Edition 06.2018. Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.
Repair Group overview for Body Repairs
Repair Group
00 – Technical data
50 – Body – front
51 – Body – centre
53 – Body – rear
CONTENTS
- 00 – Technical data
- 1 Basic instructions
- 2 Safety instructions
- 3 Specific model data
- 4 Sticker
- 4.1 Location of data labels
- 5 Bodywork tolerances
- 5.1 Panel gaps, front
- 5.2 Body panel gaps, rear section
- 6 Dimensions
- 6.1 Bodywork dimensions, front section
- 6.2 Bodywork dimensions, central section – lateral
- 6.3 Bodywork dimensions, rear section
- 6.4 Floor dimensions, without mechanics
- 7 Body elements made from ultra high strength steel
- 7.1 Locations of the components made from ultra high strength steel
- 8 Laser welding, MIG welding and MIG brazing welding (CuSi3)
- 8.1 Laser hybrid weld positions
- 8.2 Positions for MIG welding and MIG brazing
- 9 Adhesive
- 9.1 Positions for structural glue
- 9.2 Position for partial structural glue
- 10 Products for corrosion protection and noise insulation
- 10.1 Noise insulation
- 10.2 Damper blades
- 10.3 Cavity wax
- 10.4 Underseal
- 10.5 Sealing compound
- 11 Reshaping work, access zones
- 11.1 Access zones for manual straightening
- 12 Inspection areas of bodywork depending on the type of collision
- 12.1 Frontal collision
- 12.2 Front side impact
- 12.3 Central side impact
- 12.4 Rearpside impact
- 13 Platform repairs
- 13.1 Work on the straightening jig with the MZ-SAT 5310 system – mechanics installed . .
- 13.2 Work on the straightening jig with the MZ-SAT 5310 system – mechanics removed . .
- 13.3 Work on the straightening jig with the SAT 5305 electrical system
- 14 Check points for the platform
- 14.1 Platform check points, with mechanics fitted
- 14.2 Platform reference points, with mechanics removed
- 14.3 Portal gauge
- 14.4 Laser welding
- 14.5 Repair methods for replacing body parts
- 50 – Body – front
- 1 Breakdown of spare parts
- 1.1 Breakdown of spare parts, Leon 2-door
- 1.2 Breakdown of spare parts, Leon 4-door
- 1.3 Spare part breakdown, Leon ST
- 2 Engine console – engine bracket: replacement, partial
- 2.1 Initial removal of exterior and interior components
- 2.2 Replacement part
- 2.3 Cutting locations
- 2.4 Preparation for new parts
- 2.5 Straightening the joint zones
- 2.6 Part assembly
- 3 Upper outer sill: replace, complete part
- 3.1 Initial removal of exterior and interior components
- 3.2 Replacement part
- 3.3 Special characteristics of the repairs
- 3.4 Cutting locations
- 3.5 Preparation for new parts
- 3.6 Straightening the joint zones
- 3.7 Part assembly
- 3.8 Final fitting operations
- 4 Upper outer sill: replace, part
- 4.1 Initial removal of exterior and interior components
- 4.2 Replacement part
- 4.3 Cutting locations
- 4.4 Preparation for new parts
- 4.5 Straightening the joint zones
- 4.6 Part assembly
- 5 Upper inner sill: replace
- 5.1 Initial removal of exterior and interior components
- 5.2 Initial removal of bodywork elements
- 5.3 Replacement part
- 5.4 Special characteristics of the repairs
- 5.5 Cutting locations
- 5.6 Preparation for new parts
- 5.7 Straightening the joint zones
- 5.8 Part assembly
- 5.9 Final fitting operations
- 6 Front wheel housing: replace, complete part
- 6.1 Initial removal of exterior and interior components
- 6.2 Initial removal of bodywork elements
- 6.3 Replacement part
- 6.4 Special characteristics of the repairs
- 6.5 Cutting locations
- 6.6 Preparation for new parts
- 6.7 Straightening the joint zones
- 6.8 Part assembly
- 6.9 Final fitting operation
- 7 Replace front wheel housin gpanel,epartialrm .ti. ■
- 7.1 Initial removal of exterior and interior components
- 7.2 Replacement part
- 7.3 Cutting locations
- 7.4 Preparation for new parts
- 7.5 Straightening the joint zones
- 7.6 Part assembly
- 7.7 Final fitting operations
- 8 Longitudinal beam cover plate: replacement, complete part
- 8.1 Initial removal of exterior and interior components
- 8.2 Initial removal of bodywork elements
- 8.3 Replacement part
- 8.4 Special characteristics of the repairs
- 8.5 Cutting locations
- 8.6 Preparation for new parts
- 8.7 Straightening the joint zones
- 8.8 Part assembly
- 8.9 Final fitting operations
- 9 Front longitudinal member: replacement, complete part . . .
- 9.1 Initial removal of exterior and interior components
- 9.2 Initial removal of bodywork elements
- 9.3 Replacement part
- 9.4 Special characteristics of the repairs
- 9.5 Cutting locations
- 9.6 Preparation for new parts
- 9.7 Straightening the joint zones
- 9.8 Adjusting
- 9.9 Part assembly
- 9.10 Final fitting operations
- 10 Front sill: replacement, partial
- 10.1 Initial removal of exterior and interior components
- 10.2 Initial removal of bodywork elements
- 10.3 Replacement part
- 10.4 Cutting locations
- 10.5 Preparation for new parts
- 10.6 Straightening the joint zones
- 10.7 Adjusting
- 10.8 Part assembly
- 10.9 Final fitting operations
- 11.2 Initial removal of bodywork elements
- 11.3 Replacement part
- 11.4 Cutting locations
- 11.5 Preparation for new parts
- 11.6 Straightening the joint zones
- 11.7 Adjusting
- 11.8 Part assembly
- 11.9 Final fitting operations
- 12 Sill end: replace, complete part
- 12.1 Initial removal of exterior and interior components
- 12.2 Replacement part
- 12.3 Cutting locations
- 12.4 Preparation for new parts
- 12.5 Straightening the joint zones
- 12.6 Part assembly
- 13 Repair the thread for securing the subframe
- 13.1 Contents of thread repair kit
- 13.2 Repairing thread
- 1 Breakdown of spare parts
- 51 – Body – centre
- 1 Breakdown of spare parts
- 1.1 Breakdown of spare parts, Leon 2-door
- 1.2 Breakdown of spare parts, Leon 4-door
- 1.3 Spare part breakdown, Leon ST
- 2 Breakdown of spare parts (Panoramic roof)
- 2.1 Parts breakdown (panoramic roof), Leon 2-door
- 2.2 Parts breakdown (panoramic roof), Leon 4-door
- 2.3 Parts breakdown (panoramic roof), Leon ST
- 3 Roof: replace, complete part
- 3.1 Replacement of roof, full part, Leon 2-door
- 3.2 Replacement of roof, full part, Leon 4-door
- 3.3 Replacement of roof, complete, Leon ST
- 4 Panoramic roof: replace, complete part
- 4.1 Replacement of panoramic roof, full part, Leon 2-door
- 4.2 Replacement of panoramic roof, full part, Leon 4-door
- 4.3 Replacement of panoramic roof, complete, Leon ST
- 5 Front roof crossbeam: replace, complete part
- 5.1 Replacement of front cross member, full part, Leon 2-door
- 5.2 Replacement of front cross member, full part, Leon 4-door
- 5.3 Replacement of front cross member, full part, Leon ST
- 6 Replace front cross member, replace panoramic roof, full part
- 6.1 Front cross member, replace panoramic roof, full part, Leon 2-door . .
- 6.2 Front cross member, replace panoramic roof, full part, Leon 4-door . .
- 6.3 Front cross member, replace panoramic roof, full part, Leon ST . . . .
- 7 Central roof beam: replace, complete part
- 7.1 Replacement of middle cross member, full part, Leon 2-door
- 7.2 Replacement of middle cross member, full part, Leon 4-door
- 7.3 Replacement of middle cross member, full part, Leon ST
- 8 Rear roof crossbeam: replace, complete part
- 8.1 Replacement of rear cross member, full part, Leon 2-door
- 8.2 Replacement of rear cross member, full part, Leon 4-door
- 8.3 Replacement of rear cross member, full part, Leon ST
- 9 Roof member: replace
- 9.1 Replace roof member, Leon 2-door
- 9.2 Replace roof member, Leon 4-door
- 9.3 Replaced roof
- 10 Hinge pillar: replace, complete part
- 10.1 Replace hinge column, full part, Leon 2-door
- 10.2 Replace hinge column, full part, Leon 4-door
- 10.3 Replace hinge column, complete, Leon ST
- 11 Reinforcement of the hinge pillar: replace, complete part
- 11.1 Reinforcement for crossbeam: replace, complete part, Leon 2-door . .
- 11.2 Reinforcement for crossbeam: replace, complete part, Leon 4-door . .
- 11.3 Replace reinforcement for crossbeam, complete part, Leon ST
- 12 Centre B-pillar: replace, complete part
- 12.1 B-pillar: replace, complete part, Leon 4-door
- 12.2 B-pillar: replace, complete part, Leon ST
- 13 Reinforcement centre B-pillar: replace, complete part
- 13.1 Reinforcement for B-pillar: replace, complete part, Leon 2-door . . . .
- 13.2 Reinforcement for B-pillar: replace, complete part, Leon 4-door . . . .
- 13.3 Reinforcement for B-pillar: replace, complete part, Leon ST
- 14 Lower outer sill: replace, complete part
- 14.1 Outer lower sill: replace, complete part, Leon 2-door
- 14.2 Outer lower sill: replace, complete part, Leon 4-door
- 14.3 Outer sill: replace, complete part, Leon ST
- 15 Lower outer sill: replace, part
- 15.1 Replace lower outer sill, part, Leon 4-door
- 15.2 Replace outer sill, part, Leon ST
- 16 Lower inner sill: replace, complete part
- 16.1 Replace inner lower sill, complete part, Leon 2-door
- 16.2 Replace inner lower sill, complete part, Leon 4-door
- 16.3 Replace inner sill, complete part, Leon ST
- 17 Lower inner sill: replace, part
- 17.1 Replace inner lower sill, partial, Leon 2-door
- 17.2 Replace inner lower sill, partial, Leon 4-door
- 17.3 Replace inner sill, partial, Leon ST
- 18 Replacing the longitudinal member external seat guide
- 18.1 Replacement of outer longitudinal member seat guide, Leon 2-door
- 18.2 Replacement of outer longitudinal member seat guide, Leon 4-door and ST .
- 19 Seat guide crossbeam: replace, complete part
- 19.1 Seat guide crossbeam: replace, complete part, Leon 2-door
- 19.2 Seat guide crossbeam: replace, complete part, Leon 4-door and ST
- 20 Replace longitudinal member inner seat guide
- 20.1 Initial removal of exterior and interior components
- 20.2 Cutting locations
- 20.3 Preparation for new parts
- 20.4 Straightening the joint zones
- 20.5 Part assembly
- 1 Breakdown of spare parts
- 53 – Body – rear
- 1 Breakdown of spare parts
- 1.1 Breakdown of spare parts, Leon 2-door
- 1.2 Breakdown of spare parts, Leon 4-door
- 1.3 Spare part breakdown, Leon ST
- 2 End plate: replace, complete part
- 2.1 Replace lock plate, full part, Leon 2-door
- 2.2 Replace lock plate, full part, Leon 4-door
- 2.3 Replace lock plate, complete, Leon ST
- 3 Reception plate: replace, complete part
- 3.1 Replace mounting plate, full part, Leon 2-door
- 3.2 Replace mounting plate, full part, Leon 4-door
- 3.3 Replace mounting plate, complete, Leon ST
- 4 Reception plate: replacement, partial
- 4.1 Replace reception plate, partial, Leon 2-door
- 4.2 Replace reception plate, partial, Leon 4-door
- 4.3 Replace reception plate, partial, Leon ST
- 5 Replace extension rear side panel
- 5.1 Initial removal of exterior and interior components
- 5.2 Replacement part
- 5.3 Special characteristics of the repairs
- 5.4 Cutting locations
- 5.5 Preparation for new parts
- 5.6 Straightening the joint zones
- 5.7 Part assembly
- 5.8 Final fitting operations
- 6 Water drainage canal: replacement, partial
- 6.1 Replace water drain channel, partial, Leon 2-door
- 6.2 Replace water drain channel, partial, Leon 4-door
- 6.3 Replace water drain channel, partial, Leon ST
- 7 End crossbeam: replace, complete part
- 7.1 Replace lock plate crossbeam, complete part, Leon 2-door
- 7.2 Replace lock plate crossbeam, complete part, Leon 4-door
- 7.3 Replace cross beam lock plate, complete part, Leon ST
- 8 Replace extension side of luggage compartment floor
- 8.1 Replace extension side of luggage compartment floor, Leon 4-door
- 8.2 Replace extension side of luggage compartment floor, Leon ST
- 9 Luggage compartment floor: replace, complete part
- 9.1 Replace luggage compartment floor, full part, Leon 2-door
- 9.2 Replace luggage compartment floor, full part, Leon 4-door
- 9.3 Replace luggage compartment floor, complete, Leon ST
- 10 Replace luggage compartment floor, full part (Version CNG)
- 10.1 Replace luggage compartment floor, full part, (version CNG) , Leon 4-door
- 10.2 Replace luggage compartment floor, full part, (version CNG) , Leon ST . .
- 11 Rear sill: replace, part
- 11.1 Replace rear sill, part, Leon 2-door
- 11.2 Replace rear sill, part, Leon 4-door
- 11.3 Replace rear sill, partial, ST
- 12 Replace rear longitudinal member extension
- 12.1 Initial removal of exterior and interior components
- 12.2 Initial removal of bodywork elements
- 12.3 Replacement part
- 12.4 Special characteristics of the repairs
- 12.5 Cutting locations
- 12.6 Preparation for new parts
- 12.7 Straightening the joint zones
- 12.8 Adjusting
- 12.9 Part assembly
- 13 Replace rear sill end section
- 13.1 Initial removal of exterior and interior components
- 13.2 Initial removal of bodywork elements
- 13.3 Replacement part
- 13.4 Special characteristics of the repairs
- 13.5 Cutting locations
- 13.6 Preparation for new parts
- 13.7 Straightening the joint zones
- 13.8 Adjusting
- 13.9 Part assembly
- 14 Replace rear side flank, full part
- 14.1 Replacement of rear side flank, full part, Leon 2-door
- 14.2 Replacement of rear side flank, full part, Leon 4-door
- 14.3 Replacement of rear side flank, full part, Leon ST
- 15 Replace rear inner side flank, full part
- 15.1 Replacement of rear inner side flank, full part, Leon ST
- 16 Replace rear inner side flank, partial
- 16.1 Replacement of rear inner side flank, partial, Leon ST
- 17 Rear outer wheel housing: replace, complete part
- 17.1 Front front outer wheel housing liner, full part, Leon 2-door
- 17.2 Front front outer wheel housing liner, full part, Leon 4-door
- 17.3 Front front outer wheel housing liner, full part, Leon ST
- 1 Breakdown of spare parts
Language: English
Format: PDF
Pages: 1012
