Removing Rear Side Panel

Information 

• All straightening work on the body in the connection area of the sheetmetal parts to be replaced must be completed before the damaged parts are removed. 

Information 

Mark cut A  in accordance with the new part. Make sure to leave an overlap of approx. 3 cm with respect to the body.

1. Mark and make cuts in rear side panel.
   Fig 1: Rear Side Panel Component Location

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   1. 1.1. Mark cut in rear side panel at the C-pillar at dimension B. → Distance: 160 mm 
   2. 1.2. Mark cut in rear side panel at the D-pillar (window aperture) at dimension C. → Distance: 400 mm 
   3. 1.3. Mark cut in rear side panel at the D-pillar (water drain channel) at dimension D. → Distance: 146 mm 

      Information 

      Only make cuts in the top plate. Make sure not to damage the plate underneath when doing this.

   4. 1.4. Cut through the rear side panel in the area marked.
      Fig 2: Identifying Rear Side Panel Cutting Area

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   Information 

   Drill out spotweld A  through two plate thicknesses.

2. Drill out spotwelds using Spotweld Drill  .
   Fig 3: Identifying Rear Side Panel Spotwelds

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3. Loosen welded joints.
   Fig 4: Identifying Rear Side Panel Welded Joints

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   1. 3.1. Drill out spotwelds.
   2. 3.2. Grind down MIG seams.
4. Grind down the spot welds.
   Fig 5: Identifying Rear Side Panel Spot Welds

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5. Heat up connection areas using a hot-air gun.
   Fig 6: Identifying Rear Side Panel Heat Up Connection Areas

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6. Heat up connection areas using a hot-air gun.
   Fig 7: Identifying Rear Side Panel Heat Up Connection Areas

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7. Remove side panel.