General Notes
Remove back panel before beginning this repair (see section “Rear panel - Replace“)
The graphics concerning adhesive application do not show the realistic repair conditions.
Remove
- 1. Remove 4x bolts (1).
- 2. Drill out welding spots (A, B).
- 3. Grind open welding spots (A, D; one panel thickness)
- 4. Mill out welding spots with a spherical cutter (B, C; two panel thickness).
- 5. Drill out welding spots (A, B, one panel thickness).
- 6. Drill out welding spots (A, B, C, D; one panel thickness).
- 7. Drill out welding spots (A, two panel thickness).
- 8. Drill out welding spots (B, one panel thickness).
- 9. Bend open rear floor front panel flanges (arrows).
Install
Important. Observe the instructions given in the section “Bodywork repair through structural adhesive“ for all following instructions concerning adhesive application.
- 10. Fit in rear floor rear panel temporarily.
- 11. Mark position of rear floor front panel flanges on rear floor rear panel to simplify the positioning of the slots for MIG-brazing. Remove rear floor rear panel.
- 12. Prepare rear floor rear panel. Make 11x slot (5x18 mm).
- 13. Apply corrosion protection adhesive system (structural adhesive) to body when rear floor rear panel is not yet fixed in.
- 14. Apply corrosion protection adhesive system (structural adhesive) to body when rear floor rear panel is not yet fixed in.
- 15. Fit in rear floor rear panel with adjoining parts.
Note. Observe gap width tolerances of adjoining parts.
- 16. Tack weld (1) rear floor rear panel.
- 17. Weld in rear floor rear panel.
- 18. Make 18x slot for MIG-brazing while rear floor front panel flanges are bent open (5x18 mm).
- 19. Bend in rear floor front panel flanges (arrows).
- 20. MIG-braze rear floor front panel and rear floor rear panel.
- 21. Make 2x slot (1) for MIG-brazing while rear floor rear panel is fixed in (5x18 mm).
- 22. Weld in rear floor rear panel.
- 23. MIG-braze rear floor front panel and rear floor rear panel.
- 24. Apply corrosion protection adhesive system (structural adhesive) to towing rear hook when it is not yet fixed in.
- 25. Fit in towing rear hook.
- 26. Apply corrosion protection adhesive system (structural adhesive) to spare tire bracket when it is not yet fixed in.
- 27. Fit in spare tire bracket.
- 28. Make 10x slot for MIG-brazing (6x20 mm).
- 29. MIG-braze part.
- 30. Weld in parts.
- 31. Tighten 4x bolts (1, 2).
- 32. Grind MIG brazed seams.
- 33. Seal body, weld and brazing seams.
Note. Observe corrosion protection measures for seam seals.
- 34. Apply underseal.
Note. Observe corrosion protection measures for PVC protection.
- 35. Seal cavity.
Note. Observe protective wax corrosion protection measures.