41 35 101 Replacing Rear Left Side Panel
Read contents of SAFETY INFORMATION and BODY, GENERAL .
Procedure observe REPAIR STAGE 2 !
The following new body parts are required:
- (1) Side frame, rear
- Reinforcement plate, side sill
- Reinforcement plate, D-pillar
- Reinforcement plate, C-pillar
- Reinforcement plate, universal
- Shaped part entrance, outer
- Mounting nuts
Following CONSUMABLES are required:
| Material | Quantity |
|---|---|
| Adhesive K5b | 1 |
| Adhesive K5a | 1 |
| Blind rivets N3 | 15 |
| Blind rivets N1 | 3 |
| Punch rivets N4 | 39 |
| Punch rivets N5 | 1 |
| EMC screws | 2 |
| Cleaning agent R1 | 1 |
| Cavity sealing wax remover | 1 |
| Sealant D1 |
Removing side panel
Mark severance cut (1) in accordance with dimension and cut.
Mark severance cut (2) at component edge and cut.
Compare position of severance cut (1) with REINFORCEMENT PLATE .
measurement "a" = approx. 90 mm from center point of 20 mm dia. hole.
Open weld joint in areas (3).
Mark severance cuts in accordance with specified dimensions and cut.
Compare position of severance cuts with reinforcement plates.
measurement "a" = approx. 230 mm from roof edge
Dimension "b" = approx. 70 mm
Open welded connections in areas (1).
Position of cavity sealing (2).
Mark severance cut in accordance with dimension and cut.
measurement "a" = approx. 300 mm from roof edge
Open welded connections in area (1).
Open welded connections in areas (1).
Open brazed connection in area (2).
Open welded connections in areas (1).
Take off side panel.
New part preparation
Mark severance cuts on the new part according to vehicle and cut.
Prepare REINFORCEMENT PLATES (bonded) at all severance cuts.
At the severance cut of the C-pillar in the area of the water channel: Prepare the reinforcement plate, universal.
Mark severance cut (1) in accordance with vehicle and cut.
Mark severance cut (2) at component edge and cut.
Open weld joints in areas (3) and remove components (4).
Mark severance cut (1) in accordance with vehicle and cut.
Separate weld joints in areas (2) and remove component (3).
Adjust new part to fit and secure.
In areas (1) to (3), set 4.2 mm dia. holes for N3 blind rivets:
In areas (4), set three 6.8 mm dia. holes for N1 blind rivets:
| Area | Number |
|---|---|
| 1 | 4 |
| 2 | 3 |
| 3 | 2 |
| 4 | 3 |
In areas (1) and (2) set 4.2 mm dia. bore holes for blind rivets:
| Area | Number |
|---|---|
| 1 | 2 |
| 2 | 4 |
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 plates with cleaning agent R1.
Apply adhesive to reinforcement plates. Install reinforcement plates.
Apply adhesive in area (1).
Apply sealant to cavity acoustic baffles in areas (2). See INSTALLING CAVITY SEALING (EXPANDED) and INSTALLING CAVITY SEALING (NOT EXPANDED) .
Install side panel with a second person helping.
After adjusting side panel to fit, tighten nuts of reinforcement plates (1).
Secure side panel in area of reinforcement plates with gripping pliers and rivet with blind rivets.
In areas (2) to (4) use punch rivets N4.
| Area | Number |
|---|---|
| 2 | 10 |
| 3 | 14 |
| 4 | 7 |
In areas (5), screw in three screws before the adhesive hardens.
Tighten the nuts of the universal reinforcement plate (1).
Use 8 punch rivets N4 in area (2).
In the area of the bolting point (3) of the tailgate support, install an N5 punch rivet.
Once the adhesive has hardened in area (1) and in the area of the side sill, fit one EMC SCREW in each area.