41 12 535 Replacing Complete Rear Luggage Compartment Floor (Tail Panel Removed)

Read contents of, see BODY, GENERAL .

Spot-weld bonding is used on the E63. Observe specific procedure. See 4100... SPOT-WELD BONDING STEEL PARTS or 4100... OPENING ADHESIVE BONDS .

Place vehicle on straightening bench.

Following new body parts are required (refer to EPC):

Fig 1: Luggage Compartment Floor For Right, Left And Sealing Cap

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View from vehicle floorpan:

Open weld joints in areas (1).

Fig 2: Weld Joints On Areas

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Open weld joints in areas (1).

Fig 3: Weld Joints On Areas

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Carry over the work step shown symmetrically to the other side of the vehicle.

Open weld joints in areas (1).

Open adhesive bond in area (2).

Installation:

see PLUG WELD in area (2).

Fig 4: Adhesive Bond And Weld Joint On Area

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Mark severance cut in accordance with measurement a and cut frame side member on left and right.

Measurement a=150 mm from center point of bore with dia. 20 mm.

Open weld joints in area (1).

Installation:

Weld in, see REINFORCING PANELS at all severance cuts.

Fig 5: Weld Joints

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Carry over the work step shown symmetrically to the other side of the vehicle.

Cut luggage compartment floor at edge (1).

Open weld joints in areas (2) and (3).

IMPORTANT: Do not shorten height of bushing in area (2).
Grind bushing down to nominal diameter only.

Fig 6: Luggage Compartment Floor And Weld Joint

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Open weld joints in area (1).

Cut luggage compartment floor in area (2) next to spot flange.

Open adhesive bonds in areas (3).

Installation:

Spot-weld in areas (3).

Fig 7: Luggage Compartment Floor, Weld Joint And Adhesive Bonds On Areas

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Installation:

Adjust luggage compartment floor to fit with straightening attachment or universal mount.

Before welding in, also adjust tail panel, rear lid and rear lights to fit.

Fit new part in area (1) from above.

Plug weld in area (1).

Fig 8: Plug Weld On Area

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