PRE-RELEASE
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.
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Warning
| Replacement |
| 1. |
Cut according to the markings.
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| 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.
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| 3. |
Drill out the spot welds and lift away the loose piece.
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| 4. |
Cut the reinforcement. The cut must be made in the centre of the oval hole.
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| 5. |
Drill out the spot welds on the inner reinforcement.
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| 6. |
Drill out the spot welds on the inside to the reinforcement.
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| 7. |
Drill out the spot welds at the rear light cluster plate.
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| 8. |
Drill out the spot welds by the door opening and the window opening.
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| 9. |
Grind away the MIG brazing.
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| 10. |
Drill out the spot welds in the luggage compartment.
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| 11. |
Tap loose the side panel and break it loose from the wheel housing's adhesive.
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| 12. |
Straighten any deformed panels. Adjust and align all fitting surfaces.
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| 13. |
Cut the replacement panel so that it fits with the cuts previously made.
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| 14. |
Cut away a piece in order to access the reinforcement. Cut the reinforcement so that it corresponds with the cutting on the car.
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| 15. |
Drill out certain spot welds from the reinforcement so that it detaches from the section of the spare part that is not used.
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| 16. |
Drill holes for plug welding where appropriate.
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| 17. |
Grind clean the surfaces on the body and replacement panel that are to be welded.
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| 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. 
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| 19. |
Fit the spare part in place and make fine adjustments.
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| 20. |
Fully weld the inner reinforcement.
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| 21. |
Spot weld by the door opening and the window opening.
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| 22. |
Spot weld on the inside to the reinforcement.
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| 23. |
Plug weld at the rear light cluster plate.
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| 24. |
Plug weld in the luggage compartment
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| 25. |
Align the loose piece and spot weld it in.
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| 26. |
Fully weld all joints.
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| 27. |
Replace the MIG braze.
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| 28. |
Smooth off the welds.
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| 29. |
Wash away surplus welding primer. Welding primer reduces the adhesion of paint, filler and sealant.
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| 30. |
Apply primer to all bare metal surfaces.
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| 31. |
Seal joints and seams with sealant.
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| 32. |
Apply rust protector after painting. Use Terotex HV 400.
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