41 34 121 Replacing Complete Tail Panel And Luggage Compartment Floor
Read contents of BODY, GENERAL .
Use only an approved spot-welding apparatus for repairs! Place vehicle on straightening bench. Use portal fixture from set of attachments.
Necessary preliminary tasks: Remove tail panel .
Following new body parts are required
- Crossmember, luggage compartment floor
- Mounting, impact absorber
- Mountings RHT, rear (hardtop)
- Luggage compartment floor
- Side member, rear
- Luggage compartment well
- Mounting, tension strut
Following consumables are required:
CONSUMABLES
| Material | Quantity |
|---|---|
| Adhesive K5a | 1 |
| Blind rivets N1 | 21 |
| Cleaning agent R1 | 1 |
| Sealant D1 |
Removal of luggage compartment floor
View from vehicle underbody: Open welded connections in areas (1).
Operation is described on the left side. Right side identical.
Mark severance cut (1) in accordance with dimension and cut.
Measurement a = 20 mm from luggage compartment floor, front.
Mark severance cut (2) and cut.
Open welded connections in area (3).
Remove luggage compartment floor, luggage compartment well and side member.
Installation note: Weld new components in area (4) additionally.
New luggage compartment well part is installed with overlap in area of severance cut (1).
Preparation of new part:
Installation note: Tension strut mounting is bonded to luggage compartment well and riveted. All other new parts are welded during installation.
Prepare reinforcement plates at severance cuts on side members. Mark severance cut on new luggage compartment well part according to severance cut on vehicle + 20 mm material extra and cut.
Adjust new parts to fit with alignment bracket or universal mount and secure. Additionally adjust new parts to fit with tail panel, tailgate and rear lights. Position both mountings RHT, rear (1) with portal fixture from set of attachments.
View from below. Adjust tension strut mounting (1) with mounted torsion struts (2) to fit and secure. Set twenty one 4.2 mm holes for blind rivets in adhesive flange area. Remove new parts again and deburr holes.
Installing trailing link mounting
Clean all bonding surfaces (1) with cleaning agent R1. Apply adhesive to bonding surfaces (1). Rivet tension strut mounting (2) and luggage compartment well (3) with blind rivets N3.
Installation of luggage compartment floor Install new parts and reinforcement plates with alignment bracket or universal mount and weld. For mountings RHT rear, use portal fixture from set of attachments for positioning.