41 12 535 Replace Luggage Compartment Floor And Both Side Members (Tail Panel Trim Removed) (Non-Hybrid)

Read contents of BODY, GENERAL .

These repair instructions comprise the procedures for REPAIR STAGE 3 .

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

STRIP DOWN VEHICLE 

Place vehicle on straightening bench.

Following new body parts are required (refer to ELECTRONIC PARTS CATALOGUE ):

• (1) Wheel arch extension, left and right
• (2) Extension, side member, left and right
• (3) Fixture, bumper, left and right
• (4) Luggage compartment floor, rear

Following CONSUMABLES  are required:

Fig 1: Identifying Wheel Arch Extension, Side Member, Fixture, Bumper, Luggage Compartment Floor

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Removing side members and luggage compartment floor 

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

Fig 2: Identifying Luggage Compartment Floor Severance Cutting Dimension

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

Dimension a = 25 mm from component edge of front luggage compartment floor.

Open welded connections in area (2).

Remove trunk floor.

Open welded connections in area (1).

Fig 3: Identifying Dimension From Component Edge Of Front Luggage Compartment Floor

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Open welded connections in area (1).

Fig 4: Identifying Luggage Compartment Floor 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 5: Identifying Luggage Compartment Floor 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 Cutting Side Member Extension, Weld Joints Area

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

Open welded connections in area (3).

Remove side member extension (2).

Fig 7: Identifying Side Member Extension Welded Connections Area

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New part preparation 

Mark and sever the luggage compartment floor new part according to the severance cut on the vehicle + 20 mm additional material.

Disconnect required components from the new component wheel arch extension.

Flatten stampings (1) on both sides.

Fig 8: Identifying Flatten Stamping Area On Both Sides

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Adjust new parts to fit with alignment bracket or universal mounting.

Fig 9: Bending Side Member End Plate Outward

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Adjust luggage compartment well in combination with cross member and tail panel to fit and secure.

In areas (1) to (3), set 4.2 mm dia. holes for blind rivets.

Fig 10: Identifying Bore Holes For Blind Rivets

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Remove new parts and deburr bore holes.

Installing side members and luggage compartment floor: 

Install new parts with alignment bracket or universal mount and weld analogue to series standard:

• Extension, side member
• Wheel arch extension
• Mounting, bumper

Installing luggage compartment floor, middle: 

Clean all  bonding surfaces with cleaning agent R1.

Apply adhesive to bonding surfaces.

Install new part and rivet with blind rivets.

Perform MAG welding throughout to new part in area (1).

Set 20 mm MAG welds at a distance of 15 mm in area (2).

Fig 11: Identifying Luggage Compartment Floor MAG Welds Areas (Middle)

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