41 11 751 Replacing luggage compartment floor and side member on left (left side wall and tail panel removed)

Read contents of SAFETY INFORMATION and BODY, GENERAL .

Strip down vehicle. See STRIPPING OPERATIONS or STRIPPING OPERATIONS (ALL-WHEEL DRIVE VEHICLE) .

Spot-weld bonding is used on this vehicle. Observe specific procedure: See SPOT-WELD BONDING STEEL COMPONENTS or OPENING BONDED CONNECTIONS .

Place vehicle on straightening bench.

Follow procedure for REPAIR STAGE 3 .

Following new body parts are required:

(1) Wheel arch, rear, inner half, left
(2) Frame side member, left rear
(3) Luggage compartment floor, rear

Following CONSUMABLE are required:

Fig 1: Identifying Left Rear Frame Side Member

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Material	Quantity
Adhesive K5a	2
Blind rivets N6	16
EMC screws	4
Cleaning agent R1	1
Sealant D1

Removal

View from below.

Open spot-welded adhesive joints in area (1)

Remove the luggage compartment floor.

Fig 2: Identifying Luggage Compartment Floor Welded Connection Area

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Mark severance cut (1) as pictured and cut.

IMPORTANT: Cut outer panel only.

Fig 3: Identifying Severance Cut On Outer Panel

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Open welded connections in areas (1).

Open spot-welded adhesive joints in area (2)

Installation note:

Weld new components in area (3) additionally.

Fig 4: Identifying Outer Panel Welded Connection Areas

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Open welded connections in areas (1) and (2).

Remove side member and wheel arch.

Fig 5: Identifying Side Member And Wheel Arch Welded Connection Areas

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New part preparation

Mark severance cut (1) in accordance with severance cut on vehicle and cut.

IMPORTANT: Cut outer panel only.

Open welded connections in areas (2).

Fig 6: Identifying Severance Cut On Outer Panel

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Open welded connections in areas (1).

Remove components not needed.

Fig 7: Identifying Outer Panel Welded Connection Areas

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Open welded connections in area (1).

Remove components not needed.

Adjust new parts to fit with alignment bracket or universal mount and secure.

Fig 8: Identifying Alignment Bracket Welded Connection Area

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Fit luggage compartment floor from underneath and adjust in conjunction with tail panel and secure.

Set 16 4.2 mm dia. bore holes for blind rivets in area (1).

Remove new part and deburr holes.

Fig 9: Identifying Luggage Compartment Floor Welded Connection Area

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IMPORTANT: Do not grind new part for the luggage compartment floor and body in area of bonding surfaces.

Installing side members and wheel arch

Install new parts with alignment bracket or universal mount and weld.

Side member, rear left
Wheel arch, rear, inner half

Installation of luggage compartment floor

Clean all bonding surfaces with CLEANING AGENT R1 .

Apply adhesive to bonding surfaces.

Install the luggage compartment floor and rivet with blind rivets.

After hardening of the adhesive, install 4 EMC SCREWS in the areas (1).

Fig 10: Identifying Luggage Compartment Floor Screws Installation Areas

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