Body, Front
Body, Front
=> [ Lock Carrier, Service Position ]
=> [ Lock Carrier with Attachments ]
=> [ Front Brace ]
=> [ Front Fender ]
=> [ Lower Bracket for Fender ]
=> [ Center Bracket for Fender ]
Lock Carrier, Service Position
Special tools, testers and auxiliary items required
• 3411 Guide Rods
• For the service position, do not disconnect any refrigerant or coolant lines and no lines for power steering fluid circuit.
• Electrical harness connectors must not be disconnected.
• When installing lock carrier, make sure that no wires or hoses are pinched.
1 - Lock carrier
• Removal => [ Lock Carrier with Attachments ].
• For service position, front wheelhousing liner/front section removed.
• Bumper cover removed.
• Remove bolts - 2 -; - 7 -; - 9 - and - 10 -.
• Note the different lengths of bolts - 9 - and - 10 -.
• Guide Rods 3411 must be screwed respectively into threaded holes of both outer bolts - 10 -.
• Lock carrier can now be pulled approx. 10 cm toward front and secured in this position.
2 - Socket-head bolt
• M8•16
• 23 Nm
3 - Front brace
• Installation position => [ Front Brace ].
4 - Torx(R) screw
• 25 Nm.
5 - Torx(R) screw
• 25 Nm.
6 - Bracket for front brace
7 - Socket-head bolt
• 23 Nm.
• Installation position => [ Front Brace ]
8 - Combination bolt
• 10 Nm.
9 - Socket-head bolt
• M8•30 mm long
• 23 Nm
10 - Socket-head bolt
• 23 Nm
• M8•55 mm long
• For service position, only remove left bolt at top on left side and right bolt at top on right side.
• Screw in Guide Rods 3411 into free threaded holes => [ 3411 special tool ]
• Remove bolts - 2 -; - 7 -; - 9 - and - 10 -.
• Bolt - 7 - is installed behind front wheelhousing liner/front section.
• Pull off lock carrier on Guide Rods 3411 toward front and secure.
3411 special tool
- Screw special tool 3411 into threaded holes as shown.
- For service position, lock carrier can then be pulled toward approx. 10 cm on special tool and secured in this position.
Installing lock carrier
- When installing, make sure that no wires or hoses - arrows - are pinched between lock carrier and brace - 1 - or fender - 2 -.
Lock Carrier with Attachments
1 - Lock carrier
• Removing:
• Front section of front wheelhousing liner removed => [ Front Wheel Housing Liner, Front Section ] Service and Repair.
• Remove bumper.
• Disengage release cable for hood lock => [ Hood Lock Cable ] Service and Repair.
• Remove intake air duct between lock carrier and air cleaner housing at lock carrier.
• Before removing, disconnect all electrical harness connectors.
• Disconnect coolant lines and drain coolant => [ Drain coolant circuit ]
• Fill with coolant and ventilate system.
• Discharge A/C refrigerant system
• Disconnect refrigerant lines from condenser at bottom => [ Condenser Refrigerant Lines, Connecting and Disconnecting ] Condenser Refrigerant Lines, Connecting and Disconnecting.
• Disconnect hoses to power steering oil cooler below at condenser => [ Condenser Refrigerant Lines, Connecting and Disconnecting ] Condenser Refrigerant Lines, Connecting and Disconnecting.
• Disconnect hose for air guide.
• Pull off gasket for left and right front flap at juncture of fender at lock carrier - 1 -.
• Remove bolts - 2 -;- 7 -; - 9 - and - 10 -.
• Bolt - 7 - is installed behind front wheelhousing liner/front section.
• Pull lock carrier off toward front.
• Installation:
• Install in reverse order of removal.
• Headlights must be adjusted anew.
• Adjusting:
• Lock carrier - 1 - must be aligned between the fenders.
• If the fenders and the front flap are also to be changed, then adjust these to each other first.
• A second mechanic is needed to hold the lock carrier - 1 -.
2 - Socket-head bolt
• 23 Nm
3 - Front brace
• Installation position => [ Front Brace ]
4 - Torx(R) screw
• 25 Nm
5 - Socket-head bolt
• 30 Nm
6 - Bracket for front brace
7 - Socket-head bolt
• 23 Nm
• Installation position => [ Front Brace ].
8 - Combination bolt
• 10 Nm
9 - Socket-head bolt
• M8•30 mm long
• 23 Nm
10 - Socket-head bolt
• 23 Nm
• M8•55 mm long
Drain coolant circuit
- Place drip tray (V.A.G 1306) underneath engine.
- Disconnect coolant hose - 1 - to drain coolant.
- Drain refrigerant circuit.
Front Brace
Assembly overview
1 - Front brace
2 - Torx(R) bolts
• 25 Nm.
3 - Bolting points for fender flange
4 - Socket-head bolt
• 23 Nm
• When removing lock carrier, remove bolt here.
5 - Bolting points for lower fender flange
6 - Torx(R) bolts
• 25 Nm.
7 - Bolting points at longmember connecting piece
8 - Bolting points at impact absorber
9 - Socket-head bolt
• 30 Nm.
Remove dome brace
- Remove cylinder combination bolts - 1 - tightening torque 45 Nm.
- Remove cylinder combination bolts - 2 - tightening torque 3 Nm.
- -Item 3- plenum chamber, front section
- -Item 4- suspension strut holder cap
Arrow in illustration points in direction of travel.
- Remove cylinder combination bolts - 1 - tightening torque 9 Nm.
- -Item 2- transverse beam of suspension strut cap
- -Item 3- crossmember of front window
- -Item 4- support of connecting piece of window crossmember
Front Fender
Assembly overview
1 - Combination bolt
• 10 Nm
2 - Fender
• Remove bumper cover => [ Front Bumper Cover ] Front Bumper Cover.
• Remove wheelhousing liner => [ Front Wheel Housing Liner, Front Section ] Service and Repair.
• Remove headlights => Repair Manual, Electrical Equipment.
• Disconnect electrical connectors for the side blinkers.
• Remove rear bracket for fender => [ Lower Bracket for Fender ].
• Remove bolts - 1 -, - 3 -, - 4 -, - 5 - and - 7 - and remove fender.
3 - Combination bolts (2x)
• 8 Nm.
4 - Combination bolt
• 8 Nm
• Bolts are accessible only after removing lower bracket for fender => [ Lower Bracket for Fender ].
5 - Combination bolt
• 8 Nm
6 - Front brace
• Bolting points => [ Front Brace ].
7 - Combination bolt
• 8 Nm
• Bolts on the left side are located behind pump for level control system
• Bolts on the left side are located behind washer fluid reservoir.
Lower Bracket for Fender
Assembly overview
1 - Fender
2 - Bracket for fender
• Remove upper cover for sill panel cover
• Remove bolts on upper sill panel cover up to approx. B-pillar.
• Press sill panel cover to the side far enough until bolts for bracket can be removed.
• Remove bracket and remove bolts for fender at bottom.
3 - Torx(R) screw
• 8 Nm
4 - Outer A-pillar
Center Bracket for Fender
Assembly overview
1 - Socket-head bolt
• 25 Nm
• Bolted to impact absorber from rear.
2 - Brace
• Bolting points.
3 - Torx(R) screw
• 8 Nm
4 - Torx(R) screw
• 25 Nm
5 - Bracket for fender
6 - Torx(R) bolts
• 8 Nm