Info

Repairing Rear Body Section Damage

Printed in Germany

Spot weld overlap at mating seam as far as possible.

MIG weld rest of mating seam from outside, straighten, fill and grind.

Match upper contour with rear lid.

Fit and mark rear side panel, add 8mm to welding seam and shoulder with a shoulder pliers as illustrated in the figure.

Cut upper edge flush with rear window and border with wheel housing.

Match upper contour with rear lid.

Install and spot weld reinforcement frame to side panel and rear lock member.

First tack weld side panel. Check location. Then spot weld connecting surfaces.

Spot weld overlap at mating seam as far as possible.

MIG weld rest of mating seam from outside, straighten, fill and grind.

Using wire brush, grind the upper joint of the side panel/apron until it is blank and then braze so that the joint remains visible.

Cut off support bracket at apron, fit tail light housing and align the mounting surfaces if necessary.

Install lock cylinder and lock bases, and align with the rear lid.

Seal inside of side panel at connecting seams, spray out inaccessible cavities.

Seal inside connecting seams.

Fit bumper.

REPAIRING SIDE PANEL (E

Note

In addition to removal steps on pg 53 - 1 remove seatback, side trim and seat belt, side window, lock, vent cover, rear and side carpets as required.

Additional Cutting

Door pillar about 1 cm above side window sill (saw or cutting wheel).

Bottom of side panel at side member as well as center of roof frame (cut through with a cutting wheel).

Side panel along door opening, side and rear windows, wheel housing as well as floor area (pneumatic or hand chisel).

Remove damaged metalĀ« Straighten flanges. Grind down and apply a coat of spot welding paint.

TIRE FEND ER) Installing

Fit and mark side panel. Add 8 mm at mating surfaces of side member and roof frame. Then shoulder with shoulder pliers.

Install, clamp and tack weld side panel. Check position. Watch door, side window, rear lid and wheel opening alignment.

Finish side panel spot welding. MIG weld overlapped areas. Gas weld top of door pillar.

Electrodes with an opening are required to spot weld the flange to the wheel housing - see figure.

Straighten, grind, braze and clean welding areas on roof frame, side member and door pillar.

Cut off support bracket on apron. Fit tail light housing and align mounting surfaces if necessary,

Grind down entire joint from side panel to apron. Braze joint so that it remains visible. Install reinforcement brackets. See instructions on page 53-7.

Align and spot weld reinforcement frame to side panel.

Weld support bracket to luggage compartment cover.

Fit rear lid, install lock cylinder and lock base parts, and align lock.

Seal inside of side panel at connecting seams. Spray out inaccessible cavities.

Fit rear bumper.

Prepare car for painting,

53-6 Repairing Side Panel (Entire Fender)

II, 1977 - Printed in Germany

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