4112535 Replacing Complete Rear Luggage Compartment Floor (Tail Panel Removed)

Read contents of BODY, GENERAL .

STRIP DOWN vehicle.

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.

Follow procedure for REPAIR STAGE 3 .

Following new body parts are required

Luggage compartment floor, left section
Frame side member, left
Frame side member, top left
Frame, luggage compartment floor
Frame side member, top right
Frame side member, right
Luggage compartment floor, right
Mounting for left and right bumper

Following CONSUMPTION MATERIALS are required:

CONSUMABLES

Material	Quantity
Adhesive K5b	1
R1 cleaning agent	1
Blind rivets N3	14
Punch rivets N5	8
EMC screws	2
Sealant D1
Cavity wax remover

Fig 1: Identifying Frame Side Member And Luggage Compartment Floor

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Removing luggage compartment floor

Carry over the work steps shown symmetrically to the other side of the car.

Mark severance cuts (1) at edge of 20 mm diameter bore hole.

Cut frame side member (2).

Fig 2: Identifying Severance Cut And Frame Side Member

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Mark severance cuts (1) and cut.

IMPORTANT: Cut only outer panels.

Open welded connections in areas (2) and remove luggage compartment floor (3).

Fig 3: Identifying Luggage Compartment Floor Severance Cuts And Welding Areas

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Saloon and Coupe only:

Open welded connections in area (1).

Fig 4: Identifying Welding Areas (Saloon And Coupe Only)

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Touring only:

Open weld joints in areas (1) and (2).

Fig 5: Identifying Welding Areas (Touring Only)

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Open welded connections in area (1).

Installation note:

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.

Fig 6: Identifying Side Member Welding Areas

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Weld in REINFORCEMENT PLATES at severance cuts.

Cut side member (2).

Fig 7: Identifying Reinforcement Plate Severance Cuts

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Installation of luggage compartment floor

Carry over the work steps shown symmetrically to the other side of the car.

IMPORTANT: Do not grind new parts and body in area of bonding surfaces.

Clean bonding surfaces with cleaning agent R1.

Apply adhesive K5b.

Installing luggage compartment floor:

Replace along similar lines to LUGGAGE COMPARTMENT FLOOR, CENTRE .

Fig 8: Identifying Luggage Compartment Floor Severance Cuts And Welding Areas

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Apply adhesive K5b in areas (1) and (2).

Fig 9: Identifying Adhesive Applying Areas

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Saloon and Coupe only:

In area (1) apply adhesive K5b and set 7 blind rivets N3.

Fig 10: Identifying Adhesive Applying Areas (Saloon And Coupe Only)

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Touring only:

In areas (1) and (2) apply adhesive K5b and set 6 blind rivets N3.

Fig 11: Identifying Adhesive Applying Areas (Touring Only)

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In areas (1) and (2) secure luggage compartment floor to side member.

Fig 12: Identifying Areas For Securing Luggage Compartment Floor To Side Member

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After adhesive has hardened, fit 2 EMC SCREWS in area of earth support points.