Inserting rear body section into body at on side No Operation Instructions

Clean the weld areas

Clean the body areas to be welded with a hot air blower or rotary brush to remove underseal, paint etc. Remove factory-applied primer with a rotary brush from the weld areas on the replacement parts.

Fit side member and rear axle cross member into body and

Fit side member and rear axle cross member into body, secure with clamping tools and tack weld into position. Using the inert gas method, butt weld the replacement side member to the body side member with a full seam, Plug weld the side member to the cross member, engine mount and rear axle cross member. Note: The rear axle cross member may only be fitted

Insert special tool P 853

Place special tool P 853 (rear window template) into body cutout for rear window and secure with clamps to

Fit rear wheel housing into body and prepare for welding in

Trial-fit reinforcements to the side member, secure with

Trial-fit rear wheel housing to body and prepare for welding in

Trial-fit rear wheel housing to body. Drill out the rear wheel housing ready for plug welding at points not

Weld the rear wheel housing into the body (from the outside)

Secure the rear wheel housing with clamping tools and spot weld to the cross member, rear wheel housing reinforcement, side member (where accessible) and roof frame. Using the inert gas method, plug weld the rear wheel housing to the central side member in the areas of the side member and the rear wheel housing reinforcement not accessible for spot welding.

Operation

Instructions

Weld the rear wheel housing to the body (from the inside)

MIG weld the rear wheel housing to the B-post, the rear wheel housing reinforcement and the side member with

Plug weld the inner side panel to the rear window shelf

Fit the gusset plate, prepare for inserting and MIG weld

Fit the gusset plate to the rear wheel housing and the central side member. Drill out the gusset plate for plug

Plug weld the gusset plate to the rear wheel housing and the central side member, using inert gas.

Solder lid release guide tube

Fit lid release guide tube and braze to lock pillar, rear wheel housing and cross member.

Fit side panel to body

Fit side panel to body. Install door and engine compartment lid to check body contours. Gaps between door and body and between rear lid and body must be parallel all round.

Insert special tool P 854

Place special tool P 854 (template for rear side window) in the rear side window body cutout and secure to spot

Tack weld side panel under

Using inert gas, tack weld the side panel to the door sill, B-post, rear side window spot-weld flange, rear wheel housing and cross-member. Take out special tool P 854

10 Spot weld and MIG weld

Spot weld the side panel to the rear wheel housing,

MIG weld the side panel to the door sill (B-post area), outer roof sheet / rear wheel housing and cross member with a discontinuous full seam.

Fold roof over into side panel

Fold side panel edge over web on roof,

Operation

Instructions

MIG weld the ends of the fold

MIG weld the side panel to the roof at the end of the fold in the B-post area running a full seam. MIG weld the side panel to the roof at the end of the fold in the rear lid area running a full seam. Take out special tool P 853 (rear window template). Grind the inert gas weld seams.

12 Spot weld the angled surround to the inner side

13 Spot and tack weld the sectioned rail to the side

Spot weld the sectioned rail to the side member/rear wheel housing spot weld flange on the inside, and tack weld under inert gas in the engine mount area.

Fit door sill to body and prepare

Making a butt joint, fit replacement door sill to body door sill and side panel. Insert door siil into body and ad-

Remove door sill and prepare bonding area

Remove replacement door sill from body. Clean bonding areas at gusset plate and door sill and apply primer.

Preparing the bonding cartridge for application of adhesive

15 Open nozzle fitting of cartridge containing component A

Use a screwdriver to pierce the diaphragm in the nozzle fitting of the cartridge containing component A (C1).

16 Open flanged cover of cartridge containing component A

Use the screwdriver handle to pierce the flanged cover at the end of the cartridge containing component A (C1).

17 Screw filling nozzle onto cartridge containing component A

Screw filling nozzle (C10) onto cartridge containing

18 Place cartridge containing component A into bonding gun

Place cartridge containing component A (C1) into Remove screw-on cap from mixing cartridge (C3).

19 Press component A into mixing

Engage filling nozzle (C10) of cartridge containing component A (C1) into mixing cartridge (C3).

Use bonding gun (A) to press component A into mixing

20 Open nozzle fitting of cartridge containing component B

Use a knife to cut off the tip of the nozzle fitting of the cartridge containing component B (C2).

21 Screw injector nozzle onto cartridge containing

Screw injector nozzle (C7) onto cartridge containing

22 Place cartridge containing component B into bonding gun

Place cartridge containing component B (C2) into

23 Press component B into mixing cartridge with component A

Insert injector nozzle (C7) of cartridge containing component B (C2) into mixing cartridge (C3). Use the bonding gun (A) to press component B (02) into mixing cartridge (C3) with component A.

Close mixing cartridge

Pull injector nozzle (C7) out of mixing cartridge (C3) and close mixing cartridge with screw-on cap.

No. Operation

Instructions

25 Screw mixing rod into mixing

Screw mixing rod (B) manually into internal threads of mixing disc of mixing cartridge (C3). Clamp the other end of the mixing rod in a power drill chuck. Fit the power drill in a suitable clamping device.

26 Mix component A and component B

Switch on drill (speed 900 - 1200 rpm) and move mixing cartridge 25 times from stop to stop. Perform all 25 double strokes fairly rapidly!

Engage mixing disc into piston

Pull back mixing cartridge until a rattling sensation is Switch off drill and screw mixing rod out of mixing This causes the mixing disc to engage into the piston of

Place mixing cartridge with mixed 2-pack window adhesive into bonding gun.

Screw application nozzle (C8) onto mixing cartridge. Caution: Observe open time of 15 minutes!

Open time is the time available for application of the adhesive and for fitting the outer side member into the body.

28 Place mixing cartridge into bonding gun

Operation

Instructions

Apply adhesive to gusset plate

Apply 2-pack adhesive with bonding gun to entire gusset plate surface to a thickness of 4 mm. Do not apply any adhesive to the outer side member to side panel

Weld in outer side member

Fit outer side member to body and adjust to contours of

MIG-weld spare outer side member to body outer side member running a butt full seam.

Plug-weld outer side member to fender mating panel and closing panel using MIG equipment.

Spotweld outer side member to inner side member and center side member (floorpan).

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