41 12 560 Luggage Compartment Floor Replacement (Complete With Inner Wheel Arch Section, Tail Panel Removed)
Read contents of Body, general .
Remove or cover those vehicle components in the repair area which are susceptible to heat or dust.
Spot-weld bonding is used on this vehicle. Observe specific Procedure .
Use only approved Spot-Welding Apparatus for repairs!
Place vehicle on straightening bench.
Following new body parts are required:
- (1) Luggage compartment floor, upper section
- (2) Mounting, rollover protection, right
- (3) Mounting, rollover protection, left
- (4) Rear axle carrier
- (5) Wheel arch, rear, inner half, left
- (6) Wheel arch, rear, inner half, right
Carry over the work step shown symmetrically to the other side of the vehicle.
Open weld joints in areas (1).
Take off holder (2).
Carry over the work step shown symmetrically to the other side of the vehicle.
Mark severance cut in accordance with measurement a and cut.
Measurement a=40 mm behind support, frame side member (1).
Installation:
Weld in reinforcement plates at severance cuts.
Carry over the work step shown symmetrically to the other side of the vehicle.
Mark severance cut (1) and cut.
Open weld joints in areas (2).
Installation:
Weld new components in areas (3) additionally.
Carry over the work step shown symmetrically to the other side of the vehicle.
Mark severance cut (1) in accordance with measurement a and cut rear axle carrier.
Measurement a=70 mm from rear axle bushing mounting.
Open weld joints in area (2).
Installation:
Weld in reinforcement plates at severance cuts.
Carry over the work step shown symmetrically to the other side of the vehicle.
Open weld joints in areas (1).
Carry over the work step shown symmetrically to the other side of the vehicle.
Open weld joints in areas (1).
Installation:
Weld new components in areas (2) additionally.
Carry over the work step shown symmetrically to the other side of the vehicle.
Open weld joints in areas (1).
Open adhesive joints in area (2).
Remove rollover protection mounting (3).
Installation:
Plug/spot-weld in area (2) of wheel arch side.
Carry over the work step shown symmetrically to the other side of the vehicle.
Open weld joints in areas (1) and (2).
Installation:
Set 5 additional welding spots in area (3).
Carry over the work step shown symmetrically to the other side of the vehicle.
Open weld joints in area (1).
Installation:
Weld new component in area (2) additionally.
Open weld joints in area (1).
Preparation of new part:
Carry over the work step shown symmetrically to the other side of the vehicle.
Mark severance cuts (1) in accordance with measurement and cut.
Measurement a=170 mm
Measurement b = 110 mm
Installation:
The parts separated by cutting are still needed.
Weld in reinforcement plates at severance cuts.
Preparation of new part:
Carry over the work step shown symmetrically to the other side of the vehicle.
Open weld joints in areas (2).
Installation:
The parts separated by cutting are still needed.
Preparation of new part:
Open weld joints in areas (1).
Mark severance cut (2) in accordance with vehicle and cut.
Preparation of new part:
Carry over the work step shown symmetrically to the other side of the vehicle.
Open weld joints in areas (1).
Preparation of new part:
Open weld joints in areas (1).
Installation:
The parts (2) separated by cutting are still needed.
Preparation of new part:
Open weld joints in area (1).
Mark severance cut (2) in accordance with vehicle and cut.
Installation:
Adjust new parts to fit with straightening attachment or universal mount.
Before welding in, also adjust tail panel, rear lid and rear lights to fit.
Weld new components in following order: