Preparing Rear Body (Coupe) For Installation

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

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Self-tapping screws
Remove seat-well cross member.

Loosen reinforcement from rear body (Coupe). 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 (Coupe) 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  > B21 mm 

Fig 1: Checking Blind Rivets Bore Hole Drilling
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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 

> A34mm  > B 62 mm  > C115mm  > D 174.5 mm  > E 15.5 mm

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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 rear body (Coupe).
> A 15 mm  > B 49 mm  > C 15 mm

Fig 2: Checking Blind Rivets Bore Centre Points Dimensions
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Bore centre points
Apply bore centre points for blind rivets with dimensions -A.B and C- to rear body (Coupe).
> A 20 mm  > B 64 mm  > C15mm

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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 it 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- ,
> 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

> Diameter 4.1 mm

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Punch rivets
Drill bore holes for blind rivets -B- .
> 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
Position corner panel of rear cover plate (Coupe) and secure it to the body.
Drill bores for blind rivets.
> Diameter 6.6 mm

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Bore holes
Remove corner panel of rear cover plate (Coupe).
Remove rear body (Coupe).
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