Replacing Luggage Compartment Floor And Side Member On Left (Left Side Wall 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 .

Following new body parts are required (refer to appropriate parts information ):

1. Luggage compartment well
2. Luggage compartment floor, rear
3. Luggage compartment well, left
4. Frame side member, top left
5. Side member, bottom left
6. Luggage compartment floor, left section

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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	20
Blind rivet N6	8
EMC screw	7
Cleaning agent R1	1
Sealant D1

Removal of side member and luggage compartment floor: 

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 members in accordance with severance cuts on vehicle and cut.

For all severance cuts on side members, prepare reinforcement plates; refer to WELDING IN REINFORCEMENT PLATE (SHEET STEEL) .

Mark severance cut at luggage compartment floor in accordance with severance cut on vehicle + 15 mm extra material and cut (1).

Set 4 Ø4.2 mm bore holes in area (2).

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 Ø4.2 mm bore holes for blind rivet N3.

Area	Number
1	2
2	3
3	4

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If necessary, mark bore holes in area (3) on body and create after removal of new part.

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

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

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 rear luggage compartment floor and left luggage compartment floor: 

Clean all  bonding surfaces with cleaning agent R1.

Apply adhesive to bonding surfaces.

Install new part and rivet with blind rivets.

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

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

In area (1) install one EMC screw.

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In area (1) install two EMC screws.

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