Removing side members and luggage compartment floor

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

Open welded connections in area (1).

Fig 1: Identifying Welded Connections Area

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Open welded connections in area (1).

Fig 2: Identifying Welded Connections Area

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Roughly mark severance cut (1) and cut.

Open welded connections in area (2).

Remove luggage compartment floor (3).

Fig 3: Identifying Severance Cut, Welded Connections Area And Luggage Compartment Floor

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View from below.

Open welded connections in area (1).

Fig 4: Identifying Welded Connections Area

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IMPORTANT: Cut outer metal panel only.

Mark severance cut (1) approx. 6 mm from edge of component of front luggage compartment floor and disconnect.

Open welded connections in area (2).

Remove trunk floor.

Installation note:

Luggage compartment floor is installed with overlap in area of severance cut (1).

Fig 5: Identifying Severance Cut And Welded Connections Area

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Mark severance cut (1) flush with side member and cut.

After cutting side member extension (2), open weld joints in area (3).

Fig 6: Identifying Severance Cut, Side Member Extension And Weld Joints Area

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Mark severance cut (1) flush with side member and cut.

Remove side member extension (2).

Open welded connections in area (3).

Fig 7: Identifying Severance Cut, Side Member Extension And Welded Connections Area

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New part preparation

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

Open welded connections in area (1).

Fig 8: Identifying Welded Connections Area

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Open welded connections in area (1).

Remove metal section (2).

Fig 9: Identifying Welded Connections Area And Metal Section

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NOTE: To adjust new parts to fit, bend side member end plate (1) outwards slightly.

Adjust new parts, side members to fit with alignment bracket or universal mount.

Fig 10: Bending Side Member End Plate

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Set down luggage compartment well and adjust in combination with cross member and tail panel to fit and secure.

In areas (1) and (2) set 4.2 mm dia. holes for blind rivets.

Area	Number
1	5 of
2	8

Fig 11: Identifying Blind Rivets Holes Area

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Adjust side member to fit and secure.

In areas (1) to (4), set 4.2 mm dia. holes for blind rivets.

Area	Number
1	1
2	4
3	4
4	2

Fig 12: Identifying Blind Rivets Holes Area

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In area (5) prepare new parts for MAG welding.

Adjust boot floor laterally (1) to fit and secure.

Set 5 4.2 mm dia. bore holes in area (2).

Fig 13: Identifying Boot Floor And Bore Holes Area

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Set 3 4.2 mm dia. bore holes in area (1).

Fig 14: Identifying Bore Holes Area

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Set 11 4.2 mm dia. bore holes in area (1).

Remove new parts and deburr bore holes.

Fig 15: Identifying Bore Holes Area

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