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 112 of 150
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53Rear Body
Edition 03.97
Replacement parts Left and right tail light carrier
Rear end panel
Preparing new parts
- Drill
∅ 7 mm holes in tail light carrier in
connection area to end panel.
Welding in
- Match up end panel in the assembly with tail light carriers and tack weld.
- Check operation of lock and gaps of tailgate.
- Weld in tail light carriers, RP spot weld.
- Weld in remaining joint, SG plug weld.
- Weld in end panel, RP spot weld.
Page 115 of 150
Downloaded from www.Manualslib.com manuals search engine Rear Body53
Edition 03.97
Replacing rear lock carrier
End panel already removed.
Separation points
- Detach original joint to side reinforcements.
Note:
If the side reinforcements are damaged, thesehave to be straightened or replaced.
Replacement part Rear lock carrier
Welding in
- Match up rear lock carrier together with rear end panel and tack weld.
- Check operation of lock and gaps of tailgate.
- Take off end panel.
- Weld in rear lock carrier, RP spot weld.
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.)
