41 12 535 Replacing Luggage Compartment Floor And Both Side Members (Tail Panel Removed)
Read contents of SAFETY INFORMATION and BODY, GENERAL .
Place vehicle on straightening bench.
Procedure OBSERVE repair stage 3!
The following new body parts are required:
- (1) Wheel arch, rear left and right
- (2) Side member, rear left and right
- (3) Side member, top left and right
- (4) Luggage compartment floor
Following CONSUMABLES are required:
| Material | Quantity |
|---|---|
| Adhesive K5b | 1 |
| Blind rivet N3 | 24 |
| Blind rivet N6 | 16 |
| EMC screws | 8 |
| Cleaning agent R1 | 1 |
| Sealant D1 |
Removal
Most of operation is described on the left side. Right side identical.
Open welded connections in area (1).
LOOSEN spot-welded adhesive joints in area (1).
Open welded connections in area (1).
Remove middle lashing rail mounting (2).
View from below:
Open spot-welded adhesive joints in area (1)
Open welded connections in areas (2).
Mark severance cut (1) in accordance with Dimension "a" and cut.
Dimension "a" = 10 mm
Open welded connections in area (2).
Mark severance cut (1) in accordance with previous severance cut and cut.
Preparation of new part:
Mark side member new parts in accordance with severance cuts on vehicle and cut.
Adjust side member new parts to fit with alignment bracket or universal mount and with tail panel.
Prepare REINFORCEMENT PLATES at severance cuts on side members.
Most of operation is described on the left side. Right side identical.
Put middle luggage compartment floor in position from below and adjust in combination with the tail panel.
Prepare new part for plug-welding in areas (1) and (2). Note double number of welding spots in area (1).
Adjust luggage compartment floor to fit and secure.
In areas (1) to (3), set 4.2 mm diameter bore holes for blind rivets.
| Area | Number |
|---|---|
| 1 | 1 |
| 2 | 1 |
| 3 | 3 |
In areas (1) to (3), set 4.2 mm diameter bore holes for blind rivets.
| Area | Number |
|---|---|
| 1 | 4 |
| 2 | 4 |
| 3 | 1 |
In areas (1) to (3), set 4.2 mm diameter bore holes for blind rivets.
| Area | Number |
|---|---|
| 1 | 2 |
| 2 | 3 |
| 3 | 1 |
Installation of side member and middle luggage compartment floor
Install new parts and reinforcement plates with alignment bracket or universal mount and weld.
Installing luggage compartment floor
Clean all bonding surfaces on new part and on vehicle with cleaning agent R1 .
Apply adhesive on all bonding and riveting surfaces.
When installing, make sure that all bonding surfaces have sufficient adhesive.
Install new parts and rivet with blind rivets.
In areas (1) to (3), rivet new part with blind rivets.
| Area | Blind rivet |
|---|---|
| 1 | N6 |
| 2 | N6 |
| 3 | N3 |
In areas (1) to (3), use blind rivet N3/N6.
| Area | Blind rivet |
|---|---|
| 1 | N6 |
| 2 | N6 |
| 3 | N3 |
In areas (1) to (3), use blind rivet N3/N6.
Fit an EMC SCREW after adhesive has hardened in area (3).
| Area | Blind rivet |
|---|---|
| 1 | N3 |
| 2 | N3 |
| 3 | N6 |
After hardening of adhesive install 2 EMC screws in areas (1) and (2).
Fit an EMC screw after adhesive has hardened in area (1).