41 12 557 Replacing Middle Luggage Compartment Floor Section (Tail Panel Removed)

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Read contents of BODY, GENERAL .

STRIP DOWN VEHICLE .

NOTE: Observe new procedure for bonding and riveting (REPAIR STAGE 2) .

Following new body parts are required:

(1) Mounting, tension strut
(2) Luggage compartment well
(3) Crossmember, luggage compartment floor, rear

Following CONSUMABLES are required:

CONSUMABLES REFERENCE CHART

Material	Quantity
Adhesive K5b	1
Blind rivets N3	21
EMC screws	2
CleanerR1	1
Sealing compound D1

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Removal of luggage compartment floor

View from below.

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

Open weld joints in area (1).

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

Measurement a = 20 mm

Open weld joints in area (2).

Remove luggage compartment well and crossmember.

NOTE: Earth support point (3) remains on vehicle.

New part preparation

Mark new luggage compartment well part in accordance with severance cuts on vehicle + 20 mm extra material and cut.

Set down luggage compartment well (1) from above and adjust in combination with crossmember (2) and TAIL PANEL to fit and secure.

Set fourteen 4.2 mm dia. holes for blind rivets in area (3).

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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 for blind rivets with adjusted tail panel in area (3).

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View from below.

Adjust tension strut mounting (1) with mounted torsion struts (2) to fit and secure.

Set twenty one 4.2 mm dia. holes for blind rivets in adhesive flange area.

Remove all new parts again and deburr holes.

NOTE: 6 holes are sufficient for positioning the component.
Make all further holes for blind rivets if necessary on removed components.

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

Installation of luggage compartment floor

Clean all bonding surfaces (1) with cleaning agent R1.

Apply adhesive K5b to bonding surfaces (1).

Rivet tension strut mounting (2) and luggage compartment well (3) with blind rivets N3.

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Clean all bonding surfaces (1) on new part and on vehicle with cleaning agent R1.

Apply adhesive K5b to bonding surfaces (1) and to corresponding bonding surfaces on new part.

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Fit luggage compartment well (2) and rivet in area (1) with blind rivets N3.

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Installation of crossmember

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

Apply adhesive K5b to bonding surfaces (1) and to corresponding bonding surfaces on new part.

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Install crossmember and rivet in area (1) with blind rivets.

Rivet crossmember in combination with tail panel in area (2).

IMPORTANT: When installing the crossmember, make sure there is sufficient adhesive on the bonding surfaces.

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NOTE: After adhesive has hardened:
Install 2 EMC SCREWS in area of side member/rear crossmember.