1 | Install rear fender, rear-end door, taillamps, rubber seal and striker and fit. |
2 | Check gap dimensions (M, O, P, Q, R, T and V) and adjust. |
3 | Fix rear fender in place. |
4 | Remove taillamps, rubber seal and shackle. |
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5 | Drill rivet holes on rear fender (1) with dia. 6.5 mm bit (areas F and K). |
6 | Remove rear fender (1). |
7 | Deburr rivet holes on rear fender (1) on both sides. |
8 | Deburr rivet holes on body. |
9 | Coat insides of riveted joints with zinc dust paint. |
10 | Apply body sealant to foam part (2) and rear wheel well (5) in crosshatched area. |
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11 | Install rear fender (1) on rear end and upper D-pillar (3). |
The rear fender (1) can be installed behind the outer and inner rear end assembly with aid of a screwdriver (4). |
12 | Fix rear fender (1) in place. |
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13 | Rivet rear fender (1) with 6.4 x 14 Polygrip flat/round headrivets (areas F and K). |
14 | Rear fender (1) (area F1). |
15 | Rear fender (1) (area J and A1). |
16 | Rear fender (1) (area A). |
17 | Rear fender (1) (areas B, D and E). |
Weld in intervals, allow to cool down in between to minimize heat distortion (areas B, D and E). |
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18 | Rear fender (1) (areas G and H). |
19 | Rear fender (1) (area J). |
20 | Convert spot weld flange on wheel well. |
Spot weld flange position analog to undamaged vehicle side. |
21 | Rear fender (1) (areas C1 and L). |
22 | Rear fender (1) (area C). |
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23 | Grind weld joints on rear fender down flat in crosshatched areas. |
24 | Clean weld joints. |
25 | Fill surface on rear fender in area of inert gas welds with body solder and smooth. |
26 | Remove grinding and drilling chips with wet/dry vacuum cleaner. |
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