Removing Rear Side Panel

Information

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

Information

Loosen connection points on one side only. Do not damage the sheet-metal panel underneath.

Information

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

1. Mark cut on the outer side member at -Dimension A-  > Distance 227 mm  .
   Fig 1: Checking Outer Side Member Cutting Dimension

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   Cut on side member

2. Make cut.
3. Drill out penetrated joints. > Diameter 4 mm 

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   Penetrated joints

4. Drill out penetrated joints -A-  . > Diameter 4 mm 

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   Punch rivets

5. Remove punch rivets -B-  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

6. 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

7. 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

8. Remove punch rivets -A-  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

9. Drill out penetrated joints -B-  . > Diameter 4 mm 

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   Penetrated joints

10. Loosen friction element welded joint.

    > 5X00IN29 REPLACING FRICTION ELEMENT WELDED JOINT

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    Friction element

11. Drill out penetrated joints. > Diameter 4 mm 

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    Penetrated joints

12. Bend up seam in door aperture.
    1. 12.1  Heat bonding areas using > V.A.G 1416 - hot-air blower  .

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       Bonding areas

    2. 12.2  Bend up seam in the door aperture using > VAS 6635 - crimping pliers set, 4-piece  .

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       Seam

13. Bend up seam in rear wheel arch.
    1. 13.1  Heat bonding areas using > V.A.G 1416 - hot-air blower  .
    2. 13.2  Bend up seam in rear wheel arch using > VAS 6635 - crimping pliers set, 4-piece  .

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       Rear wheel arch

14. Cut welded seam

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    Welded seam

15. Heat bonding areas using > V.A.G 1416 - hot-air blower  .

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    Bonding areas

16. Detach expanding foam in the marked area.

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    Expanding foam

17. Remove rear side section.