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Part of rear side plate, 5D, spare part complete side

Part of rear side plate, 5D, spare part complete side

Certain welded joints on the car may be MIG brazed with bronze as the filling material. A MIG brazed seam may be recognised from the gold colour of the joint. A MIG brazing must always be replaced by a new MIG brazing.

Warning

Repairs to MIG brazing using conventional welding methods and normal filler material are forbidden. Cracks can arise which can impair performance in a collision.


Replacement


1. Cut according to the markings.


2. Cut as follows: 20 mm below the plate joint and 140 mm above the plate joint. The cutting is necessary in order to access the spot welds underneath.


3. Drill out the spot welds and lift away the loose piece.

4. Cut the reinforcement. The cut must be made in the centre of the oval hole.


5. Drill out the spot welds on the inner reinforcement.

6. Drill out the spot welds on the inside to the reinforcement.


7. Drill out the spot welds at the rear light cluster plate.


8. Drill out the spot welds by the door opening and the window opening.


9. Grind away the MIG brazing.


10. Drill out the spot welds in the luggage compartment.


11. Tap loose the side panel and break it loose from the wheel housing's adhesive.

12. Straighten any deformed panels. Adjust and align all fitting surfaces.

13. Cut the replacement panel so that it fits with the cuts previously made.


14. Cut away a piece in order to access the reinforcement. Cut the reinforcement so that it corresponds with the cutting on the car.

15. Drill out certain spot welds from the reinforcement so that it detaches from the section of the spare part that is not used.

16. Drill holes for plug welding where appropriate.

17. Grind clean the surfaces on the body and replacement panel that are to be welded.

18. Apply welding primer to the surfaces to be spot and plug welded. Use Teroson Zink Spray

Apply Teroson 6700 on the edge of the outer wheel housing.


19. Fit the spare part in place and make fine adjustments.

20. Fully weld the inner reinforcement.

21. Spot weld by the door opening and the window opening.


22. Spot weld on the inside to the reinforcement.


23. Plug weld at the rear light cluster plate.


24. Plug weld in the luggage compartment


25. Align the loose piece and spot weld it in.


Warning

Repairs to MIG brazing using conventional welding methods and normal filler material are forbidden. Cracks can arise which can impair performance in a collision.


26. Fully weld all joints.

27. Replace the MIG braze.


28. Smooth off the welds.

29. Wash away surplus welding primer. Welding primer reduces the adhesion of paint, filler and sealant.

30. Apply primer to all bare metal surfaces.

31. Seal joints and seams with sealant.

32. Apply rust protector after painting. Use Terotex HV 400.