41 35 101 Replacing Rear Left Side Panel

Read contents of BODY, GENERAL  and observe relevant procedures.

STRIP DOWN  vehicle

Following new body parts are required:

• (1) Side frame, rear
• Reinforcement plate, side sill
• Reinforcement plate, C-pillar
• Reinforcement plate, D-pillar
• Shaped part entrance, outer
• Shaped part, C-pillar
• Shaped part, D-pillar, outer
• Mounting nuts

Fig 1: Identifying Side Frame, Rear

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Removing side panel 

Mark severance cut (1) in accordance with dimension and cut.

Mark severance cut (2) at component edge and cut.

Measurement a = approx. 90 mm from center point of 20 mm dia. hole.

Open weld joint in areas (3).

Fig 2: Identifying Severance Cut Areas And Weld Joint Areas

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Fig 3: Identifying Template

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Mark severance cuts in accordance with specified measurements and cut.

Measurement a = approx. 130 mm from roof edge

Measurement b = approx. 95 mm

Open weld joints in areas (1).

(2) Position of cavity acoustic baffles

Fig 4: Identifying Severance Cut Areas And Weld Joint Areas

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Open welded connections in areas (1).

Open brazed connections in areas (2).

Fig 5: Identifying Weld Joints Area And Brazed Joint Areas

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Open welded connections in area (1).

Take off side panel.

Fig 6: Identifying Weld Joints Area

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New part preparation 

Prepare REINFORCEMENT PLATES  (bonded) at all severance cuts.

Mark severance cut (1) in accordance with vehicle and cut.

Mark severance cut (2) at component edge and cut.

Open weld joints in areas (3) and remove components (4).

Mark further severance cuts in accordance with vehicle and cut.

Fig 7: Identifying Adhesive Areas

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Adjust new part to fit and secure.

In areas (1) to (3), set 4.2 mm dia. holes for N3 blind rivets  :

In area (4), set 6.8 mm dia. holes for N1 blind rivets  :

Fig 8: Identifying Rivet Areas

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In areas (1) and (2) set 4.2 mm dia. bore holes for blind rivets:

Fig 9: Identifying Rivet Areas

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Remove new part again and deburr bore holes.

Installing side wall 

Clean all bonding surfaces on vehicle, on the new part and on the reinforcement plates with cleaning agent R1.

Apply adhesive to reinforcement plates. Install reinforcement plates.

Apply adhesive in areas (1).

Apply sealant to cavity acoustic baffles in areas (2). See cavity acoustic baffle (expanded)  and cavity acoustic baffle (not expanded) 

Fig 10: Identifying Sealant Areas And Adhesive Areas

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Install side panel with a second person helping.

After adjusting side panel to fit, tighten nuts of reinforcement plates (1).

Secure side panel in area of reinforcement plates with gripping pliers and rivet with blind rivets.

In areas (2) to (4) use punch rivets N4.

In areas (5), screw in the screws before the adhesive hardens.

Tighten screws hand-tight.

Fig 11: Identifying Reinforcement Plates, Screw Areas, And Rivet Areas

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Use 8 N4 punch rivets in area (1).

Fig 12: Identifying Area For Rivets

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Once the adhesive has hardened in area (1) and in the area of the side sill, fit one EMC SCREW  in each area.

Fig 13: Identifying Adhesive/Screw Area

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