41 35 101 Replacing Rear Left Side Panel

Following new body parts are required (see CONSUMABLES ):

(1) Rear side wall
Reinforcement plate, side sill
Reinforcement, B-pillar
Reinforcement plate, C-pillar
Mounting nuts

Following CONSUMABLES are required:

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Material	Quantity
Adhesive K5b	1
Adhesive K5a	1
Blind rivets N3	16
Punch rivets N4	32
Punch rivets N5	8
EMC screws	3
Cleaning agent R1	1
Cavity sealing wax remover	1
Sealant D1

Removing side panel

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Mark severance cuts in accordance with specified dimensions and cut.

IMPORTANT: Cut outer panel only.

Compare position of severance cuts with REINFORCEMENT PLATES .

Dimension a = approx. 80 mm from center of 20 mm dia. hole

Dimension b = approx. 75 mm from corrugation dia. 20 mm

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

Dimension d = approx. 110 mm from edge of roof frame

Open welded connections in areas (1).

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

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Open welded connections in areas (1).

Open brazed connection in area (2).

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Open welded connections in areas (1).

Open brazed connection in area (2).

Release side wall from cavity sealing and remove.

NOTE: Position of cavity sealings described in Installing side wall.

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New part preparation

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

Prepare REINFORCEMENT PLATES at severance cuts.

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

Mark severance cut (2) at outer edge radius and cut.

Mark further severance cuts in accordance with vehicle and cut.

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Adjust new part to fit and secure.

In areas (1) to (3) set 4.2 mm diameter bore holes for blind rivets N 3:

Area	Number
1	1
2	6
3	3

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In areas (1) and (2) set 4.2 mm diameter bore holes for blind rivets N 3:

Area	Number
1	2
2	4

Remove new part again and deburr bore holes.

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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.

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Apply adhesive in area (1).

Coat CAVITY SEALINGS (2) with sealant.

Fig 1: Identifying Side Panel Punch Rivets Area

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Install side panel with a second person helping.

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

After pressing the side wall in position, tighten nuts of reinforcement plates (1).

Secure side wall with clamping pliers in areas of the reinforcement plates and attach with blind rivets.

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

Area	Number	Remarks
2	8	Punch rivet N5
3	8	Punch rivet N4
4	10	Punch rivet N4

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

Area	Number
1	4 (up to cut)
2	3
3	7

In area (4), secure side wall with gripping pliers until adhesive has hardened.

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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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