41 35 101 Replacing Rear Left Side Panel

Read contents of Body, General  . Refer to 41 0 Contents Of Body, General .

Use only approved spot-welding apparatus  for repairs. Refer to 41 00... Workshop Equipment .

Spot-weld bonding is used on this vehicle. Observe specific procedure  . Refer to 41 00... Opening Adhesive Bonds  and/or 41 00... Spot-Weld Bonding Steel Parts .

Remove or cover those vehicle components in the repair area which are susceptible to heat or dust.

Following new body parts are required:

• (1) Side panel, rear

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Open weld joints in areas (1).

Open brazed connection in area (2).

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Open weld joints in areas (1).

Open brazed connections in areas (2).

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Open spot-welded adhesive joints in areas (1).

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Open brazed joints in area (1).

Take off side panel.

Installation: 

When sealing in area (2), ensure sufficient clearance for outer window cavity cover strip.

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Preparation of new part: 

Adjust new part to fit and secure. In areas (1) and (2) set 4.2 mm diameter bore holes for blind rivets N 3:

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Set four 4.2 mm bore holes for blind rivets N 3 in area (1).

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Set four 4.2 mm bore holes for blind rivets N 3 in area (1).

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Set four 4.2 mm bore holes for blind rivets N 3 in areas (1).. Remove new part again and deburr bore holes.

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Installation note:  Apply sealant to cavity sealing (2).

Installing side wall:  Clean all bonding surfaces on vehicle and on new part with cleaning agent R1. Apply adhesive to bonding surfaces.

Install side panel with a second person helping.

Secure side wall and rivets with blind rivets. Use punch rivets in areas (1) and (2).

In area (3), secure side wall with gripping pliers until adhesive has hardened.

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Use punch rivets N4 in areas (1) and (2).

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Use N4 punch rivets in areas (1) to (3).

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After adhesive has hardened, install one EMC screw in each case in areas (1). Additionally, install EMC screw in sill area.

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