Installing Rear Side Panel (Cabriolet)

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. Tack on sheetmetal insert used as welding backing strip on the body.

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   Sheetmetal insert

2. Install baffle plate -1-  in rear side panel (Cabriolet).
   1. 2.1  Clip baffle plate -1-  into rear side panel (Cabriolet).
   2. 2.2  Apply body foam filler -2-  to the baffle plate

      > 5X00IN22 WORKING WITH BODY FOAM FILLER

      Make sure that all openings and gaps are closed off with body foam filler.

      The gap between the inner side panel and rear side panel (Cabriolet) must be closed when fitting it on the body.

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      Bulkhead part

3. Install rear side panel (Cabriolet) and check that it fits perfectly.
4. Apply adhesive evenly over the entire bonding surface -A-  of the body. > Application depth 0.5 mm 

   > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

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   Connection areas

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   Bonding areas

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   Bonding areas

5. Apply adhesive on the rear side panel (Cabriolet) in areas -A-  .

   Apply adhesive evenly over the entire bonding surface. > Application depth 0.5 mm 

   Also apply an adhesive bead of sealant all around the bonding surface. > Application depth 3 mm 

   > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

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   Connection areas

6. Apply body foam filler -2-  on the bracket

   > 5X00IN22 WORKING WITH BODY FOAM FILLER

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   Bracket

7. Fit in rear side panel (Cabriolet), secure it and check gap dimensions.

   > 5X00IN41 GAP DIMENSIONS

8. Rivet in rear side panel (Cabriolet).

   > 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

   -A-  > FLOW-FORM RIVETS 9A7.008.473.00 

   -B-  > BLIND RIVETS 999.190.229.01 

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   Blind rivets

9. Rivet in rear side panel (Cabriolet). > BLIND RIVETS 999.190.227.01 

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   Blind rivets

10. Rivet in rear side panel (Cabriolet).

    > 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

    -A-  > FLOW-FORM RIVETS 9A7.008.606.00  .

    -B-  > FLOW-FORM RIVETS 9A7.008.607.00  .

    -C-  > BLIND RIVETS 999.190.227.01 

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    Blind rivets

11. Rivet in rear side panel.

    > 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

    -A-  > RIVET 9A7.008.606.00 

    -B-  > RIVET 9A7.008.607.00 

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    Flow-form rivets

12. Rivet in rear side panel (Cabriolet) in the convertible top compartment area.

    > 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

    > FLOW-FORM RIVETS 9A7.008.606.00  .

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    Clinch points

13. Rivet in rear side panel.

    > BLIND RIVET PAF.009.461 

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    Punch rivets

14. Rivet in rear side panel.

    > BLIND RIVET PAF.912.885 

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    Countersunk blind rivets

15. Apply aluminium weld on rear side panel (Cabriolet).

    > 5X00IN10 WELDING ALUMINIUM

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    Applying aluminium weld on rear side panel (Cabriolet)

16. Fold over seam in the door aperture using > VAS 6635 - crimping pliers set, 4-piece  .

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    Seam in door aperture

17. Fold over roll fold in rear wheel arch using > VAS 6635 - crimping pliers set, 4-piece  .

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    Roll fold in rear wheel arch