41 35 101 Replacing Rear Left Side Panel

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Read contents of BODY, GENERAL and observe relevant procedures.

STRIP DOWN vehicle.

Observe REPAIR STAGE 2 .

Following new body parts are required :

(1) Rear side wall
(2) Attachment, entrance, outer
Reinforcement plate, side sill
Reinforcement plate, C-pillar
Shaped part entrance, rear
Mounting nuts

Fig 1: Identifying Side Panel, Rear And Attachment, Entrance, Outer

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Removing side panel:

Mark severance cut (1) at outer entrance attachment (2) in accordance with measurement a and cut.

Dimension "a" = 100 mm in front of 20 mm dia. hole.

Open weld joints on outer entrance attachment (2) and remove component.

Fig 2: Opening Weld Joints On Outer Entrance

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Mark severance cuts in accordance with specified measurements and cut.

IMPORTANT: Cut outer metal sheet only. Compare position of severance cuts with REINFORCEMENT PLATES .
Sunroof water drain hose is located behind severance cut "b".

Dimension "a" = approx. 25 mm from center point of 20 mm diameter hole. (left side of vehicle only)

Dimension "b" = approx. 100 mm from roof edge.

Dimension "c" = approx. 20 mm from outer edge of sill

Open welded connections in areas (1).

Open weld connections on bulkhead in area (2).

Release side wall from cavity acoustic baffles (4).

Fig 3: Identifying Severance Cuts And Specified Dimensions

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NOTE: In addition to the dimensions, the position of the separating cut can be determined with a TEMPLATE (1).

Fig 4: Using Template

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Right side of vehicle only:

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

Dimension "a" = approx. 20 mm before center of 20 mm dia. hole.

IMPORTANT: Cut outer panel only.

Separation cut (2) analogous with left side of vehicle.

Fig 5: Identifying Dimension "A"

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Side panel omitted for clarity.

Open bonded connection (1) of reinforcement of C-pillar lock striker.

This bonded connection is not restored during the repair procedure.

Fig 6: Identifying Contact Surface Of Reinforcement

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Open welded connections in areas (1).

Open brazed connections in areas (2).

Take off side panel.

Fig 7: Open Welded Connections In Areas 1 And 2

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Right side of vehicle only:

If necessary, open weld joints in area (1).

Fig 8: Open Welded Joints In Area 1

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New part preparation:

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

Prepare REINFORCEMENT PLATES (bonded) at all severance cuts.

Rear side panel must be trimmed.

1 = Body outer side

Fig 9: Identifying Body Outer Side

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

Measurement a = approx. 30 mm.

Measurement b = approx. 50 mm

IMPORTANT:

Distance to outer edge (3) is 3 mm in area (2).

The trim must have a radius of approx. 4 mm in area (2).

Otherwise there is a risk that the metal plate of the rear side wall will begin breaking!

Fig 10: Identifying Outer Edge Area

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View of trimmed rear side panel.

1 = Body outer side

2 = Radius of trimmed side panel

Fig 11: Identifying View Of Trimmed Rear Side Panel

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Cut new part on sill outer edge radius (1).

Fig 12: Cutting New Part On Sill Outer Edge Radius

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Open welded connections in areas (1).

Centre punch the welded connections in area (2) in the middle and drill through with a drill diameter of 6.8 mm.

Then sand off the remaining welding spots with a belt sander from inside and take off section (3).

Fig 13: Open Welded Connections In Area 1

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Adjust new part to fit and secure.

In areas (1) and (2) set five 4.2 mm dia. holes for blind rivets in each area. in the reinforcement plate of jacking point (3) in area (4): set 6.8 mm dia. bore holes for N1 blind rivets.

Fig 14: Adjusting New Part To Fit And Secure

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Set three 4.2 mm dia. holes for blind rivets in area (1).

Fig 15: Set Three 4.2 mm Diameter Holes For Blind Rivets

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Severance cut (2) at entrance attachment (1).

Mark severance cut with extra material in accordance with dimension "a" and cut.

Dimension "a" = 50 mm from severance cut on vehicle.

Entrance attachment section is installed overlapping by dimension "a".

Fig 16: Severance Cut (2) At Entrance Attachment (1)

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Adjust new entrance attachment part (1) to fit and secure.

Set ten 4.2 mm dia. holes for blind rivets in areas (2).

Area (3): 1 hole.

Remove new parts and deburr bore holes.

NOTE: New entrance attachment part (1) is only bonded in area (4). New entrance attachment part may need to be fitted in area (4) for riveting of jacking point reinforcement.

Fig 17: Adjust New Entrance Attachment Part

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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 plates with cleaning agent R1.

Apply adhesive to reinforcement plates. Install reinforcement plates.

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 18: Applying Adhesive In Areas

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Apply adhesive (1) to inside of side wall (2) at distance "a".

Dimension "a" = 10 mm

Fig 19: Apply Adhesive (1) To Inside Of Side Wall (2) At Distance A

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Install side wall with a second person helping.

NOTE:

When installing side panel, make sure there is sufficient adhesive on bonding surfaces.

Secure side panel 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).

Area	Number
2	11
3	4

Fig 20: Identifying Rivet Areas (1 Of 2)

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

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

Area	Number
2	3
3	2
4	5

Fig 21: Identifying Rivet Areas (2 Of 2)

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Also apply adhesive (2) to outer wheel arch section (3).

(1) Rear side wall.

Fig 22: Identifying C-Pillar Reinforcement, Cavity Acoustic Baffle, Severance Cut Mark And Welded Connection Area

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Rivet reinforcement of jacking point (1) with side wall (2).

Fig 23: Riveting Reinforcement Of Jacking Point With Side Wall

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Flange the edge of side wall in area (1) flush to outer wheel arch section.

Dimension a = 140 mm from edge of entrance.

Fig 24: Identifying Flange Area And Dimension From Edge Of Entrance

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Do not create sharp edges on the wheel arch when flanging as otherwise the flange edge may begin to tear.

Dimension (A) = 5 mm.

(1) Adhesive

(2) Rear side wall

Also seal in area (3) according to standard.

IMPORTANT:

Flange edge must be completely filled with adhesive (1).

The wheel arch must be flanged immediately after riveting before the adhesive hardens.

Fig 25: Identifying Rear Side Wall Adhesive Applying Area

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Rivet reinforcement of jacking point (1) with side wall (2).

Fig 26: Riveting Reinforcement Of Jacking Point (1) With Side Wall (2)

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Entrance attachment:

Clean bonding surface (1) with cleaning agent R1.

Apply adhesive to bonding surface.

Fig 27: Cleaning Bonding Surface (1) With Cleaning Agent

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Install entrance attachment (1) and rivet in areas (2) and (3).

No riveting in area (4).

After adhesive has hardened in the lower sill area, install an EMC SCREW .

Fig 28: Installing Entrance Attachment And Rivets

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IMPORTANT: The wheel arch must be flanged immediately after riveting before the adhesive hardens.

Seal new component from inside in area (1) with sealing compound.

Fig 29: Identifying Seal Component From Inside Area

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