41 12 535 Rear Luggage Compartment Floor Complete Replacement (Tail Panel Removed)

Read contents of BODY, GENERAL .

Spot-weld bonding is used on this vehicle.

Observe relevant procedures in BODY, GENERAL .

Place vehicle on straightening bench.

Following new body parts are required:

1. Luggage compartment floor
2. Support, luggage compartment floor, left
3. Holder, spare wheel
4. Support, luggage compartment floor, right

Fig 1: Identifying Luggage Compartment Floor

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View from vehicle floorpan:

Open weld joints in areas (1).

Fig 2: Identifying Weld Joints Areas

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Open weld joints in areas (1).

Fig 3: Identifying Weld Joints Areas

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Open weld joints in areas (1).

Fig 4: Identifying Weld Joints Areas

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Open weld joints in area (1).

Fig 5: Identifying Weld Joints Areas

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Open weld joints in area (1) on both sides of vehicle.

Fig 6: Identifying Weld Joints Areas

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Open weld joints in areas (1).

Cut luggage compartment floor along line (2) next to spot flange.

Fig 7: Identifying Weld Joints Areas

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Installation: 

Adjust luggage compartment floor to fit with straightening attachment or universal mount.

Before welding in, also adjust tail panel, rear lid and rear lights to fit.

Fit new part in area (1) from above.

Plug weld in area (1).

Fig 8: Identifying Area

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New part preparation: 

Carry over the work steps shown symmetrically to the other side of the car.

Adjust new parts in conjunction with tail panel, tailgate and rear lights to fit and secure.

Set 4.2 mm dia. bore holes for blind rivets in the areas shown in the illustration.

Larger area: 6 holes.

Smaller area: 2 holes.

Fig 9: Identifying Rivet Bore Hole And Adhesive Areas

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Clean bonding surfaces with cleaning agent R1.

Installation of luggage compartment floor: 

Carry over the work steps shown symmetrically to the other side of the car.

Weld in luggage compartment floor.

Apply adhesive K5a in the areas shown in the illustration and rivet support on left and right sides.

Fig 10: Identifying Rivet Bore Hole And Adhesive Areas

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After adhesive has hardened, fit 2 EMC SCREWS  in area of earth support points.