41 12 590 Replace Luggage Compartment Floor (Complete, I.E. Including Inner Wheel Arch Section On The Left Or Right, Tail Panel Removed)

Read contents of BODY, GENERAL .

Remove or cover those vehicle components in the repair area which are susceptible to heat or dust.

Use only approved SPOT-WELDING APPARATUS  for repairs.

Place vehicle on straightening bench.

Following new body parts are required (see CONSUMABLES ):

• (1) Upper part of the luggage compartment floor
• (2) Rear axle support
• (3) Wheel arch, rear, inner half, left

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Removal of luggage compartment floor 

Mark severance cut in accordance with Dimension a and cut.

Dimension a = 40 mm behind side member support (1).

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Mark severance cut (1) and cut.

Open welded connections in areas (2).

Installation note: 

Weld new components in areas (3) additionally.

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Mark severance cut (1) in accordance with dimension a and disconnect rear axle support.

Dimension a = 70 mm from the rear axle bushing fixture.

Open welded connections in area (2).

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Open welded connections in area (1).

Installation note: 

Weld new components in areas (2) additionally.

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Coupe only: 

Open welded connections in area (1).

Installation note: 

Additionally weld new parts in this area (2)

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Open welded connections in areas (1) and (2).

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Open welded connections in area (1).

Installation note: 

Additionally weld new part in this area (2).

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Mark severance cut (1) in the center and disconnect.

Disconnect floor panel and cross member underneath.

Open welded connections in area (2).

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New part preparation 

Mark severance cuts on new parts according to severance cuts on vehicle and sever.

Prepare REINFORCEMENT PLATES  at severance cuts.

Mark severance cut (1) in accordance with dimension and cut.

Dimension a=170 mm

Measurement b = 110 mm

Installation note: 

The removed part will be refitted.

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Open welded connections in area (2).

Installation note: 

The removed part will be refitted.

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Open welded connections in area (1).

Mark and disconnect severance cuts (2) according to the severance cuts on the vehicle.

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Open welded connections in area (1).

Installation note: 

The removed part (2) will be refitted.

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Open welded connections in area (1).

Mark severance cut (2) in accordance with vehicle and cut.

Insert new parts using an alignment bracket or a universal mount and fit as a combination of tail panel, tailgate and rear lights.

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Installation of luggage compartment floor 

Install new parts and reinforcement plates with alignment bracket or universal mount and weld.

Weld new parts in the following sequence:

• (1) Rear axle support
• (2) Upper part of the luggage compartment floor
• (3) Support, frame side member
• (4) Wheel arch, rear, inner half

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For reasons of accessibility, the sequence to fit the components during repair work differs from that during series production.

In this area (1) insert new part from top, adjust and weld.

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