 34 19 Removing and installing side-section trim - as of MY 2005......................................................2625
Preliminary work..............................................................................................................................2625
Preliminary work.........................................................................................................................2625
Removing side-section trim..............................................................................................................2625
Removing side-section trim.........................................................................................................2625
Installing side-section trim................................................................................................................2626
Installing side-section trim..........................................................................................................2626
Subsequent work...............................................................................................................................2627
Reworking...................................................................................................................................2627
66 36 19 Removing and installing roof joint strip - as of MY 2005.........................................................2630
Tools..................................................................................................................................................2630
Removing roof joint strip..................................................................................................................2630
Removing roof joint cover strip..................................................................................................2630
Disassembling roof joint cover strip.................................................................................................2631
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66 36 19 Removing and installing roof joint strip - as of MY 2005
Disassembling roof joint cover strip...........................................................................................2631
Assembling roof joint cover strip.....................................................................................................2633
Assembling roof joint cover strip................................................................................................2633
Installing roof joint strip...................................................................................................................2634
Installing roof joint cover strip....................................................................................................2635
66 50 55 Replacing rear logo - as of MY 2005...........................................................................................2638
Tools..................................................................................................................................................2638
Replacing rear logo...........................................................................................................................2638
Removing the rear logo...............................................................................................................2638
Replacing model logo.......................................................................................................................2639
Replacing the Carrera 4S model logo..........................................................................................2640
66 50 55 Replacing rear logo - as of MY 2005...........................................................................................2643
Tools..................................................................................................................................................2643
Replacing rear logo...........................................................................................................................2643
Removing the rear logo...............................................................................................................2643
Replacing model logo.......................................................................................................................2644
Replacing the Carrera model logo...............................................................................................2645
66 50 55 Replacing rear logo - as of MY 2005...........................................................................................2648
Tools..................................................................................................................................................2648
Replacing rear logo...........................................................................................................................2648
Removing the rear logo...............................................................................................................2648
Replacing model logo.......................................................................................................................2649
Replacing the Carrera 4 model logo............................................................................................2650
66 50 55 Replacing rear logo - as of MY 2005...........................................................................................2653
Tools..................................................................................................................................................2653
Replacing rear logo...........................................................................................................................2653
Removing the rear logo...............................................................................................................2653
Replacing model logo.......................................................................................................................2654
Replacing the Carrera S model logo............................................................................................2655
66 54 19 Removing and installing switch for rearview mirror - as of MY 2005....................................2658
Removing switch for rearview mirror...............................................................................................2658
Removing switch for rear-view mirror........................................................................................2658
Installing switch for rearview mirror................................................................................................2659
Installing switch for rear-view mirror.........................................................................................2659
66 71 19 Removing and installing engine for rear spoiler - as of MY 2005............................................2662
Preliminary work..............................................................................................................................2662
Preliminary work.........................................................................................................................2662
Removing engine for rear spoiler.....................................................................................................2662
Removing engine for rear spoiler................................................................................................2662
Installing engine for rear spoiler.......................................................................................................2663
Installing engine for rear spoiler.................................................................................................2663
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66 71 19 Removing and installing engine for rear spoiler - as of MY 2005
Subsequent work...............................................................................................................................2664
Subsequent work.........................................................................................................................2664
66 72 19 Removing and installing spoiler drive - as of MY 2005.............................................................2667
Removing spoiler drive.....................................................................................................................2667
Removing upper part of spoiler...................................................................................................2667
Removing the lower part of the spoiler.......................................................................................2668
Removing spoiler drive...............................................................................................................2668
Installing spoiler drive......................................................................................................................2670
Installing spoiler drive.................................................................................................................2670
Mounting the lower part of the spoiler........................................................................................2671
Mounting upper part of spoiler....................................................................................................2672
66 77 55 Replacing stone guard film - as of MY 2005...............................................................................2675
Replacing stone guard film...............................................................................................................2675
General affixing regulations for the stone guard film.................................................................2675
Affixing the stone guard film......................................................................................................2675
66 82 19 Removing and reinstalling mirror adjuster motor - as of MY 2005........................................2679
Preliminary work..............................................................................................................................2679
Preliminary work.........................................................................................................................2679
Removing mirror adjuster motor......................................................................................................2679
Removing mirror adjusting motor...............................................................................................2679
Installing mirror adjuster motor........................................................................................................2680
Installing mirror adjuster motor..................................................................................................2680
Subsequent work...............................................................................................................................2681
Subsequent work.........................................................................................................................2681
66 89 19 Removing and installing rear-view mirror - as of MY 2005.....................................................2684
Removing rear-view mirror..............................................................................................................2684
Removing trim panel for mirror triangle.....................................................................................2684
Removing seal for mirror triangle...............................................................................................2685
Disconnecting electrical plug connection....................................................................................2685
Removing rear-view mirror.........................................................................................................2686
Installing rear-view mirror................................................................................................................2687
Installing rear-view mirror..........................................................................................................2687
Locking electrical plug connection.............................................................................................2687
Fitting seal for mirror triangle.....................................................................................................2688
Installing trim panel for mirror triangle......................................................................................2689
66 92 19 Removing and installing the roof transport system - as of MY 2005.......................................2692
General warning notes......................................................................................................................2692
Warning notes..............................................................................................................................2692
Removing the roof transport system.................................................................................................2693
Removing the Roof Transport System........................................................................................2693
Removing base plate of roof transport system..................................................................................2695
Removing base plate of Roof Transport System.........................................................................2695
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66 92 19 Removing and installing the roof transport system - as of MY 2005
Installing base plate of roof transport system...................................................................................2697
Installing base plate of Roof Transport System..........................................................................2697
Installing the roof transport system...................................................................................................2698
Installing the Roof Transport System..........................................................................................2698
68 05 19 Removing and installing inner door sill trim - as of MY 2005..................................................2703
Removing inner door sill trim...........................................................................................................2703
Removing inner door sill trim (driver's side)..............................................................................2703
Removing inner door sill trim (passenger's side)........................................................................2704
Installing inner door sill trim............................................................................................................2706
Installing inner door sill trim (driver's side)................................................................................2706
Installing inner door sill trim (passenger's side)..........................................................................2707
68 07 19 Removing and installing cover strip - as of MY 2005................................................................2711
Preliminary work..............................................................................................................................2711
Preliminary work.........................................................................................................................2711
Removing cover strip........................................................................................................................2711
Removing cover strip..................................................................................................................2711
Installing cover strip.........................................................................................................................2712
Installing cover strip....................................................................................................................2712
Subsequent work...............................................................................................................................2714
Subsequent work.........................................................................................................................2714
68 11 19 Removing and installing glove compartment lock - as of MY 2005.........................................2716
Removing glove compartment lock..................................................................................................2716
Removing support for glove compartment lid............................................................................2716
Removing glove compartment lock............................................................................................2717
Installing glove compartment lock....................................................................................................2718
Installing glove compartment lock..............................................................................................2718
Installing support for glove compartment lid..............................................................................2719
68 12 19 Removing and installing lid for glove compartment - as of MY 2005......................................2722
Preliminary work..............................................................................................................................2722
Preliminary work.........................................................................................................................2722
Removing lid for glove compartment...............................................................................................2722
Removing lid for glove compartment.........................................................................................2722
Installing lid for glove compartment.................................................................................................2723
Installing lid for glove compartment...........................................................................................2724
Subsequent work...............................................................................................................................2725
Subsequent work.........................................................................................................................2725
68 14 19 Removing and installing centre console cover - as of MY 2005................................................2728
Preliminary work..............................................................................................................................2728
Preliminary work.........................................................................................................................2728
Removing centre console cover........................................................................................................2728
Removing footwell outlet vent cover..........................................................................................2728
Removing centre console cover..................................................................................................2729
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68 14 19 Removing and installing centre console cover - as of MY 2005
Installing centre console cover..........................................................................................................2730
Installing centre console cover....................................................................................................2730
Installing footwell outlet vent cover............................................................................................2731
Subsequent work...............................................................................................................................2732
Subsequent work.........................................................................................................................2733
68 15 19 Removing and installing glove compartment - as of MY 2005.................................................2735
Preliminary work..............................................................................................................................2735
Preliminary work.........................................................................................................................2735
Removing glove compartment..........................................................................................................2735
Removing glove compartment....................................................................................................2735
Installing glove compartment...........................................................................................................2737
Installing glove compartment......................................................................................................2737
Subsequent work...............................................................................................................................2739
Subsequent work.........................................................................................................................2739
68 16 19 Removing and installing oddments tray. - as of MY 2005........................................................2742
Preliminary work..............................................................................................................................2742
Preliminary work.........................................................................................................................2742
Removing oddments tray..................................................................................................................2742
Removing shelf............................................................................................................................2742
Installing oddments tray....................................................................................................................2743
Installing shelf.............................................................................................................................2743
Subsequent work...............................................................................................................................2744
Subsequent work.........................................................................................................................2744
68 17 19 Removing and installing centre console - as of MY 2005..........................................................2747
Preliminary work..............................................................................................................................2747
Preliminary work.........................................................................................................................2747
Removing centre console..................................................................................................................2747
Removing cover for parking-brake lever....................................................................................2747
Disconnecting wire harness plug connection for centre console................................................2748
Removing centre console............................................................................................................2749
Installing centre console...................................................................................................................2751
Installing centre console..............................................................................................................2751
Locking wire harness plug connection for centre console..........................................................2752
Installing cover for parking-brake lever......................................................................................2753
Subsequent work...............................................................................................................................2754
Subsequent work.........................................................................................................................2754
68 17 37 Disassembling and assembling the centre console - as of MY 2005.........................................2757
Preliminary work..............................................................................................................................2757
Preliminary work.........................................................................................................................2757
Disassembling the centre console.....................................................................................................2757
Disassembling centre console.....................................................................................................2757
Assembling the centre console..........................................................................................................2759
Assembling centre console..........................................................................................................2759
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68 17 37 Disassembling and assembling the centre console - as of MY 2005
Subsequent work...............................................................................................................................2761
Subsequent work.........................................................................................................................2761
68 19 19 Removing and installing cover for centre console - as of MY 2005..........................................2764
Preliminary work..............................................................................................................................2764
Preliminary work.........................................................................................................................2764
Removing cover for centre console..................................................................................................2764
Removing cover for support frame.............................................................................................2764
Removing frame..........................................................................................................................2765
Removing Tiptronic cover...........................................................................................................2766
Installing cover for centre console....................................................................................................2768
Installing Tiptronic cover............................................................................................................2768
Installing frame............................................................................................................................2769
Installing cover for support frame...............................................................................................2770
Subsequent work...............................................................................................................................2770
Subsequent work.........................................................................................................................2771
68 20 19 Removing and installing front ashtray - as of MY 2005............................................................2773
Removing front ashtray.....................................................................................................................2773
Removing front ashtray...............................................................................................................2773
Installing front ashtray......................................................................................................................2773
Installing front ashtray.................................................................................................................2773
68 23 19 Removing and installing sun visor - as of MY 2005...................................................................2776
Removing sun visors.........................................................................................................................2776
Removing sun visor.....................................................................................................................2776
Installing sun visors..........................................................................................................................2777
Fitting sun visor...........................................................................................................................2777
68 23 37 Disassembling and assembling sun visor - as of MY 2005........................................................2780
Preliminary work..............................................................................................................................2780
Preliminary work.........................................................................................................................2780
Disassembling sun visor...................................................................................................................2780
Removing mirror insert...............................................................................................................2780
Removing bulb and contact clips................................................................................................2781
Removing mirror housing...........................................................................................................2781
Assembling sun visor........................................................................................................................2782
Installing mirror housing.............................................................................................................2782
Inserting contact clips and bulb...................................................................................................2783
Installing mirror insert.................................................................................................................2783
Subsequent work...............................................................................................................................2784
Reworking...................................................................................................................................2784
68 30 19 Removing and installing cup holder - as of MY 2005................................................................2786
Removing cup holder........................................................................................................................2786
Removing cup holder..................................................................................................................2786
Installing cup holder.........................................................................................................................2786
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68 30 19 Removing and installing cup holder - as of MY 2005
Installing cup holder....................................................................................................................2786
68 31 19 Removing and installing cassette/CD box - as of MY 2005.......................................................2789
Preliminary work..............................................................................................................................2789
Preliminary work.........................................................................................................................2789
Removing CD box............................................................................................................................2789
Removing CD holder...................................................................................................................2789
Installing CD box..............................................................................................................................2790
Installing CD holder....................................................................................................................2790
Subsequent work...............................................................................................................................2791
Subsequent work.........................................................................................................................2791
69 01 01 Airbag diagnosis - as of MY 2005................................................................................................2794
Tools..................................................................................................................................................2794
Airbag diagnosis...............................................................................................................................2794
69 12 19 Removing and installing rear three-point belt - as of MY 2005...............................................2798
Preliminary work..............................................................................................................................2798
Preliminary work.........................................................................................................................2798
Removing rear three-point belt.........................................................................................................2798
Undoing seat belt and fitting.......................................................................................................2798
Removing rear three-point belt....................................................................................................2799
Installing rear three-point belt...........................................................................................................2800
Installing rear three-point belt.....................................................................................................2800
Fastening seat belt with fitting....................................................................................................2802
Subsequent work...............................................................................................................................2802
Subsequent work.........................................................................................................................2802
69 12 19 Removing and installing rear three-point belt - as of MY 2005...............................................2805
Preliminary work..............................................................................................................................2805
Preliminary work.........................................................................................................................2805
Removing rear three-point belt.........................................................................................................2805
Undoing seat belt and fitting.......................................................................................................2805
Removing rear three-point belt....................................................................................................2806
Installing rear three-point belt...........................................................................................................2806
Installing rear three-point belt.....................................................................................................2806
Fastening seat belt with fitting....................................................................................................2807
Subsequent work...............................................................................................................................2808
Subsequent work.........................................................................................................................2808
69 13 01 Checking seat belts - as of MY 2005............................................................................................2811
General warning notes......................................................................................................................2811
Warning note for seat belts..........................................................................................................2811
Checking seat belts...........................................................................................................................2811
Checking procedure for seat belt.................................................................................................2811
Checking belt strap......................................................................................................................2812
Checking automatic belt device (locking effect).........................................................................2813
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69 13 01 Checking seat belts - as of MY 2005
Checking look and operation of seat-belt buckle........................................................................2814
Checking sash guides..................................................................................................................2814
Checking mounting elements and mounting points....................................................................2815
69 13 19 Removing and installing front three-point belt with seat-belt tensioner - as of MY 2005.....2817
Tools..................................................................................................................................................2817
Preliminary work..............................................................................................................................2817
Preliminary work.........................................................................................................................2817
General warning notes......................................................................................................................2817
Safety instructions for seat-belt tensioner unit............................................................................2817
Removing three-point belt with seat-belt tensioner..........................................................................2818
Removing three-point belt with seat-belt tensioner....................................................................2818
Installing three-point belt with seat-belt tensioner............................................................................2820
Installing three-point belt with seat-belt tensioner......................................................................2820
Subsequent work...............................................................................................................................2822
Subsequent work.........................................................................................................................2822
69 13 19 Removing and installing front three-point belt with seat-belt tensioner - as of MY 2005.....2825
Tools..................................................................................................................................................2825
Preliminary work..............................................................................................................................2825
Preliminary work.........................................................................................................................2825
General warning notes......................................................................................................................2825
Safety instructions for seat-belt tensioner unit............................................................................2825
Removing three-point belt with seat-belt tensioner..........................................................................2826
Removing front three-point belt with seat-belt tensioner............................................................2826
Installing three-point belt with seat-belt tensioner............................................................................2828
Installing three-point belt with seat-belt tensioner......................................................................2828
Subsequent work...............................................................................................................................2829
Subsequent work.........................................................................................................................2829
69 24 19 Removing and installing front belt lock - as of MY 2005..........................................................2832
Preliminary work..............................................................................................................................2832
Preliminary work.........................................................................................................................2832
Removing front belt lock..................................................................................................................2832
Removing control unit for memory seat adjustment with support..............................................2832
Removing front belt lock.............................................................................................................2833
Installing front belt lock....................................................................................................................2836
Installing front belt lock..............................................................................................................2836
Installing control unit for memory seat adjustment with support...............................................2838
Subsequent work...............................................................................................................................2839
Subsequent work.........................................................................................................................2839
69 25 19 Removing and installing rear belt lock - as of MY 2005...........................................................2841
Preliminary work..............................................................................................................................2841
Preliminary work.........................................................................................................................2841
Removing rear belt lock....................................................................................................................2841
Removing rear belt lock..............................................................................................................2841
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69 25 19 Removing and installing rear belt lock - as of MY 2005
Installing rear belt lock.....................................................................................................................2842
Installing rear belt lock................................................................................................................2842
Subsequent work...............................................................................................................................2843
Subsequent work.........................................................................................................................2843
69 36 19 Removing and installing adjustment fitting (seat belt height adjuster) - as of MY 2005.......2846
Preliminary work..............................................................................................................................2846
Preliminary work.........................................................................................................................2846
Removing adjustment fitting (seat belt height adjuster)...................................................................2846
Removing adjustment fitting (seat belt height adjuster).............................................................2846
Installing adjustment fitting (seat belt height adjuster).....................................................................2847
Installing adjustment fitting (seat belt height adjuster)...............................................................2847
Subsequent work...............................................................................................................................2848
Subsequent work.........................................................................................................................2848
69 51 19 Removing and installing airbag sensor - as of MY 2005...........................................................2851
Tools..................................................................................................................................................2851
Preliminary work..............................................................................................................................2851
Preliminary work for front airbag sensor....................................................................................2851
Preliminary work for centre airbag sensor..................................................................................2852
General warning notes......................................................................................................................2852
Safety instructions for airbag sensor...........................................................................................2852
Tools and materials...........................................................................................................................2852
Tools............................................................................................................................................2853
Removing airbag sensor....................................................................................................................2853
Removing sensor for front airbag................................................................................................2853
Removing sensor for centre airbag..............................................................................................2854
Installing airbag sensor.....................................................................................................................2855
Installing sensor for front airbag.................................................................................................2855
Installing sensor for centre airbag...............................................................................................2856
Reworking.........................................................................................................................................2857
Work in wake of front airbag sensor...........................................................................................2858
Work in wake of centre airbag sensor.........................................................................................2858
69 53 19 Removing and installing triggering unit for airbag - as of MY 2005.......................................2861
Tools..................................................................................................................................................2861
Preliminary work..............................................................................................................................2861
Preliminary work for triggering unit...........................................................................................2861
General warning notes......................................................................................................................2862
General warning notes for airbag triggering unit........................................................................2862
Removing triggering unit for airbag.................................................................................................2862
Overview, triggering unit for the airbag......................................................................................2862
Removing triggering unit for airbag............................................................................................2863
Installing the triggering unit.............................................................................................................2864
Installing triggering unit..............................................................................................................2864
Subsequent work...............................................................................................................................2865
Subsequent work for triggering unit............................................................................................2865
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Diagnostic system: reading out fault memory and activating systems
Table of Contents
69 53 19 Removing and installing triggering unit for airbag - as of MY 2005
Programming triggering unit............................................................................................................2865
Triggering unit - reading out and writing in data........................................................................2865
Coding triggering unit.......................................................................................................................2866
Coding triggering unit.................................................................................................................2866
69 54 19 Removing and installing the contact unit - as of MY 2005.......................................................2872
Tools..................................................................................................................................................2872
Preliminary work..............................................................................................................................2872
Preliminary work for contact unit...............................................................................................2872
General warning notes......................................................................................................................2872
General warnings for contact unit...............................................................................................2873
Removing contact unit for airbag.....................................................................................................2873
Removing contact unit for airbag................................................................................................2873
Installing airbag contact unit.............................................................................................................2874
Installing contact unit for airbag.................................................................................................2874
Reworking.........................................................................................................................................2874
Work in wake of airbag contact unit...........................................................................................2874
Calibrating steering-angle sensor......................................................................................................2875
Calibrating steering-angle sensor................................................................................................2875
69 58 19 Removing and installing driver's airbag unit - as of MY 2005.................................................2878
Preliminary work for driver's airbag unit...........................................................................................2878
General warning notes......................................................................................................................2878
General warnings for driver's airbag unit....................................................................................2878
Removing driver's airbag unit...........................................................................................................2879
Removing driver's airbag unit.....................................................................................................2879
Installing driver's airbag unit............................................................................................................2882
Installing driver's airbag unit.......................................................................................................2882
Reworking.........................................................................................................................................2883
Work in wake of driver's airbag unit...........................................................................................2883
69 59 19 Removing and installing passenger's airbag unit - as of MY 2005...........................................2886
Preliminary work..............................................................................................................................2886
Preliminary work - airbag unit, passenger's side.........................................................................2886
Safety instructions, passenger's airbag unit.................................................................................2886
Removing passenger's airbag unit.....................................................................................................2887
Removing passenger's airbag unit...............................................................................................2887
Installing passenger's airbag unit......................................................................................................2889
Installing passenger's airbag unit.................................................................................................2889
Reworking.........................................................................................................................................2892
Reworking for passenger's airbag unit........................................................................................2892
69 63 19 Removing and installing side airbag - as of MY 2005...............................................................2895
Preliminary work..............................................................................................................................2895
Preliminary work for side airbag.................................................................................................2895
General warning notes......................................................................................................................2895
General warnings for side airbag.................................................................................................2895
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Table of Contents
69 63 19 Removing and installing side airbag - as of MY 2005
Removing side airbag.......................................................................................................................2896
Removing side airbag..................................................................................................................2896
Installing side airbag.........................................................................................................................2897
Installing side airbag...................................................................................................................2897
Reworking.........................................................................................................................................2898
Work in wake of side airbag........................................................................................................2898
69 66 19 Removing and installing the head airbag unit - as of MY 2005................................................2901
Preliminary work..............................................................................................................................2901
Preliminary work.........................................................................................................................2901
General warning notes......................................................................................................................2901
Safety instructions for head airbag unit.......................................................................................2901
Removing head airbag unit...............................................................................................................2902
Removing head airbag unit..........................................................................................................2902
Installing head airbag unit.................................................................................................................2903
Installing head airbag unit...........................................................................................................2903
Reworking.........................................................................................................................................2905
Work in wake..............................................................................................................................2905
69 68 19 Removing and installing AWS control unit - as of MY 2005....................................................2907
Tools..................................................................................................................................................2907
Preliminary work..............................................................................................................................2907
Preliminary work for AWS control unit......................................................................................2907
Removing AWS control unit............................................................................................................2908
Removing AWS control unit.......................................................................................................2908
Installing AWS control unit..............................................................................................................2909
Installing AWS control unit........................................................................................................2909
Subsequent work...............................................................................................................................2910
Subsequent work for AWS control unit......................................................................................2910
Programming AWS control unit.......................................................................................................2911
Reading and writing values for AWS control unit......................................................................2911
69 72 01 Checking roll-over protection system - as of MY 2005.............................................................2914
Tools..................................................................................................................................................2914
Preliminary work..............................................................................................................................2914
Preliminary work.........................................................................................................................2914
General warning notes......................................................................................................................2914
Safety instructions for work on the roll-over protection system.................................................2914
Checking roll-over bar.................................................................................................................2915
Subsequent work...............................................................................................................................2916
Subsequent work.........................................................................................................................2916
69 72 19 Removing and installing roll-over bar - as of MY 2005............................................................2919
Tools..................................................................................................................................................2919
Preliminary work..............................................................................................................................2919
Preliminary work.........................................................................................................................2919
General warning notes......................................................................................................................2919
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Table of Contents
69 72 19 Removing and installing roll-over bar - as of MY 2005
Safety instructions for work on the roll-over protection system.................................................2920
Removing roll-over bar.....................................................................................................................2920
Mechanical emergency triggering of the roll-over protection system........................................2920
Removing roll-over bar module..................................................................................................2921
Installing roll-over bar module.........................................................................................................2923
Installing roll-over bar module....................................................................................................2923
Subsequent work...............................................................................................................................2925
Subsequent work.........................................................................................................................2925
69 72 19 Removing and installing roll-over bar - as of MY 2005............................................................2928
Tools..................................................................................................................................................2928
Preliminary work..............................................................................................................................2928
Preliminary work.........................................................................................................................2928
Removing roll-over bar.....................................................................................................................2928
Mechanical emergency triggering of the roll-over protection system........................................2928
Removing roll-over bar module..................................................................................................2930
Installing roll-over bar module.........................................................................................................2931
Installing roll-over bar module....................................................................................................2931
Subsequent work...............................................................................................................................2933
Subsequent work.........................................................................................................................2933
69 77 19 Removing and installing frame for roll-over protection system - as of MY 2005...................2936
Preliminary work..............................................................................................................................2936
Preliminary work.........................................................................................................................2936
Removing frame for roll-over protection system..............................................................................2937
Removing frame for roll-over protection system........................................................................2937
Installing frame for roll-over protection system...............................................................................2938
Installing frame for roll-over protection system..........................................................................2938
Diagram of frame for roll-over protection system......................................................................2940
Subsequent work...............................................................................................................................2941
Subsequent work.........................................................................................................................2941
70 02 19 Removing and installing wing flange cover - as of MY 2005....................................................2944
Removing wing flange cover............................................................................................................2944
Removing cover for wing flange.................................................................................................2944
Installing wing flange cover..............................................................................................................2944
Installing cover for wing flange..................................................................................................2944
Additional assembly instructions for replacing Velcro fasteners................................................2945
70 08 19 Removing and installing trim panel for convertible top rest - as of MY 2005........................2949
Preliminary work..............................................................................................................................2949
Preliminary work.........................................................................................................................2949
Removing trim panel for convertible top rest...................................................................................2949
Removing trim panel for convertible top rest.............................................................................2949
Installing trim panel for convertible top rest.....................................................................................2950
Installing trim panel for convertible top rest...............................................................................2950
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Table of Contents
70 16 19 Removing and installing instrument panel cover - as of MY 2005...........................................2953
Removing instrument panel cover....................................................................................................2953
Removing instrument panel cover...............................................................................................2953
Installing the instrument panel cover................................................................................................2954
Installing the instrument panel cover..........................................................................................2954
70 18 19 Removing and installing instrument panel - as of MY 2005.....................................................2957
Preliminary work..............................................................................................................................2957
Preliminary work.........................................................................................................................2957
Removing instrument panel..............................................................................................................2958
Removing the device carrier........................................................................................................2958
Undoing intermediate piece for defroster cover..........................................................................2959
Removing instrument panel.........................................................................................................2959
Installing instrument panel................................................................................................................2961
Checking instrument panel clips.................................................................................................2962
Installing instrument panel..........................................................................................................2962
Securing intermediate piece for defroster cover..........................................................................2964
Installing the device carrier.........................................................................................................2965
Subsequent work...............................................................................................................................2966
Subsequent work.........................................................................................................................2966
70 19 19 Removing and installing trim under dashboard - as of MY 2005............................................2969
Preliminary work..............................................................................................................................2969
Preliminary work.........................................................................................................................2969
Removing trim under the dashboard on the driver's side..................................................................2969
Removing trim under the dashboard on the driver's side............................................................2969
Disconnecting the electrical plug connections............................................................................2970
Installing trim under instrument panel on driver's side.....................................................................2971
Locking electrical plug connections............................................................................................2971
Installing trim under dashboard on the driver's side...................................................................2972
Removing and installing the cover under the instrument panel on the passenger's side..................2973
Removing the cover under the instrument panel on the passenger's side...................................2973
Installing the cover under the instrument panel on the passenger's side.....................................2974
Reworking.........................................................................................................................................2975
Reworking...................................................................................................................................2975
70 20 19 Removing and installing cover for instrument panel (defroster cover) - as of MY 2005.......2978
Preliminary work..............................................................................................................................2978
Preliminary work.........................................................................................................................2978
Removing cover for instrument panel (defroster cover)...................................................................2978
Removing cover for centre instrument panel (defroster cover)..................................................2978
Removing cover for instrument panel (defroster cover) on right and left...................................2979
Installing cover for instrument panel (defroster cover)....................................................................2980
Installing cover for instrument panel (defroster cover) on right and left....................................2980
Installing cover for centre instrument panel (defroster cover)....................................................2981
Subsequent work...............................................................................................................................2982
Reworking...................................................................................................................................2982
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Table of Contents
70 22 19 Removing and installing cover (cold air bulkhead) - as of MY 2005.......................................2985
Removing cover (cold air bulkhead).................................................................................................2985
Removing cover (cold air bulkhead)...........................................................................................2985
Installing cover (cold air bulkhead)..................................................................................................2986
Installing cover (cold air bulkhead).............................................................................................2986
70 24 19 Removing and installing front side section trim - as of MY 2005............................................2989
Removing front side section trim......................................................................................................2989
Removing front side section trim panel (driver's side)...............................................................2989
Removing front side section trim panel (passenger's side).........................................................2989
Installing front side section trim.......................................................................................................2990
Installing front side section trim panel (passenger's side)...........................................................2990
Installing front side section trim panel (driver's side).................................................................2990
70 30 19 Removing and installing front luggage compartment cover - as of MY 2005.........................2993
Preliminary work..............................................................................................................................2993
Preliminary work.........................................................................................................................2993
Removing front luggage compartment cover...................................................................................2993
Removing luggage compartment cover.......................................................................................2993
Installing front luggage compartment cover.....................................................................................2994
Installing luggage compartment cover........................................................................................2995
Subsequent work...............................................................................................................................2996
Subsequent work.........................................................................................................................2996
70 31 19 Removing and installing rear wall trim panel - as of MY 2005................................................2998
Removing rear wall trim panel.........................................................................................................2998
Removing rear wall trim panel....................................................................................................2998
Installing rear wall trim panel...........................................................................................................2999
Installing rear wall trim panel.....................................................................................................2999
70 35 19 Removing and installing footrest - as of MY 2005.....................................................................3002
Removing footrest.............................................................................................................................3002
Removing footrest.......................................................................................................................3002
Installing footrest..............................................................................................................................3003
Installing footrest.........................................................................................................................3003
70 39 19 Removing and installing cover for front lock mount - as of MY 2005.....................................3006
Removing cover for lock mount.......................................................................................................3006
Removing cover for lock support................................................................................................3006
Installing cover for front lock mount................................................................................................3007
Installing cover for lock support.................................................................................................3007
Additional assembly instructions for replacing Velcro fasteners................................................3008
70 53 19 Removing and installing rear cover. - as of MY 2005...............................................................3011
Preliminary work..............................................................................................................................3011
Preliminary work.........................................................................................................................3011
Removing rear cover.........................................................................................................................3011
Remove trim for the rear.............................................................................................................3011
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Diagnostic system: reading out fault memory and activating systems
Table of Contents
70 53 19 Removing and installing rear cover. - as of MY 2005
Installing rear cover..........................................................................................................................3013
Installing cover for rear...............................................................................................................3013
Subsequent work...............................................................................................................................3014
Subsequent work.........................................................................................................................3014
70 57 19 Removing and installing A-pillar trim - as of MY 2005............................................................3017
Preliminary work..............................................................................................................................3017
Preliminary work.........................................................................................................................3017
Removing A-pillar trim....................................................................................................................3017
Removing A-pillar trim...............................................................................................................3017
Installing A-pillar trim......................................................................................................................3018
Installing A-pillar trim panel.......................................................................................................3018
Subsequent work...............................................................................................................................3019
Subsequent work.........................................................................................................................3019
70 57 19 Removing and installing A-pillar trim - as of MY 2005............................................................3022
Preliminary work..............................................................................................................................3022
Preliminary work.........................................................................................................................3022
Removing A-pillar trim....................................................................................................................3022
Removing convertible-top peg mount.........................................................................................3022
Removing A-pillar trim...............................................................................................................3023
Installing A-pillar trim......................................................................................................................3025
Installing A-pillar trim.................................................................................................................3025
Installing convertible-top peg mount..........................................................................................3026
Subsequent work...............................................................................................................................3027
Subsequent work.........................................................................................................................3027
70 59 19 Removing and installing door trim panel - as of MY 2005.......................................................3030
Remove door trim panel....................................................................................................................3030
Removing trim panel for mirror triangle.....................................................................................3030
Removing lever for door handle..................................................................................................3031
Removing covers for door trim panel..........................................................................................3031
Releasing door trim panel............................................................................................................3032
Disconnecting the electrical plug connections............................................................................3033
Removing actuating cable for door lock.....................................................................................3034
Install door trim panel.......................................................................................................................3035
Checking fastening clips.............................................................................................................3035
Installing actuating cable for door lock.......................................................................................3036
Locking electrical plug connections............................................................................................3037
Installing door trim panel............................................................................................................3038
Installing covers for door trim panel...........................................................................................3039
Installing lever for door handle...................................................................................................3040
Installing trim panel for mirror triangle......................................................................................3041
70 61 19 Removing and installing cover for door trim panel - as of MY 2005.......................................3045
Tools..................................................................................................................................................3045
Preliminary work..............................................................................................................................3045
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Diagnostic system: reading out fault memory and activating systems
Table of Contents
70 61 19 Removing and installing cover for door trim panel - as of MY 2005
Preliminary work.........................................................................................................................3045
Removing cover for door trim panel...........................................................................................3045
Installing cover for door trim panel.............................................................................................3046
Subsequent work...............................................................................................................................3049
Subsequent work.........................................................................................................................3049
70 63 19 Removing and installing inner door handle - as of MY 2005...................................................3051
Preliminary work..............................................................................................................................3051
Preliminary work.........................................................................................................................3051
Removing inner door handle.............................................................................................................3051
Removing inner door handle.......................................................................................................3051
Installing inner door handle..............................................................................................................3052
Installing inner door handle.........................................................................................................3052
Subsequent work...............................................................................................................................3053
Subsequent work.........................................................................................................................3053
70 65 19 Removing and installing oddments compartment lid - as of MY 2005....................................3056
Preliminary work..............................................................................................................................3056
Preliminary work.........................................................................................................................3056
Removing lid for oddments compartment........................................................................................3056
Removing lid for oddments compartment...................................................................................3056
Installing lid for oddments compartment..........................................................................................3058
Installing lid for oddments compartment....................................................................................3058
Subsequent work...............................................................................................................................3059
Reworking...................................................................................................................................3059
70 67 19 Removing and installing B-pillar trim - as of MY 2005............................................................3062
Removing B-pillar trim.....................................................................................................................3062
Removing B-pillar trim panel......................................................................................................3062
Installing B-pillar trim......................................................................................................................3063
Installing B-pillar trim panel.......................................................................................................3063
70 68 19 Removing and installing C-pillar trim - as of MY 2005............................................................3067
Preliminary work..............................................................................................................................3067
Preliminary work.........................................................................................................................3067
Removing C-pillar trim.....................................................................................................................3067
Removing C-pillar trim panel......................................................................................................3067
Installing C-pillar trim......................................................................................................................3068
Installing C-pillar trim panel.......................................................................................................3069
Subsequent work...............................................................................................................................3070
Subsequent work.........................................................................................................................3070
70 70 19 Removing and installing trim panel for mirror triangle - as of MY 2005...............................3072
Removing trim panel for mirror triangle..........................................................................................3072
Removing trim panel for mirror triangle.....................................................................................3072
Installing trim panel for mirror triangle............................................................................................3073
Installing trim panel for mirror triangle......................................................................................3073
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Page 99
Diagnostic system: reading out fault memory and activating systems
Table of Contents
70 75 19 Removing and installing rear side-panel lining - as of MY 2005..............................................3076
Preliminary work..............................................................................................................................3076
Preliminary work.........................................................................................................................3076
Removing side-panel lining at rear...................................................................................................3076
Removing seat belt and fitting.....................................................................................................3076
Removing cover of three-point seat belt.....................................................................................3077
Removing side panel trim at rear................................................................................................3078
Installing rear side trim panel......................................................................................................3079
Installing cover of three-point seat belt.......................................................................................3080
Installing seat belt and fitting......................................................................................................3081
Subsequent work...............................................................................................................................3082
Subsequent work.........................................................................................................................3082
70 75 19 Removing and installing rear side-panel lining - as of MY 2005..............................................3085
Preliminary work..............................................................................................................................3085
Preliminary work.........................................................................................................................3085
Removing side-panel lining at rear...................................................................................................3085
Removing side-panel lining at rear.............................................................................................3085
Installing side-panel lining at rear.....................................................................................................3087
Installing rear side trim panel......................................................................................................3087
Subsequent work...............................................................................................................................3090
Subsequent work.........................................................................................................................3090
70 84 19 Removing and installing roof lining - as of MY 2005................................................................3092
Preliminary work..............................................................................................................................3092
Preliminary work.........................................................................................................................3092
Removing roof lining........................................................................................................................3092
Removing cover for motor for sliding roof.................................................................................3092
Disconnecting electric plug connection......................................................................................3093
Removing mounting saddle and pivot bearing for sun visor.......................................................3094
Removing headliner....................................................................................................................3095
Installing roof lining.........................................................................................................................3097
Fitting headliner..........................................................................................................................3098
Installing mounting saddle and pivot bearing for sun visor........................................................3100
Locking electric plug connection................................................................................................3101
Installing cover for sunroof motor...............................................................................................3102
Subsequent work...............................................................................................................................3103
Subsequent work.........................................................................................................................3103
70 85 19 Removing and installing rear roof lining - as of MY 2005........................................................3106
Removing rear roof lining.................................................................................................................3106
Removing rear roof trim panel....................................................................................................3106
Installing rear roof lining..................................................................................................................3107
Installing rear roof trim panel......................................................................................................3107
70 86 19 Removing and installing slide/tilt sunroof trim - as of MY 2005..............................................3110
Preliminary work..............................................................................................................................3110
Preliminary work.........................................................................................................................3110
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Diagnostic system: reading out fault memory and activating systems
Table of Contents
70 86 19 Removing and installing slide/tilt sunroof trim - as of MY 2005
Removing slide/tilt sunroof trim.......................................................................................................3110
Removing slide/tilt sunroof trim.................................................................................................3110
Additional instructions for removing the inner panels................................................................3111
Installing slide/tilt sunroof trim........................................................................................................3112
Additional instructions for fitting the inner panels.....................................................................3113
Installing slide/tilt sunroof trim...................................................................................................3113
Subsequent work...............................................................................................................................3115
Subsequent work.........................................................................................................................3115
72 01 19 Removing and installing front seat - as of MY 2005..................................................................3118
Removing front seat..........................................................................................................................3118
Removing seat rail cover.............................................................................................................3118
Undoing seat screws at front.......................................................................................................3119
Undoing seat screws at rear.........................................................................................................3120
Releasing electrical wire.............................................................................................................3120
Disconnecting central plug..........................................................................................................3121
Disconnecting electrical plug connection (power seat)...............................................................3122
Installing front seat...........................................................................................................................3123
Fastening electric line..................................................................................................................3123
Connecting electrical plug connection (power seat)...................................................................3125
Locking central plug....................................................................................................................3126
Tightening seat screws at rear.....................................................................................................3127
Tightening seat screws at the front..............................................................................................3128
Fit seat rail cover.........................................................................................................................3129
72 01 19 Removing and installing front seat - as of MY 2005..................................................................3132
Removing front seat..........................................................................................................................3132
Removing seat rail cover.............................................................................................................3132
Undoing seat screws at front.......................................................................................................3133
Undoing seat screws at rear.........................................................................................................3134
Releasing electrical wire.............................................................................................................3134
Disconnecting central plug..........................................................................................................3135
Disconnecting electrical plug connection (power seat)...............................................................3136
Disconnecting the electrical plug connection of the AWS control module................................3137
Installing front seat...........................................................................................................................3139
Fastening electric line..................................................................................................................3139
Locking the electrical plug connection of the AWS control module..........................................3140
Connecting electrical plug connection (power seat)...................................................................3141
Locking central plug....................................................................................................................3142
Tightening seat screws at rear.....................................................................................................3143
Tightening seat screws at the front..............................................................................................3144
Fit seat rail cover.........................................................................................................................3145
Subsequent work...............................................................................................................................3146
Subsequent work.........................................................................................................................3146
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