41 35 101 Replacing Rear Left Side Panel

Read contents of BODY, GENERAL .

STRIP DOWN VEHICLE 

Procedure OBSERVE  repair stage 2!

The following new body parts are required (refer to Electronic Parts Catalogue):

• (1) Side frame, rear
• (2) Reinforcement plates (not pictured)
• (3) Lock nuts (not pictured)

Following CONSUMABLES  are required:

Fig 1: Identifying Rear Side Frame

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Removing side wall 

Fig 2: Identifying Outer Panel Cutting Dimension

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Mark severance cuts in accordance with specified dimensions and cut.

Fig 3: Identifying Template

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Open welded connections in areas (1).

Take off side panel.

Fig 4: Identifying Side Panel Welded Connection Areas

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Open welded connections in area (1).

Release bonded joint (2).

Fig 5: Identifying Welded Connections Areas And Bonded Joint

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Preparation of new part 

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

Prepare REINFORCEMENT PLATES  (bonded) at all severance cuts.

Separate weld joints in area (1) from inside.

Remove sill section (2).

Fig 6: Identifying Weld Joints Area And Sill Section

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Adjust new part to fit and secure.

In areas (1) and (2) set 4.2 mm dia. bore holes for blind rivets:

Area (1): 4 bore holes

Area (2): 4 bore holes

Fig 7: Identifying Blind Rivets Bore Hole Areas

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In areas (1) and (2) set 4.2 mm dia. bore holes for blind rivets:

Area (1): 2 bore holes

Area (2): 7 bore holes

Remove new part again and deburr bore holes.

Fig 8: Identifying Blind Rivets Bore Hole Areas

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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.

Fig 9: Identifying Cavity Acoustic Baffles Sealant And Adhesive Applying Areas

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Apply adhesive in areas (1).

Apply sealant to cavity acoustic baffles  See 41 00... INSTALLING A CAVITY ACOUSTIC BAFFLE (EXPANDED)  or 41 00... INSTALLING A CAVITY ACOUSTIC BAFFLE (NOT EXPANDED)  in areas (2).

Apply adhesive to inside of side wall (in wheel arch area) at spacing a.

Dimension a = approx. 5 mm.

Fig 10: Identifying Side Wall Adhesive Applying Area

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Fig 11: Identifying Side Panel Installing Position

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Install side panel with a second person helping.

In areas (1), rivet side wall with blind rivets.

Use 4 N4 punch rivets in area (2).

Fig 12: Identifying Blind Rivet And N4 Punch Riveted Areas On Side Wall

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

1. Rear side wall.
   Fig 13: Identifying Outer Wheel Arch Section Adhesive Applying Area

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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.

Fig 14: Identifying Rear Side Wall Adhesive Applying Area

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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.

Graphic representation similar.

Fig 15: Identifying EMC Screw Installing Areas

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