41 35 101 Replacing Rear Left Side Panel

Read contents of BODY, GENERAL .

STRIP DOWN VEHICLE 

Procedure OBSERVE  repair stage 2!

Following new body parts are required (refer to ELECTRONIC PARTS CATALOGUE ):

• (1) Rear side wall
• (2) Reinforcement plates (not pictured)
• (3) Lock nuts (not pictured)

Following CONSUMABLES  are required:

Fig 1: Identifying Rear Side Wall

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Removing side wall: 

Fig 2: Identifying Side Wall Severance Cutting Dimension

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Mark severance cuts in accordance with specified dimensions and cut.

Fig 3: Identifying Side Wall Template

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Open welded connections in areas (1) and (2).

Take off side panel.

Fig 4: Identifying Side Wall Welded Connections Areas

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Open welded connections in area (1).

Release bonded joint (2).

Remove lock striker reinforcement.

Fig 5: Identifying Lock Striker Reinforcement Bonded Joint

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Preparation of new part: 

Mark severance cuts on new part in accordance with severance cuts on vehicle and cut.

Prepare REINFORCEMENT PLATES  at severance cuts.

Open welded connections in area (1).

Remove sill section.

Fig 6: Identifying Sill Section Welded Connections Area

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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): 3 bore holes

Area (2): 4 bore holes

Fig 7: Identifying Bore Holes Areas

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

Area (1): 3 bore holes

Area (2): 1 bore hole

Remove new part again and deburr bore holes.

Fig 8: Identifying Bore Holes Blind Rivets 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.

Apply adhesive in areas (1).

Apply sealant to CAVITY ACOUSTIC BAFFLES  in areas (2).

Apply adhesive to new part in area (3).

Fig 9: Identifying Side Wall Cavity Acoustic Baffles Sealant Applying Area

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Apply adhesive in area (1) of lock striker reinforcement.

Fig 10: Identifying Lock Striker Reinforcement Adhesive Applying Area

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

Dimension a = approx. 5 mm.

Fig 11: Identifying Adhesive Applying Area On Inside Of Side Wall

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Fig 12: Identifying Side Panel Adhesive Applying And Punch Rivets Area

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Install side panel with a second person helping.

In areas (5), fix the side wall using gripping pliers until the adhesive hardens.

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

Use N5  punch rivets in areas (4) and (5).

Fig 13: Identifying Punch Rivets Areas

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

1. Rear side wall.
   Fig 14: Identifying Outer Wheel Arch Section Adhesive 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 15: Identifying Adhesive, Rear Side Wall

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Graphic representation similar.

After hardening of the adhesive, install two EMC SCREWS  in the areas (1).

Additionally, install EMC screw in sill area.

Fig 16: Identifying EMC Screw In Sill Area

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