Rear Shelf: Service and Repair
WM 512155 Replacing rear centre panel reinforcement
- General warning notes
- Tools and materials
- Preliminary work for body repairs
- Removing rear centre panel reinforcement
- Preparing connection areas of the body for installing rear centre panel reinforcement
- Preparing rear centre panel reinforcement for installation
- Installing rear centre panel reinforcement
- Subsequent work
Tools
General warning notes
Safety instructions for body repairs
-> 5X00IN04 Safety instructions 5X00IN04 Safety instructions
Tools and materials
Tools and materials
Spotweld drill bit Nr.129
Spotweld cutter Nr.128-2
Star gauge Nr.127-1 Pos.1
Star gauge Nr.127-1 Pos.2
Star gauge Nr.127-1 Pos.3
Pneumatic body saw PS 1 WE 1138
Hot-air blower, Leister-Electron/V.A.G. 1416 WE 1119
Inverter welder ATL InvertaSpot WE WE1194
Special electric cutter - fine WE 1137
Pneumatic spot-weld remover, Vario drill WS 90 WE 1139
Vice-grip wrench WE 1269
Body straightening system, Celette WE 1121
Preliminary work for body repairs
Preliminary work for body repairs
Information
- If it can be ensured there has been no deformation of the vehicle structure, the following repair can be carried out without the need of a straightening bench. In this case, the vehicle must not be raised when welding the component; it must stand on its wheels on an even surface.
1. Remove accessories in the repair area
1.1. Remove accessories in the repair area according to the extent of damage to the vehicle.
2. Equip straightening bench with straightening attachments
2.1. Equip straightening bench with the straightening attachments according to the setup plans included with the straightening attachments.
3. Place vehicle on the straightening bench
3.1. Position vehicle on the straightening bench, align according to the reference holes and bolt firmly to the straightening attachments.
4. Cover accessories adjacent to the vehicle repair area
4.1. Cover all accessories remaining on the vehicle and adjacent areas with fire-proof protective covers.
5. Reshape connection area of the sheetmetal parts to be replaced
6. Expose welding areas
6.1. Remove undersealing, paint, etc. from the welding areas of the body with a hot-air gun or rotary brush.
Removing rear centre panel reinforcement
Removing rear centre panel reinforcement
Installation position of rear centre panel reinforcement
1. Milling off spotwelds
1.1. Mill off spotwelds in areas -A, B, C, D- using a spotweld cutter.
Milling off spotwelds
Information
Removing expanded sealant
- The rear centre panel reinforcement is factory-sealed to the rear cross member with expanded sealant in area -Y-.
- This expanded sealant is destroyed when replacing the rear centre panel reinforcement and must be replaced.
Expanded sealant
2. Separating bonded joints and removing expanded sealant
2.1. Heat up bonded joints in the areas -A, B, C, D- between the rear centre panel reinforcement and rear cross member using the Leister Elektron hot-air gun; see Gr. 3.5, Workshop Equipment Manual 00000 and remove rear centre panel reinforcement.
Separating bonded joints and removing expanded sealant
Preparing connection areas of the body for installing rear centre panel reinforcement
Safety instructions for dealing with flying sparks during grinding and welding work
WARNING
Grinding and welding work
- Danger of fire or explosion
-> Avoid working in an area with highly inflammable or explosive materials.
-> Cover highly inflammable or explosive areas.
-> Remove highly inflammable or explosive parts.
Preparing connection areas of the body for installing rear centre panel reinforcement
1. Clean undersealing, adhesive residue and paint off the body connecting flanges in the marked areas -A- and -B- using a hot-air gun or rotary brush. Grind the connecting flanges until bare.
Preparing connection areas of the body for installing rear centre panel reinforcement
2. Clean undersealing, adhesive residue and paint off the body connecting flanges in the marked areas -A, B, C, D- using a hot-air gun or rotary brush. Grind the connecting flanges until bare.
Preparing connection areas of the body for installing rear centre panel reinforcement
Information
- Keep bonding areas clean and free of grease and do not coat with zinc powder paint.
3. Coating spot-weld flange areas with zinc powder paint
3.1. Coat all spot-weld flange areas with zinc powder paint.
Preparing rear centre panel reinforcement for installation
Safety instructions for sharp-edged body and unit parts
CAUTION
Pointed or sharp objects
- Risk of cracks, pricks or cuts
-> Wear personal protective gear.
Preparing rear centre panel reinforcement for installation
1. Cleaning the welding areas
1.1. Grind both sides of the connecting flange of the rear centre panel reinforcement in the marked areas -A- and -B- until bare using a rotary brush.
Cleaning the welding areas
Information
- Keep bonding areas clean and free of grease and do not coat with zinc powder paint.
2. Coating spot-weld flange areas with zinc powder paint
2.1. Coat spot-weld flange areas with zinc powder paint.
Installing rear centre panel reinforcement
Danger of injury while welding
WARNING
Electric welding
- Risk of electric shock or burns
-> Wear personal protective gear.
-> Disconnect both battery terminals.
-> Do not weld in a damp area or when it is wet under foot.
-> Move highly inflammable materials out of the work area. Vertilate the work area well.
-> Remove smoke gases with an extraction system.
-> Read specific safety information for the welder.
-> Check that welder is working perfectly before use.
Installing rear centre panel reinforcement
WARNING
Risk of damage if the processing time is not observed!
- The quality of the joint will be affected if the adhesive processing time is not observed.
-> The new part must be welded within 30 minutes in the area of the adhesive, otherwise the adhesion of the adhesive will be affected.
1. Applying body sealant to the seal
1.1. In areas -A- and -B- , apply a triangular bead of body sealant measuring -dimension X= approx. 12 mm- high all around the seal.
Applying body sealant
2. Applying adhesive to the rear centre panel reinforcement
2.1. On the inside of the rear centre panel reinforcement in areas -A- and -B- , apply a triangular bead of adhesive (Teromix-6700) measuring -dimension X= approx. 8 mm-.
Applying adhesive to the rear centre panel reinforcement
3. Fitting rear centre panel reinforcement to the body
3.1. Fit the rear centre panel reinforcement to the body and fix in place with tensioning clamps.
4. Welding in the rear centre panel reinforcement
4.1. Resistance spot-weld the rear centre panel reinforcement in areas -A, B, C, D-.
Welding in the rear centre panel reinforcement
Subsequent work
Subsequent work for body repairs
1. Remove vehicle from straightening bench
2. Clean spot-welded joints and sheetmetal flanges with a wire brush
3. Prime flange areas with 2K primer
4. Restore standard sealing with body sealant
-> 5000IN Seam sealing
5. Restore standard undersealing with underbody sealant
-> 5000IN Undersealing
6. Paint repair area and adjacent surfaces, if necessary
7. Install any accessories you removed in the repair area
8. Apply cavity preservation.