41 12 548 Replacing Rear Cross Member On Luggage Compartment Floor (Tail Panel Removed): Notes

Read contents of BODY, GENERAL .

STRIP DOWN VEHICLE .

Observe procedure for REPAIR STAGE 2 .

Following new body parts are required:

• (1) Cross member, luggage compartment floor, rear

Following CONSUMABLES  are required:

Fig 1: Identifying Cross-Member - Luggage Compartment Floor (Rear)

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Removing cross-member 

Open welded connections in areas (1).

Fig 2: Identifying Weld Joints Area

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Open welded connections in areas (1).

Fig 3: Identifying Weld Joints Area

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View from below.

Operation is described on the left side. Right side identical.

Open welded connections in area (1).

Remove cross member.

Fig 4: Identifying Weld Joints Area

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New part preparation 

Adjust cross-member in combination with tail panel to fit and secure.

Set three 4.2 mm dia. holes for blind rivets in area (1).

Set four 4.2 mm dia. holes for blind rivets in areas (2).

Set holes with adjusted tail panel in area (3).

Remove new parts again and deburr holes.

Fig 5: Identifying Blind Rivets Holes Area

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Installing cross-member: 

Clean all bonding surfaces on new part and on vehicle with cleaning agent R1.

Apply adhesive to bonding surfaces (1) and to corresponding bonding surfaces on new part.

Fig 6: Identifying Bonding Surfaces

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Install cross-member and rivet in area (1) with blind rivets.

Rivet cross-member in combination with tail panel in area (2).

Fig 7: Identifying Cross-Member And Tail Panel Rivet Area

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After hardening of the adhesive install 4 EMC SCREWS  in the areas shown (1).

Fig 8: Identifying EMC Screws Installation Area

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