The following steps are shown on the left side of the vehicle and must be accomplished analogously on the right side in the event of damage.
When MIG welding ( ) prepare welds by grinding down to bare metal with stainless steel brush. Tack weld weld seams at start and end. Weld seam gap should be greater than 1 mm, if required, preweld.
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1 | Install rear fender (1) with trunk lid, door, taillamp and rubber seal and fit. |
2 | Check and adjust gap dimensions. |
3 | Fix rear fender (1) in place. |
4 | Remove taillamp and rubber seal. |
5 | Drill Ø 6.7 mm rivet holes in rear fender (1) (area Y). |
6 | Drill Ø 5.1 mm rivet holes on rear fender (1) (area A). |
Ensure that the present holes in the rear fender (1) used as rivet holes only if they coincide with the present holes in the vehicle. A deviation of approx. 1 mm is permissible. If deviations are greater, punch new rivet holes between the existing holes. |
7 | Drill Ø 5.1 mm rivet holes on rear fender (1) (area B). |
Ensure that the present holes in the rear fender (1) used as rivet holes only if they coincide with the present holes in the vehicle. A deviation of approx. 1 mm is permissible. If deviations are greater, punch new rivet holes between the existing holes. |
8 | Remove rear fender (1) and deburr rivet holes on both sides. |
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9 | Apply sealant to foam part (area AA) and wheel well (area AB). |
10 | 2KApply 2-component adhesive to crosshatched areas. |
Refer to manufacturer specifications for 2-component adhesive curing and application times.2K |
11 | Install rear fender (1) and fix in place |
12 | Rivet rear fender (1) with Ø 4.88 blind rivets (area C). |
13 | Rivet rear fender (1) with Ø 6.414 blind rivets (area D). |
14 | Rear fender (1) (areas E and F). |
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15 | Rivet rear fender (1) with Ø 4.88 blind rivets (area G). |
16 | Rear fender (1) (area H). |
17 | Rivet rear fender (1) with flow-form rivets (area I). |
Use flow drill rivet with 3.35 mm to 4.1 clamping range. |
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18 | Rivet rear fender (1) with flow-form rivets (area K). |
Use flow drill rivet with 3.35 mm to 4.1 clamping range. |
19 | Clean weld joints on rear fender (1). |
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20 | Heat wheel arch on rear fender (1) and crimp carefully. |
Heat area on rear fender (1) to be crimped. |
The crimp can also be made with an approved, standard commercial crimping tool. |
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21 | Heat wheel arch on rear fender (1), crimp with bending pliers (area N). |
Heat area on rear fender (1) to be crimped. |
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