41 12 548 Replacing Rear Cross Member on Luggage Compartment Floor (Tail Panel Removed)

41 12 548 Replacing Rear Cross Member On Luggage Compartment Floor (Tail Panel Removed)







Read contents of Body, General. Strip down vehicle







Observe (repair stage 2) procedure.







Following new body parts are required (refer to Electronic Parts Catalogue):
- (1) End of luggage compartment floor

Following consumables are required:

Material Quantity
Adhesive K5a 1
Blind rivets N3 3
Blind rivets N6 10
EMC screws 3
Cleaning agent R1 1
Cavity wax remover
Sealant D1







Removing cross-member







Open welded connections in area (1).







Operation is described on the left side.
Right side identical.
Open welded connections in the area (1) and remove cross member (2).







New part preparation







Open welded connections in area (1) and remove cross member (2).







View from below.
Adjust cross member in combination with tail panel to fit and secure.
Set 6 bore holes - 4.2 mm for blind rivets N6 in the area (1).
In areas (2) set 3 bore holes - 4.2 mm for blind rivets N3.







Operation is described on the left side.
Right side identical.
Set 2 bore holes - 4.2 mm for blind rivets N6 in the area (1).
Remove cross member (2) again and deburr bore holes.







Installing cross-member:







IMPORTANT: Do not grind new parts and body in area of bonding surfaces.







Clean all bonding surfaces on new part and on vehicle with cleaning agent R1.
Apply adhesive to bonding surfaces.
Install cross member and rivet with blind rivets.







After hardening of the adhesive install 3 EMC screws in the areas shown (1).