Replacing Luggage Compartment Floor And Right Side Member (Right Side Panel And Tail Panel Removed)

Read contents of body, general; refer to CONTENTS OF BODY, GENERAL .

STRIP DOWN VEHICLE. 

Place vehicle on straightening bench.

Observe procedure of REPAIR TECHNIQUES, REPAIR STAGE 3 .

The following new parts are required (refer to appropriate parts information ):

1. Luggage compartment well
2. Luggage compartment floor, rear
3. Luggage compartment well, right
4. Bottom right side member
5. Frame side member, top right
6. Luggage compartment floor, right

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The following consumables are required (refer to OVERVIEW OF CONSUMABLES (ELECTRONIC PARTS CATALOG) .

Material	Quantity
Adhesive K5a	2
Blind rivet N3	11
Blind rivet N6	8
EMC screw	4
Cleaning agent R1	1
Sealant D1

Removal: 

Open welded connections in area (1).

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Open welded connections in area (1).

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Mark severance cut (1) next to reinforcement (2) and disconnect.

Open welded connections in area (3).

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Open welded connections in area (1).

Remove the luggage compartment floor.

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Mark and cut severance cut (1) through Ø 20 mm hole.

Cut side member.

Mark severance cut (2) through elongated hole for MAG weld seam and cut.

Open welded connections in areas (3).

Remove side member.

Preparation of new part: 

Mark severance cuts on side member in accordance with severance cuts on vehicle and cut.

Mark severance cut on luggage compartment floor in accordance with severance cut on vehicle + 15 mm for extra material and cut.

Prepare for severance cuts on the side member reinforcement plates; refer to WELDING IN REINFORCEMENT PLATE (SHEET STEEL) .

Adjust new parts with alignment bracket or universal mount and in conjunction with side wall and tail panel and secure.

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In areas (1) to (3), set bore holes Ø4.2 mm for blind rivet.

Area	Number
1	5
2	6
3	4 of

Remove new parts and deburr bore holes.

Installation of side member and luggage compartment well: 

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

1. Extension, bottom side member
2. Extension, top side member
3. Luggage compartment well, left
4. Luggage compartment well

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Installation of right luggage compartment floor: 

Install new part and weld in area (1).

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Installation of rear luggage compartment floor: 

Clean all  bonding surfaces with cleaning agent R1.

Apply adhesive to bonding surfaces.

When installing the new part, make sure that all bonding surfaces have sufficient adhesive.

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Install new part and rivet with blind rivets.

Area	Number	Remarks
1	5	Blind rivet N3
2	6	Blind rivet N3
3	4 of	Blind rivet N6

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