Vehicles after change point in 1982 RREPLACING RIGHT REAR SIDE PANEL Refer to information on page 41 - 001. Remove rear window, trunk lid, trunk lid rubber seal, tail lights, rear bumper, fuel tank, both rear seats, center armrest, side trim panel, seat belt, B pillar trim, shoulder plate, inside window cover plate, headrests with holders and trim, side window complete with regulator, window guide rails, striker, inside entrance strip, rubbing strips, outside B pillar plate, door edge guards and seals, entrance plate, door pillar plate, entrance strip, fuel tank flap, trunk mat, spare wheel, tail panel and sied panel trim, rear rain molding strip and rear wheel. Unscrew exhaust assembly. Loosen carpet and roof liner partially. | |
Remove tin from side panel/roof connection. |  |
Remove tin from side panel/cowl panel connection. |  |
Remove tin from side panel/tail panel connection. |  |
Cut off side panel along line. |  |
Cut side panel along line. |  |
Cut side panel along line. |  |
Remove scrap metal. |  |
Remove scrap metal on C pillar. |  |
Remove scrap metal on wheel opening edge. |  |
Remove scrap metal. Remove scrap metal on tail panel connections. Straighten and grind both sides of all mating surfaces, and coat with zinc dust paint. |  |
Grind mating surfaces of new side panel on both sides. |  |
Cut off new side panel in area of C pillar to guarantee an overlap to approx. 60 mm (2.362´´). |  |
Fit in and clamp side panel with body pliers. Check door clearance (A). |  |
Check trunk lid clearance (B). |  |
Tack weld side panel in area of C pillar. |  |
Inert gas weld overlap on inside. |  |
Inert gas weld side panel in area of rear window frame. |  |
Inert gas weld side panel in area of side window opening edge. |  |
Inert gas spot weld side panel on B pillar. |  |
Drill holes in area of entrance for inert gas plug welding. |  |
Inert gas plug weld side panel in area of entrance. |  |
Inert gas weld reinforcement for car jack take-up. |  |
Autogen weld side panel on wheel house. |  |
Spot weld side panel in wheel house opening. |  |
Spot weld side panel on entrance. |  |
Spot weld side panel in area of side window opening and inert gas weld C pillar. |  |
Spot weld side panel in area of rear window. |  |
Spot weld side panel on trunk floor plate. |  |
Inert gas weld tank filler housing on trunk floor plate. |  |
Braze tail panel on side panels and cut off strips in tail light opening. |  |
Braze side panel in area of entrance. Grind down all welding seams. |  |
Tin out C pillar connection. |  |
Tin out side panel/rear window frame connection. |  |
Tin out side panel/tail panel connections and trunk lid. |  |
Tin out side panel/entrance connection. |  |
Coat all welding seams with zinc dust paint*. Coat joints in area of side window opening with joint sealing compound*.  * Source: HWB
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Coat joints in area of wheel house, tank filler housing and trunk floor plate with joint sealing compound*. Spray out tail panel and side panel with antidrumming compound. * Source: HWB
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