41 35 102 Replacing Rear Left Side Panel (Partial Replacement Behind Wheel Arch)
Read contents of BODY, GENERAL .
Use only approved SPOT-WELDING APPARATUS for repairs.
Remove or cover those vehicle components in the repair area which are susceptible to heat or dust.
Following new body parts are required:
- (1) Rear side wall
Removing side wall:
Open welded connections in areas (1).
Open brazed connection in area (2).
Mark severance cut (1) in accordance with dimension a and cut.
Dimension a = 220 mm from corner of side panel.
Open welded connections in area (2).
Only sever outer panel in area (1) of the severance cut.
Open welded connection in area (2).
Take off side wall section.
Preparation of new part:
Procedure deviating from standard:
Adjust new part (2) to fit in conjunction with all relevant add-on parts.
Make 15 mm wide reinforcement plate (1).
Bring reinforcement plate from inside into contact with side panel.
(3) Severance cut, outer side.
Prepare REINFORCEMENT PLATE at water channel severance cut.
Installing side wall:
Install new part.
Previous illustration: Set tacking points area of severance cut from outer side. As you do so, exert pressure on the reinforcement plate from the inside to enlarge gap at severance cut by approx 0.5 mm. This reduces warpage in the welding area.
Weld severance cut completely on outer side.
Weld new part.