41 12 557 Replacing Middle Luggage Compartment Floor (Tail Panel Has Been Removed): Notes

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Read contents of BODY, GENERAL .

Observe procedures for (REPAIR STAGES 3) .

STRIP DOWN VEHICLE

Remove or cover those vehicle components in the repair area which are susceptible to heat or dust.

Operation is partially described on the left side. Right side identical.

The following new body parts are required :

(1) Luggage compartment floor, rear
(2) Reinforcement, side member

Following CONSUMABLES are required:

Fig 1: Identifying Rear Luggage Compartment Floor And Side Member Reinforcement

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Material	Quantity
Adhesive K5b	1
Blind rivets N3	40
Cleaning agent R1	1
Sealant D1

Removal of luggage compartment floor

View from below.

Open welded connections in area (1).

Fig 2: Identifying Welded Connections Area

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Fig 3: Identifying Outer Metal Panel Severance Cut Mark And Welded Connection Area

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Mark severance cut (1) approx. 6 mm from edge of component of front luggage compartment floor and disconnect.

IMPORTANT: Cut outer metal panel only.
Open welded connections in area (2).
Remove the luggage compartment floor.

Installation note:

Luggage compartment floor is installed with overlap in area of severance cut (1).

New part preparation

Set down luggage compartment well and adjust in combination with cross member and tail panel to fit and secure.

In areas (1) and (2) set 4.2 mm dia. holes for blind rivets.

Area	Number
1	5 of
2	8

Fig 4: Identifying Luggage Compartment Floor Blind Rivets Hole Areas

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Adjust side member to fit and secure.

In areas (1) to (4), set 4.2 mm dia. holes for blind rivets.

Area	Number
1	1
2	4
3	4
4	2

Fig 5: Identifying Blind Rivet Areas

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In area (5) prepare new parts for MAG welding.

Remove new parts and deburr bore holes.

IMPORTANT: Do not grind new parts and body in area of bonding surfaces.

Installing luggage compartment floor and side member reinforcements

Clean all bonding surfaces with cleaning agent R1.

Apply adhesive to bonding surfaces.

Install new parts and rivet with blind rivets.

Perform MAG welding throughout to new part in area (1).

Set 20 mm MAG welds at a distance of 15 mm in area (2).

IMPORTANT: Risk of damage to adhesive area!
Avoid applying excessive heat to the neighboring adhesive areas!

Fig 6: Identifying MAG Welding Application Areas

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Weld new parts in area (5).

(1) to (4) = Adhesive riveted areas.

Fig 7: Identifying Blind Rivet Areas

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