Installing Rear Side Member

→ Weld in the new part within 30 minutes.

→ Only apply MIG welds on the side member.

→ Do not butt-weld thick body panels (more than → Length: +1.5 mm  thick) without a welding gap during MIG welding.

→ To achieve the required welding quality, maintain the specified welding gap.

→ Do not grind down the welded seams.

Fig 1: Identifying Installation Position Of Rear Side Member

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1. Floorpan, centre left
2. Rear side member
3. Left floor section (luggage compartment)

1. Apply adhesive to the side member.
   1. 1.1. Apply Teromix-6700 two-component adhesive  to the side member in area -A-  . Maintain the application depth → Application depth: 4 mm  .
      Fig 2: Applying Adhesive To Side Member

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2. Fit side member to the body.

   Information 

   • To fit the rear side member, the frame head (impact absorber mount) must be secured to the straightening set  .
   1. 2.1. Secure the frame head of the rear side member to the straightening set.
   2. 2.2. Fix the side member to the body using tensioning clamps.
      Fig 3: Overview Of Side Member (Below)

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3. Weld the front side member using inert gas.
   1. 3.1. Use an inert-gas arc welder to weld the side member to the inside and outside of the carrier in areas -A and C-  .
      Fig 4: Identifying Welded Joints On Front Side Member

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   2. 3.2. Plug-weld the side member in area -B-  to the underside of the carrier using inert gas.
      Fig 5: Overview Of Side Member (Below)

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4. Weld in side member on the centre floorpan.
   1. 4.1. Plug-weld the side member in areas -A and B-  using inert gas.
      Fig 6: Identifying Welded Joints On Centre Floorpan

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      Fig 7: Overview Of Side Member (Below)

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5. Weld in side member on cross member.
   1. 5.1. Plug-weld the side member in areas -A and B-  using inert gas.
      Fig 8: Identifying Welded Joints On Cross Member

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      Fig 9: Overview Of Side Member (Below)

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6. Weld in side member on inner lower side member.
   1. 6.1. Plug-weld the side member in area -A-  using inert gas.
      Fig 10: Identifying Welded Joints On Inner Lower Side Member (Centre)

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   2. 6.2. Resistance spot-weld the side member in area -A-  .
      Fig 11: Identifying Welded Joints On Inner Lower Side Member (Rear)

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   3. 6.3. Plug-weld the side member in area -B-  using inert gas.
      Fig 12: Overview Of Side Member (Behind)

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7. Weld in the side member on the rear floorpan and spare-wheel well.
   1. 7.1. Resistance spot-weld the side member in areas -A and C-  .
      Fig 13: Identifying Welded Joints On Rear Floorpan And Spare-Wheel Well

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   2. 7.2. Plug-weld the side member in area -B-  using inert gas.
   3. 7.3. Plug-weld the side member in area -A-  using inert gas.
      Fig 14: Identifying Welded Joints On Rear Floorpan (Inner)

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      Fig 15: Overview Of Side Member - Inside

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8. Weld in side member on the centre floorpan (from outside).
   1. 8.1. Resistance spot-weld the side member in areas -A and B-  .
      Fig 16: Identifying Welded Joints On Rear Floorpan (Outer)

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      Fig 17: Overview Of Side Member - Outside

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9. Weld in side member on the floorpan and centre side member.
   1. 9.1. Plug-weld the side member in areas -A, B and C-  using inert gas.
      Fig 18: Identifying Welded Joints On Centre Floorpan

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   2. 9.2. Weld the side member in areas -A, B, C and D-  using inert gas.
      Fig 19: Identifying Welded Joints On Centre Of Side Member

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10. Insert lid on rear floorpan and weld it in.
    1. 10.1. Insert lid -1-  on floorpan from above -arrow-  .
       Fig 20: Inserting Lid On Rear Floorpan

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    2. 10.2. Weld the lid in areas -A, B and C-  using inert gas.
    3. 10.3. Grind down MIG seams on top of the lid in area -A-  .
       Fig 21: Grinding Down MIG Seams On Lid

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11. Insert lid on centre floorpan and weld it in.
    1. 11.1. Insert lid -1-  on floorpan from above -arrow-  .
       Fig 22: Inserting Lid On Centre Floorpan

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    2. 11.2. Weld the lid in areas -A and D-  using inert gas.
       Fig 23: Identifying Welded Joints On Lid Of Centre Floorpan

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    3. 11.3. Plug-weld the lid in areas -B and C-  using inert gas.
    4. 11.4. Grind down MIG seams on top of the lid in areas -A, B, C and D-  .
       Fig 24: Grinding Down MIG Seams On Lid

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       Fig 25: Overview Of Side Member (Behind)

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12. Apply adhesive to the rear side member.
    1. 12.1. Apply Teromix-6700 two-component adhesive  to the side member in areas -A and B-  . Maintain the application depth → Application depth: 4 mm  .
       Fig 26: Applying Adhesive

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13. Fit the floor section (luggage compartment) to the body and weld it in.
    1. 13.1. Fix the floor section to the body with tensioning clamps.
    2. 13.2. Resistance spot-weld the floor section in areas -A, B. D and E-  .
       Fig 27: Identifying Welded Joints On Floor Section

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    3. 13.3. Plug-weld the floor section in area -C-  using inert gas.

       Information 

       • The rear side member is also glued ex-works at the point of contact to the centre floorpan and to the rear floorpan. When replacing the side member, adhesive must not be applied to these areas since these areas will be welded in using MIG plug-welds and this would burn the adhesive. 
       • Body sealant must be applied carefully from the outside to these areas of the rear side member following repairs  .
14. Seal side member from the outside.
15. Fill the side member with foam.
    1. 15.1. Fill the side member with foam from behind through the opening on the frame head -arrow-  close to the seal -A-  . → 5000IN PROCESSING BODY ACOUSTIC FOAM 2K-AFS VARIO .
       Fig 28: Filling Rear Side Member With Foam

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16. Install D-pillar reinforcement. → Installing Outer And Inner D-Pillar With Reinforcements 
17. Install (inner) rear wheel housing. → Installing Rear Wheel Housing 
18. Install (outer) rear wheel housing. → Installing Rear Wheel Housing 
19. Install rear side section. → Installing Rear Side Panel 
20. Install lock carrier. → Installing Lock Carrier 
21. Install end plate. → Installing End Plate