41 35 101 REPLACE THE SIDE WALL ON THE REAR LEFT (M-135i)

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STRIP DOWN VEHICLE 

Procedure observe REPAIR STAGE 2 !

Following new body parts are required (see CONSUMABLES ):

• (1) Rear side wall
• Reinforcement plate, side sill
• B-pillar reinforcement plate
• 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	25
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.

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 corner of roof outer skin.

Open welded connections in areas (1).

Open SEAM ADHESIVE BOND  in area (2).

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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.

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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

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Remove new part again and deburr bore holes.

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.

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Install side panel with a second person helping.

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.

Use punch rivets in areas (2) to (4).

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

The side wall is bonded and flanged in area (5).

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

1. Rear side wall

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Flange edge of wheel arch (3) of side wall flush to outer wheel arch section.

Do not create sharp edges 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.

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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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