4135101 Replacing Left Rear Side Panel

NOTE: Observe procedure for bonding and riveting (REPAIR STAGE 2) .

Rear side panel
Reinforcement plates (not pictured)
Lock nuts (not pictured)

Following CONSUMABLES are required:

CONSUMABLES

Material	Quantity
Adhesive K5b	1
Adhesive K5a	1
Sealant D1
Blind rivets N3	17
Punch rivets N4	26
EMC screws	1
R1 cleaning agent	1

Fig 1: Identifying Rear Side Panel

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Removing side wall

Fig 2: Identifying Welding Areas With Dimension a And b On Left Rear Side Panel

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Mark severance cuts in accordance with specified dimensions and cut.

IMPORTANT: Cut outer panel only.

Before loosening the wheel arch welding connections:

Straighten wheel arch edge similarly to new part.

Compare position of severance cuts with REINFORCEMENT PLATES .

Dimension a = approx. 110 mm from roof edge.

Dimension b = approx. 250 mm to centrepoint of 25 mm diameter hole.

Open welded connections in areas (1).

Open brazed connections in areas (2).

Fig 3: Identifying Welding And Brazed Connection Areas

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Preparation of new part

IMPORTANT: Release entrance section from new part.

Mark severance cuts on the new part according to vehicle and cut.

Prepare REINFORCEMENT PLATES at all severance cuts.

Adjust new part to fit and secure.

Set 4.2 mm diameter bore holes for blind rivets in areas (1) and (2).

Area (1): 5 bore holes

Area (2): 6 bore holes

Fig 4: Identifying Rivet Areas

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Set 4.2 mm diameter bore hole for blind rivets in bulkhead of jacking point in the area (1).

Fig 5: Identifying Rivets Areas In Bulkhead Of Jacking Point

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

Area (1): 4 bore holes

Area (2): 1 bore hole

Remove new part again and deburr bore holes.

Fig 6: Identifying Rivet Areas

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IMPORTANT: Do not grind/sand new part in area of bonding surfaces.

Installing side wall

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

Apply adhesive to reinforcement plates. Install reinforcement plates.

Fig 7: Identifying Adhesive Applying Areas On Rear Side Panel

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Apply adhesive in areas (1).

Adhesive must be applied to new part in area (2).

Apply sealant D1 to cavity sealing in areas (3).

Fig 8: Identifying Rivet Areas On Left Rear Side Panel

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Install side wall with a second person helping.

NOTE: When installing side wall, make sure there is sufficient adhesive on bonding surfaces.
Rivet side wall with blind rivets in areas (1).
Use punch rivets N4 in areas (2) and (3).

PUNCH RIVETS REFERENCE CHART

Area	Number
2	10
3	6

Secure side wall next to reinforcement plates with gripping pliers.

Rivet side wall with blind rivets in areas (1).

Use punch rivets N4 in areas (2) and (3).

PUNCH RIVETS REFERENCE CHART

Area	Number
2	5
3	5

Fig 9: Identifying Rivet Areas

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IMPORTANT: The wheel arch must be bordered immediately after riveting before the adhesive hardens.
After adhesive has hardened in the lower sill area, install an EMC SCREW .