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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   Drilling holes

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

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   Fitting in moulded part

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

   Working with structural body adhesive.

   > 5X00IN21 WORKING WITH STRUCTURAL BODY ADHESIVE - section on "Installing"

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   Preparing wheel housing for installation

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

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   Bonding in wheel housing

6. Check that the moulded part is seated correctly -arrows-  .

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   Fitting and securing moulded part

7. Apply foam filler to the body.

   > 5X00IN22 WORKING WITH BODY FOAM FILLER - section on "Installing"

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   Bonding in moulded part

8. Apply foam filler to the side panel.

   > 5X00IN22 WORKING WITH BODY FOAM FILLER - section on "Installing"

   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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   Bonding in moulded part

9. Adhesive is applied as shown. > Application depth 3.0 mm 

   Working with structural body adhesive.

   > 5X00IN21 WORKING WITH STRUCTURAL BODY ADHESIVE - section on "Installing"

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   Applying adhesive

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   Applying adhesive

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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    Welding side panel

12. Resistance spot-weld the water drain area.

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    Welding side panel

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    Welding side panel

13. Resistance spot-weld the light housing area.

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    Welding side panel

14. Resistance spot-weld the wheel housing area.

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    Welding side panel

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

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    Welding side panel

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

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    Welding side panel

17. Plug-weld the wheel housing area.

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    Welding side panel

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

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    Riveting in side panel

19. Flange edge of wheel arch.

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    Flanging edge of wheel arch