Preparing Rear Side Panel For Installation

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. 

Information 

Mark cuts in accordance with the new part. Make sure to leave an overlap of approx. 30 mm with respect to the body.

1. Fit in rear side section.

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   Cut A

   Fig 1: Checking Rear Side Panel Cutting Dimension

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   Cut B

   1. 1.1 Mark and cut rear side panel at the points where it joins the body.
   2. 1.2 Fit in rear side panel and secure it to the body.

      > 5X00IN GAP DIMENSIONS

   3. 1.3 Make cuts
2. Cut sheetmetal insert used as a welding backing strip for the welding areas from the old rear side panel.
3. Drill bore for blind rivet -2-  through both sheetmetal plates using >diameter 6.6 mm  .

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   Joint connections

4. Drill bore holes for blind rivets through both sheetmetal plates using >diameter 6.6 mm  .

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   Blind rivets

5. Punch holes for flow-form rivets.

   > 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

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   Flow-form rivets

6. Prepare joints in the rear lid area.

   > 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

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   Joints

   1. 6.1 Drill bore holes for blind rivets
   2. 6.2 Punch holes for flow-form rivets
7. Prepare joints in the rear window area.

   > 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

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   Joints

   1. 7.1 Punch holes for flow-form rivets
   2. 7.2 Drill bore hole for countersunk blind rivet -RHD vehicle -  through both sheetmetal panels using >diameter 4.1 mm  .
   3. 7.3 Make counterbore at the rivet hole
8. Remove rear side panel.
9. Prepare rear side panel for bonding and riveting.

   > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

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   Bonding areas

10. Prepare rear side panel for joining.

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    Joint areas

    1. 10.1 Prepare rear side panel for bonding and riveting in areas
    2. 10.2 Prepare rear side panel for aluminium welding in areas