Vehicles before change point in 1982
REPLACING REAR RIGHT SIDE RANEL AND TAIL PANEL
Read "Introduction"!
Remove rear window, trunk lid, trunk lid lock,
trunk lid rubber seal, lock cylinder, both tail
lights, both license plate lights, rear bumper,
tank, both rear seats, center armrest, side trim,
seat belt/B-pillar trim, waistline strips, inner
window strip, headrests with holders and trim,
side window and regulator, window guide
rails, striker, inner entrance rail strip, buffer
strips, outer B-pillar plate, edge guard and
seal for door, entrance plate, door pillar plate,
entrance strip, tank flap, trunk mats, spare
wheel, tail and side panel trim, rear rain
molding and rear wheel.
Detach exhaust, carpets and headliner as
required.

Detin side panel/roof joint.

Detin side panel/apron joint.

Detin side panel/tail panel joint.

Cut through side panel along line.

Cut through side panel along line.

Cut through side panel along line.

Cut out tail panel along line.

Remove scrap metal.

Remove scrap metal from C-pillar.

Remove scrap metal from wheel opening.

Remove scrap metal.
Remove scrap metal from tail panel mating
surfaces.
Align all mating surfaces, grind both sides
until bright and coat with powdered zinc
paint.

Grind both sides of new side panel mating
surfaces until bright.

Cut off new side panel in area of C-pillar
that an overlap of about 60 mm (2.362´´)
is guaranteed.

Grind both sides of tail panel mating
surfaces until bright.

Fit side panel and tail panel and hold in
place with body pliers.

Check door gap (A).

Check trunk lid gap (B).

Tack weld side panel in area of C-pillar.

Shield arc weld inside of overlap.

Shield arc weld side panel in area of rear
window.

Shield arc weld side panel in area of side
window opening.

Shield arc spot weld side panel to B-pillar.

Drill holes for shielded arc plug welding in
area of entrance.

Shield arc plug weld side panel in area of
entrance.

Shield arc weld car jack holder reinforcement.

Gas weld (autogen) side panel to wheelhouse.

Spot weld side panel in wheelhouse
opening.

Spot weld side panel to entrance.

Spot weld side panel in area of side window
opening and shield arc weld to C-pillar.

Spot weld side panel in area of rear window.

Spot weld side panel to trunk floor plate.

Shield arc weld tank filler housing to trunk
floor plate.

Spot weld tail panel to trunk floor plate.

Braze tail panel to side panels and cut off
lands in tail light openings.

Shield arc weld trunk partition walls to tail
panel.

Shield arc weld lock support to trunk floor
plate.

Shield arc weld trunk floor reinforcement to
tail panel.

Braze side panel in area of entrance.
Grind all welding seams.

Tin C-pillar joint.

Tin side panel / rear window frame joint.

Tin side panel / tail panel and trunk lid
joints.

Tin side panel / entrance joint.

Coat all welding seams with powdered zinc
paint.
Coat joints in area of side window opening
with a joint sealing compound.

Coat joints in area of trunk floor plate / tail
panel and side panel with a joint sealing
compound.

Spray tail panel and side panel with
Bodyplast.

Vehicles after change point in 1982
REPLACING RIGHT REAR SIDE
PANEL AND TAIL PANEL
Refer to information on page 41 - 001.
Remove rear window, trunk lid, trunk lid lock,
trunk lid rubber seal, lock cylinder, both tail
lights, both license plate lights, rear bumper,
fuel tank, both rear seats, center armrest, side
trim panel, seat belt, B pillar tirm, shoulder
plate, inside window cover strip, 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 guard and weatherstrip, plate
on entrance, tank flap, trunk mat, spare wheel,
tail panel and side 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.

Cut out tail 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 both sides of mating surfaces on new
side panel.

Cut off new side panel in area of C pillar in such
a manner that an overlap of approx. 60 mm
(2.362´´) is guaranteed.

Grind both sides of mating surfaces on tail
panel.

Fit in side panel and tail panel, clamping 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.

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.

Spot weld tail panel on trunk floor plate.

Braze tail panel on side panels and cut off
strips in tail light opening.

Inert gas weld trunk walls on tail panel.

Inert gas weld lock supports on trunk floor
plate.

Inert gas weld trunk floor plate brace on tail
panel.

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.

Coat joints in area of trunk floor plate/tail panel
and side panel with joint sealing compound.

Spray out tail panel and side panel with
antidrumming compound.