Installing Rear Side Panel

Information 

• Before final assembly, make sure you fully understand all the work steps involved and carry out a trial assembly without applying adhesive  .
• The bonding process can only be carried out reliably when a smooth and swift sequence of operations is guaranteed  .
• Do not begin bonding work until all materials and tools necessary for later repair work are available  .

1. Install side panel with wheel housing and check that it fits perfectly. Check gap dimensions. →  5X00IN DIAGRAM - BODY GAP DIMENSIONS  . 
2. Drill holes for rivets. → Diameter: 6.5 mm 

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3. Check that there is no gap between the molded part -1-  and the seal -2-  .

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4. Apply adhesive to the wheel housing. → Application depth: 3.0 mm 

   Working with structural body adhesive. → 5X00IN21 WORKING WITH STRUCTURAL BODY ADHESIVE .

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5. Fit wheel housing on the side panel using pliers and fix in place.

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6. Check that the molded part is seated correctly.

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7. Apply foam filler to the body. → 5X00IN22 WORKING WITH BODY FOAM FILLER .

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8. Apply foam filler to the side panel. → 5X00IN22 WORKING WITH BODY FOAM FILLER .

   Make sure that all openings and gaps are closed off with the sealing compound.

   The gap between the inner side section and the side panel must be closed when fitting it on the body.

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9. Adhesive is applied as shown. → Application depth: 3.0 mm 

   Working with structural body adhesive. → 5X00IN21 WORKING WITH STRUCTURAL BODY ADHESIVE .

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10. Fit and secure rear side section.

    Check gap dimensions. →  5X00IN DIAGRAM - BODY GAP DIMENSIONS  . 

11. Resistance spot-weld area -A-  at the door aperture and at the wheel housing.
    1. 11.1. Plug-weld area -B-  of the rear side section.

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12. Resistance spot-weld the water drain area.

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13. Resistance spot-weld the light housing area.

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14. Resistance spot-weld the wheel housing area.

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15. Resistance spot-weld the B-pillar area.

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16. Resistance spot-weld the rear side section in the air intake area.

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17. Plug-weld the wheel housing area.

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18. Rivet in the side panel in the hood compartment area. → BLIND RIVET 999.190.229.01

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19. Flange edge of wheel arch.

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