41 12 590 Luggage Compartment Floor Replacement (Complete With Left Or Right 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.
Necessary preliminary work:
- Remove mounting for tension strut at rear
Following new body parts are required:
- (1) Luggage compartment floor, upper section
- (2) Rear axle carrier
- (3) Mounting, rollover protection, left
- (4) Wheel arch, rear, inner half, left
Open weld joints in areas (1).
Take off holder (2).
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.
Mark severance cut (1) and cut.
Open weld joints in areas (2).
Installation:
Weld new components in areas (3) additionally.
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.
Open weld joints in areas (1).
Open weld joints in areas (1).
Installation:
Weld new components in areas (2) additionally.
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.
Open weld joints in areas (1) and (2).
Installation:
Set 5 additional welding spots in area (3).
Open weld joints in area (1).
Installation:
Weld new component in area (2) additionally.
Mark severance cut (1) centrally and cut.
Cut floor pan and cross-member underneath.
Open weld joints in area (2).
Preparation of new part:
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:
Open weld joints in areas (2).
Installation:
The parts 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.
Preparation of new part:
Open weld joints in areas (1).
Preparation of new part:
Open weld joints in area (1).
Installation:
The cut part (2) is not 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:
- (1) Rear axle carrier
- (2) Luggage compartment floor, upper section
- (3) Support, frame side member
- (4) Wheel arch, rear, inner half
- (5) Mounting, rollover protection