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Longitudinal member for wheel housing to cowl panel frame/A-pillar
Rectangular cut-out on fender joining plate
Luggage compartment bracket to fender joining plate
Luggage compartment bracket to front side member
Outer rear side section to inner rear side section/cross member
Outer rear side section to outer rear wheel housing

Procedure:
Information
Mask or cover all adjacent components before starting sealing work.
The surfaces to be sealed must be free of grease and dirt before applying body sealant. For this purpose,
clean all affected areas with cleaning solution and a lint-free cloth.
1

Rework bodyshell mounting for battery console
holder and firewall.
1.1

Apply body sealant to the area marked in
yellow ⇒ Figure 29 inside and outside ⇒
Figure 29 -arrows A- the bodyshell mounting
and spread it out evenly with a brush.

1.2

Apply body sealant to the area marked in
yellow ⇒ Figure 29 over the welded seams
and spread it out evenly with a brush.
Make sure not to block the water drain bore
⇒ Figure 29 -arrow B- with body sealant.

A

A

B

Figure 29

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1.3

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Apply body sealant to the area marked in
yellow on the welded seams joining the
firewall upper section to the firewall lower
section and spread it out evenly with a brush.

Figure 30
2

Rework joint between longitudinal member for wheel
housing upper section and cowl panel frame/A-pillar
at both sides.
2.1

Apply body sealant to the area marked in
yellow above the cowl panel frame ⇒ Figure
31 -arrow A- and spread it out evenly with a
brush.

2.2

Apply body sealant to the area marked in
yellow below the cowl panel frame ⇒ Figure
31 -arrow B- and spread it out evenly with a
brush.

A

B
Figure 31

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Technical Information

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Rework rectangular cut-out on wing joining plate at
both sides.
3.1

3.2

Mask rectangular cut-out using a round
self-adhesive sticker from the adhesive film,
Part No.000.043.303.38 (⇒ Figure 32
-1-).

1

Apply body sealant over the masked cut-out
in the area marked in yellow ⇒ Figure 32
-2- and spread it out evenly with a brush.

2

Figure 32
4

Rework joint between luggage compartment bracket
and wing joining plate at both sides.
To do this, apply body sealant to the area marked in
yellow ⇒ Figure 33 and spread it out evenly with a
brush.
Make sure to spread the body sealant down over the
outer edge ⇒ Figure 33 -arrow-.

Figure 33

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5

Rework joint between luggage compartment bracket
and front side member at both sides.
To do this, apply body sealant to the area marked in
yellow ⇒ Figure 34 and spread it out evenly with a
brush.

Figure 34
6

Rework joint between outer rear side section and
inner rear side section/cross member at both sides.
To do this, apply body sealant to the area marked in
yellow ⇒ Figure 35 and spread it out evenly with a
brush.
Make sure to spread the body sealant up to approx.
10 mm below the sheetmetal flange.

Figure 35

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Technical Information

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Rework joint between outer rear side section and
outer rear wheel housing at both sides.
7.1

Pull speed nut off the body flange.

7.2

Apply body sealant to the area marked in
yellow ⇒ Figure 36 and spread it out evenly
with a brush.

7.3

Re-fit speed nut immediately after spreading
out the body sealant.

Information
The seam seal can be painted when it has reached approx.
70% hardness. This generally requires a hardening time of
approx. 4 - 5 hours at 73° F (23° C), 50% relative humidity.
Higher air humidity or dampening with water accelerates
the hardening process.
Figure 36
The hardening can be checked with a nail test. Press a
finger nail gently into the hardened body sealant. If this causes no damage to the surface, the seam seal
can be painted.
8

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Once the hardening process is complete, paint all areas on which you have applied body sealant
with top-coat paint (touch-up stick in vehicle color) until adequate coverage is achieved.

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5

Sealing cavities in longitudinal member for wheel housing upper section

1
2

Figure 37
Foam point 1 – Opening on longitudinal member for wheel housing upper section
Foam point 2 – Opening on wing joining plate

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Procedure:

ENU

9

Technical Information

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Mask the marked area at the two upper corners of the
luggage compartment with adhesive tape ⇒ Figure
38 -1- to prevent sealing foam from getting into the
luggage compartment.

Information
Always observe the current work safety regulations
when working with sealing foam ⇒ Workshop Manual
’5X00IN22 Working with body foam filler’.
One can of sealing foam must be used for each side of the
vehicle. When applying sealing foam, approx. 50% of the
can must be used for foam point 1 and 50% for foam point
2.
10 Activate the foam can, Part No. 999.915.337.40,
in accordance with the manufacturer’s instructions on
the can.

1
Figure 38

11 Fill longitudinal member for wheel housing upper
section with foam (foam point 1).
11.1

Guide spray pipe of foam can through the
opening on the longitudinal member for
the wheel housing upper section ⇒ Figure
39 -arrow- as far as possible towards the
A-pillar.

11.2

Fill longitudinal member for wheel housing
upper section with foam for approx. 15
seconds. During the last 5 seconds, pull the
spray pipe out slowly and evenly.

Figure 39

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Information
To make it easier to press in the stopper, coat the stopper with commercially available
silicone spray beforehand.
11.3

Close off the opening on the longitudinal
member for the wheel housing upper section
using a stopper, Part No. 999.703.421.40
, immediately after pulling out the spray pipe
⇒ Figure 40 -arrow-.

11.4

Remove any sealing foam that has oozed
out immediately, ensuring that there are no
traces of sealing foam remaining, and clean
using cleaning solution.

Figure 40
12 Fill longitudinal member for wheel housing upper
section close to the wing joining plate with foam
(foam point 2).
12.1

12.2

Guide spray pipe of foam can through the
opening on the wing joining plate as far as
possible towards the A-pillar ⇒ Figure 41
-arrow A-.
Fill longitudinal member for wheel housing
upper section towards the A-pillar with foam
for approx. 10 seconds.
When the foam filling process is almost
complete, pull the foam pipe out slightly until
it can be turned in the opening of the wing
joining plate.
Guide in the spray pipe in the opposite
direction of the front end ⇒ Figure 41 -arrow
B- and fill that area with foam for a further 5
seconds.

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A

B
Figure 41

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Information
To make it easier to press in the stopper, coat the stopper with commercially available
silicone spray beforehand.
12.3

Close off the opening on the wing joining plate
using a stopper, Part No. 999.703.421.40,
immediately after pulling out the spray pipe ⇒
Figure 42 -arrow-.

12.4

Remove any sealing foam that has oozed
out immediately, ensuring that there are no
traces of sealing foam remaining, and clean
using cleaning solution.

13 Perform steps 5 to 7 on the opposite side of the
vehicle.

Figure 42
14 When the chemical reaction of the sealing foam is
complete, remove strips of adhesive tape ⇒ Figure
43 -1- from the luggage compartment.

1
Figure 43

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Subsequent work
Procedure:

Subsequent work for rear end
1

Engage emergency release cable and clip in the inner
cover at the right ⇒ Figure 44 -arrow-.

Figure 44
2

Slide on sealing strip ⇒ Figure 45 -1- over the body
flange.

1

Figure 45

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4

Technical Information

37/12

Install upper part of oil filler neck.
3.1

Unscrew the coolant cap ⇒ Figure 46 -3-.

3.2

Fit upper part of oil filler neck ⇒ Figure 46
-2- to the oil filler hose ⇒ Figure 46 -5- and
secure with the spring band clamp ⇒ Figure
46 -4-.

3.3

Position upper part of oil filler neck ⇒ Figure
46 -2- and secure with the fastening screw ⇒
Figure 46 -1-.

3.4

Screw in the coolant cap ⇒ Figure 46 -3-.

1
2

3

5

Install engine-compartment blower ⇒ Workshop
Manual ’198119 Removing and installing enginecompartment blower - section on "Installing"’.

4

5

Install rear wheel housing liner at the left and right ⇒