Page 111 of 150
Downloaded from www.Manualslib.com manuals search engine Rear Body53
Edition 03.97
Repairing rear body Replacing rear end panel
Separation points
- Detach original joint at left and right of tail
light carrier.
- Pull tail light carrier down and forward behind side part and remove.
- Detach original joint to boot floor and rear
lock carrier.
- Take off rear end panel.
Page 122 of 150
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53Rear Body
Edition 03.97
Replacing boot floor
Rear end panel and lock carrier already re- moved.
Separation points
- Detach original joint to side members and
left reinforcement.
- Position front separation cut about 100 mm behind cross member between wheel-houses.
- Remove remaining pieces.
Note: If the side connection panels are damaged,these have to be straightened or replaced.
Replacement parts Boot floor
Left boot floor reinforcement
Preparing new parts
- Pierce new part in connection area to wheel-
house.
- Drill
∅ 7 mm holes in the rear connection
area to side members. (RP spot weld in the area of spot weld tongs.)
Page 123 of 150
Downloaded from www.Manualslib.com manuals search engine Rear Body53
Edition 03.97
Welding in
- Match up boot floor with vehicle standing on
its wheels or on straightening rig and check gaps with end panel and tailgate fitted.
- Tack weld boot floor.
- Take off end panel.
- Weld in boot floor, RP spot weld.
- Weld in left reinforcement of boot floor, RP
spot weld.
- Weld separation cut, SG continuous weld
staggered.
- Weld in remaining joint, SG plug weld.
Page 128 of 150
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53Rear Body
Edition 03.97
Replacing rear side member -attached piece-
End panel already removed.
Separation point
- Detach original joint. Left side only:
- Cut out reinforcement of boot floor.
Notes:
The illustrations show the right-hand side member.
The procedure described is basically also thesame, however, for the left-hand sidemember. Only the position of the connection
to the boot floor is not identical.
Replacement part Side member attached piece
Preparing new part
- Match up new part.
Welding in
- Fix side member attached piece on straightening jig.
- Weld in side member, SG plug weld.
- Weld in remaining joint, RP spot weld.
