41 35 101 Replacing Rear Left Side Panel

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Read contents of BODY, GENERAL .

STRIP DOWN VEHICLE .

Follow procedures for REPAIR STAGE 2 .

The following body new parts are required:

(1) Rear side wall
(2) Reinforcement plate, universal (not shown)
(3) Reinforcement plate, side sill (not shown)
(4) Reinforcement plate, C-pillar (not shown)
(5) Reinforcement plate, D-pillar (not shown)
(6) Lock nut (not pictured)

Fig 1: Identifying Rear Side Wall
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The following consumables are required:

Material	Quantity
Adhesive K5b	1
Adhesive K5a	1
Blind rivets N3	10
Punch rivets N4	45
EMC screws	3
Cleaning agent R1	1
Cavity sealing wax remover	1
Sealant D1	1

Removing side wall

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. 55 mm from edge of impression.
Dimension "b" = approx. 30 mm from edge of recess.
Dimension "c" = approx. 190 mm from corner of roof outer skin.
Open welded connections in areas (1).
Open SEAM ADHESIVE BOND in area (2).
Release side wall from cavity sealing (3) and bonded connection (4).

NOTE: Bonded connection (4) is replaced with sealant during installation.

Fig 2: Identifying Cutting Dimensions, Welded Connections, Adhesive Bond Area, Cavity Sealing, And Bonded Connection

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

Fig 3: Identifying Template

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

IMPORTANT: Cut outer panel only.
Dimension "a" = approx. 267 mm from corner of roof outer skin.
Open welded connections in area (2).

Fig 4: Identifying Welded Connections And Cutting Dimension

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Release welded connections in areas (1) and remove side wall.

IMPORTANT: In the area of the tailgate gasket, the welding spots must be detached from the direction of the side wall.

Take off side panel.

Fig 5: Identifying Welded Connections

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New part preparation

Cavity sealing, D-pillar:

Cut (1) according to the schematic diagram.

Release welded connection (2) and take off holder (3) for cavity sealing.

Fig 6: Identifying Cutting Line, Welded Connection, And Holder

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

Prepare REINFORCEMENT PLATES at severance cuts.

Fig 7: Identifying Universal Reinforcement Plate And Impression

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D-pillar in area of water channel:

Introduce a recess into UNIVERSAL REINFORCEMENT PLATE (1) for impression (2) and fit.

Adjust side panel and secure.

IMPORTANT: Fit the side wall without tension, especially in the area of the D-pillar.
Straightening after the adhesive has hardened is not possible.

In areas (1), set 9 4.2-mm dia. bore holes for blind rivet N3.

Fig 8: Identifying Areas For Setting Blind Rivet Bore Holes

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Prepare area (1) for bonded connection with sealant.

Remove new part again and deburr bore holes.

Fig 9: Identifying Area For Bonded Connection

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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.

Apply sealant to CAVITY SEALING .

Apply adhesive to bonding surfaces on vehicle.

Apply adhesive to new part in area of wheel arch.

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

Distance "a" = approx. 5 mm.

Fig 10: Identifying Adhesive Application Dimension

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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 adjusting side wall to fit, tighten nuts of reinforcement plates.
Secure side wall in area of reinforcement plates with gripping pliers.
Rivet side panel with blind rivets.
In areas (1) to (4) use punch rivets N4.

Area	Number
1	14
2	13
3	3
4	2

Fig 11: Identifying Punch Rivets N4 Areas

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

Area	Number
1	3
2	9

Fig 12: Identifying Areas For Punch Rivets

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

(1) Rear side wall.

Fig 13: Identifying Rear Side Wall And Adhesive Application Area On Outer Wheel Arch Section
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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.

Adhesive
Rear side wall

Also seal in area (3) according to standard.

Fig 14: Identifying Rear Side Wall And Adhesive/Sealing Areas

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IMPORTANT: Flange edge must be completely filled with adhesive.

After adhesive has hardened, install one EMC SCREW in each case in areas (1).

Additionally, install EMC screw in sill areas (1).

Fig 15: Identifying Areas For Installing EMC Screw

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