Prepare New Parts

Replacing the coarse thread bolt and threaded weld bolts (steel surface) 

• Renew the coarse thread bolt (1) and the threaded weld bolt (2).

  Parts:  Coarse thread bolt, threaded weld bolt

  Take the number and position from the component to be replaced or the add-ons.

• Weld the coarse thread bolt (1) and threaded weld bolt (2) onto the new part.

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Check ground pins and replace if necessary 

• Check the ground pins (1) for stability and renew if necessary.

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Prepare new parts, left side rail 

• Adjust new parts to fit with alignment bracket or universal mount and secure.
• Prepare areas (1) and (2) for structural adhesive bonding of steel to aluminum.
• Assign the positions of the bores already present in areas (1) and (2) of the vehicle to the new part. Place bores in areas (1) and (2) Ø 6.8 mm for blind rivet.

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• Prepare area (1) for structural adhesive bonding of steel to aluminum.
• Assign the positions of the bores already present in area (1) of the vehicle to the new part. Place bores in area (1) Ø 6.8 mm for blind rivet.

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• Prepare area (1) for structural adhesive bonding of steel to aluminum.
• Assign the positions of the bores already present in area (1) of the vehicle to the new part. Place bore in area (1) Ø 6.8 mm for blind rivet.

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• Prepare areas (1) for joining by welding.

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• Prepare areas (1) for joining by welding.

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Prepare new parts, left side rail 

• Adjust new parts to fit and secure.
• Prepare areas (1) for joining by welding. Ensure sufficient distance to the adhesive area in doing so.
• Prepare area (2) for joining using the rivet-and-bonding method. Do not grind bonding surfaces down or off.
• In area (2), assign the two bores present in the side member to the new part.
• Drill out holes to dia. 6.8 mm.

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• Prepare areas (1) and (2) for joining with the glue rivet technique. Do not grind bonding surfaces down or off.
• In areas (1) and (2), assign the bores already present to the new part.
• Drill out holes to dia. 6.8 mm.
• Prepare areas (3) for joining by welding.

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• Replace series of welded connection (1) by MAG-weld seam (2). Prepare in area (2), a MAG-weld seam of length 10 mm. Ensure sufficient distance to the bonded rivet connection (3).
• Remove new parts.
• Deburr bores.

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Prepare new part, middle luggage compartment floor 

• Adjust new parts to fit and secure.
• Prepare area (1) for structural adhesive bonding of steel to aluminum.
• Assign the positions of the holes already present in area (2) of the vehicle to the new part. Set holes (2) Ø 6.8 mm for blind rivet.
• Mark area (1) for later adhesive application.

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• Prepare area (1) for structural adhesive bonding of steel to steel and aluminum.
• Assign the positions of the holes already present in area (2) of the vehicle to the new part. Set holes (2) Ø 6.8 mm for blind rivet.
• Set hole (3) Ø 6.8 mm according to dimension b. Dimension b = 30 mm from component edge.
• Prepare area (4) according to dimension a for joining by welding. Dimension a = 40 mm.

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• (2) Mark area (1) for later adhesive application.

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  NOTE: Perform the steps on the left and right side.
• Adjust the new parts in combination with the tail panel to fit and secure.
• Prepare area (1) for structural adhesive bonding of steel to steel and aluminum.
• Transfer the position of the hole (2) that resulted from the removal on the vehicle to the new part. Set hole (2) Ø 6.8 mm for blind rivet.

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• Set the new hole (3) Ø 6.8 mm according to the specified dimensions.

  Dimension a = 40 mm from hole Ø 12 mm.

  Dimension b = 24 mm of hole Ø 12 mm.

• Prepare area (4) from the reference line (5) for joining by welding.
• (2) Mark area (1) for later adhesive application.

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• Prepare areas (1) for joining by welding.

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• Prepare areas (1) for joining by welding.

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• Prepare areas (1) for joining by welding.

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• Prepare areas (1) for joining by welding.

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• Prepare areas (1) for joining by welding.
• Remove new part and deburr holes.

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