41 12 535 Replacing Complete Rear Luggage Compartment Floor (Tail Panel Removed)
Read contents of BODY, GENERAL .
Use only approved SPOT-WELDING APPARATUS for repairs.
Place vehicle on straightening bench.
Follow procedure for REPAIR STAGE 3 .
Following new body parts are required (refer to CONSUMABLES ):
- (1) Luggage compartment floor, left section
- (2) Frame side member, left
- (3) Frame side member, top left
- (4) Frame, luggage compartment floor
- (5) Frame side member, top right
- (6) Frame side member, right
- (7) Luggage compartment floor, right
- (8) Mounting for left and right bumper
- (9) Left C-pillar reinforcement (not shown)
Following CONSUMABLES are required:
| Material | Quantity |
|---|---|
| Adhesive K5b | 1 |
| Blind rivets N3 | 26 |
| Punch rivets N5 | 8 |
| EMC screws | 8 |
| Cleaning agent R1 | 1 |
| Cavity wax remover | 1 |
| Sealant D1 |
Removal of luggage compartment floor:
Operation is partially described on the left side. Right side identical.
Mark severance cuts (1) at edge of 20 mm dia. bore hole.
Cut side member (2).
Mark severance cuts (1) and cut.
Open weld joints in area (2) and remove luggage compartment floor (3).
Open welded connection in area (1).
Open welded connections in area (1).
Mark severance cut (2) next to reinforcement (3) and disconnect.
Open welded connections in area (1).
Remove luggage compartment floor and side member.
Installing side members
Adjust new parts to fit with alignment bracket or universal mounting.
Before welding in side member, also adjust tail panel, tailgate and rear lights to fit.
Weld REINFORCEMENT PLATES at the severance cuts (1).
Cut side member (2).
Preparation of new part, bonding technology:
Mark severance cut on luggage compartment floor frame in accordance with severance cut on vehicle + 15 mm extra material and cut.
Mark severance cuts on outer luggage compartment floor in accordance with severance cuts on vehicle + 15 mm extra material and cut.
Adjust new part in combination with tail panel to fit and secure.
In areas (1) and (2) set 4.2 mm dia. holes for blind rivets.
| Area | Number |
|---|---|
| 1 | 5 |
| 2 | 8 |
Remove new parts and deburr bore holes.
Installing luggage compartment floor:
Clean all bonding surfaces on new part and on vehicle with cleaning agent R1.
Apply adhesive to bonding surfaces.
Luggage compartment floor frame:
Install luggage compartment floor (1) and rivet in the areas (2) with 8 punch rivetsN5.
Luggage compartment floor, left and right:
Ensure to apply sufficient adhesive to the bonding surfaces when installing the new part!
Install new part and rivet with blind rivets.
In area (1) secure luggage compartment floor until adhesive has hardened at side member.
After hardening of the adhesive install 4 EMC SCREWS in the areas (1).