Preparing Rear Body (Cabriolet) For Installation

Remove self-tapping screws -1- and screws -2- .

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Self-tapping screws
Remove the seat-well cross member.

Loosen reinforcement from rear body (Cabriolet). Re-use reinforcement.

3.1 Unscrew self-tapping screws -1- .

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Self-tapping screws

3.2 Remove punch rivets using > VAS 852 001 - body dent removal system, aluminium and > VAS 6790 - compact booster .

> 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

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Punch rivets

3.3 Heat the marked bonding areas using > V.A.G 1416 - hot-air blower .

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Bonding areas

3.4 Remove reinforcement.

Fit in rear body (Cabriolet) and secure it to the body.
Drill bore holes for blind rivets -A- and -B- .
> 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

> Diameter 6.6 mm

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Bore holes
Pre-drill bore hole for self-tapping screw with dimensions -A and B- .
> 5X00IN24 SETTING SELF-TAPPING SCREWS

> A7.5 mm > B 21 mm

Fig 1: Checking Self-Tapping Screw Bore Hole Drilling Dimensions
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Blind rivets
Drill bore holes for blind rivets with dimensions -A.B.C.D.E and F-.
> 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

> Diameter 6.6 mm

> A34 mm > B 62 mm > C115 mm > D 174.5 mm > E 15.5 mm

Fig 2: Checking Blind Rivets Bore Holes Drilling Dimensions
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Bore centre points
Drill bore holes for blind rivets.
> 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

> Diameter 6.6 mm

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Blind rivets
Drill bore holes for blind rivets.
> 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

> Diameter 6.6 mm

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Bore holes
Apply bore centre points for blind rivets with dimensions -A, B and C- to the rear body (Cabriolet).
> A15 mm > B49 mm > C15 mm

Fig 3: Checking Blind Rivets Bore Centre Points
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Bore centre points
Apply bore centre points for blind rivets with dimensions -A.B and C- to the rear body (Cabriolet).
> A20 mm > B64 mm > C15 mm

Fig 4: Checking Blind Rivets Bore Centre Points
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Bore centre points
Drill bore holes for blind rivets through both sheetmetal panels.
> 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

> Diameter 6.6 mm

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Bore holes
Fit in filler plate and secure to the body.
Drill bore holes for blind rivets.
> 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

> Diameter 6.6 mm

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Joints
Drill holes for self-tapping screws -1- through the existing holes.
> 5X00IN24 SETTING SELF-TAPPING SCREWS

> Diameter 4.0 mm

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Bore holes
Fit in adapter plate for lower door sill and secure it to the body.
Drill bore holes for blind rivets -A- and
> 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

> Diameter 4.1 mm

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Punch rivets
Drill bore holes for blind rivets -B- and
> 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

> Diameter 6.6 mm

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Punch rivets
Remove adapter plate for lower door sill.
Prepare marked areas for bonding and riveting.
> 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

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Bonding areas
Remove filler plate.
Prepare marked areas for bonding and riveting.
> 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

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Bonding areas
Remove rear body (Cabriolet).
Prepare marked areas for bonding and riveting.
> 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

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Marked areas
Prepare marked areas for bonding and riveting.
> 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

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Bonding areas
Prepare marked areas for aluminium MIG welding.
> 5X00IN10 WELDING ALUMINIUM

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Welding areas