41 12 700 Replacing luggage compartment floor and side member on the left (rear quarter panel and tail panel removed): Notes

Read contents of BODY, GENERAL .

Follow procedure for REPAIR STAGE 3 .

STRIP DOWN VEHICLE. 

Spot-weld bonding is used on this vehicle. Observe specific PROCEDURE .

Place vehicle on straightening bench.

The following new parts are required:

1. Rear wheel arch
2. Side member, rear
3. Luggage compartment floor

Fig 1: Rear Wheel Arch, Rear Side Member And Luggage Compartment Floor

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The following CONSUMABLES  are required:

Removal: 

Mark severance cut (1) in accordance with Dimension "a" and cut.

Dimension "a" = 30 mm from component edge, cross-member.

Open welded connections in areas (2).

Remove the luggage compartment floor.

Fig 2: Severance Cut Mark And Welded Connections Areas

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Mark severance cut (1) in accordance with Dimension "a" and cut.

Dimension "a" = 82 mm from 8 mm dia. hole.

Fig 3: Luggage Compartment Floor Severance Cutting Dimension

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Mark severance cut (1) in accordance with Dimension "a" and cut.

Dimension "a" = 10 mm from the edge of the embossing.

Open welded connections in areas (2).

Fig 4: Severance Cut Mark And Welded Connections Areas

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Mark severance cut (1) in accordance with Dimension and cut.

Dimension "a" = approx. 145 mm from component edge, reinforcement.

Release welded connections in areas (2) and remove side member.

(3) = severance cut from prior operation.

Fig 5: Severance Cuts And Welded Connections Areas

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Preparation of new part: 

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

Prepare REINFORCEMENT PLATE  for severance cut (1).

Mark severance cut (2) in accordance with severance cut on vehicle +15 mm extra material and cut.

Open welded connections in areas (3).

(4) = Severance cut route on vehicle.

Prepare new part for joining by welding.

Fig 6: Severance Cut Marks And Welded Connections Areas

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

Prepare reinforcement plate for severance cut (1).

Prepare new part for joining by welding.

Adjust new parts side member and wheel arch using alignment bracket or universal mount and secure.

Fig 7: Adjusting Side Member Parts And Wheel Arch Using Alignment Bracket/Universal Mount

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Mark severance cut on new part in accordance with severance cut on vehicle + 15 mm for extra material and cut.

Adjust luggage compartment floor in combination with tail panel to fit and secure.

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

Fig 8: Adjusting Luggage Compartment Floor

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Remove new parts and deburr bores.

Installing side member and wheel arch: 

Install new parts using an alignment bracket or universal mount.

Fig 9: Installing Side Member And Wheel Arch

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Weld new parts and reinforcement plates in area of severance cut (1).

Weld new parts and reinforcement plate at severance cuts (1) and in areas (2).

Fig 10: Severance Cuts/Welding Areas

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Weld new parts in areas (1) and (2).

Fig 11: Welding Areas

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Installation of luggage compartment floor: 

Clean all bonding surfaces with CLEANING AGENT R1 .

Apply adhesive to bonding surface (1).

Fig 12: Bonding Surface

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Install the luggage compartment floor and rivet areas (1) and (2) with the blind rivet N3

Fig 13: Adjusting Luggage Compartment Floor

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Remove excess adhesive.

After hardening of the adhesive, install 5 EMC SCREWS  in the areas (1).

Fig 14: EMC Screws Installation Areas

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