41 35 101 Replacing Left Rear Side Panel

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Read contents of BODY, GENERAL .

STRIP DOWN VEHICLE

Procedure OBSERVE repair stage 2!

Following new body parts are required (see OVERVIEW OF CONSUMABLES ):

(1) Rear side wall
Reinforcement plate, side sill
Reinforcement plate, C-pillar
Reinforcement plate, D-pillar
Mounting nuts

Following CONSUMABLES are required:

Fig 1: Identifying Rear Side Wall

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Material	Quantity
Adhesive K5b	1
Adhesive K5a	1
Blind rivets N3	11
Punch rivets N4	46
EMC screws	2
Cleaning agent R1	1
Cavity sealing wax remover	1
Sealant D1

Removing side panel

Mark dimension a for severance cut (1) on D-pillar.

Dimension a = approx. 75 mm from corner of mark (2).

Fig 2: Identifying D-Pillar Severance Cutting Dimension

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Mark dimension a for severance cut (1) on D-pillar.

Dimension a = approx. 135 mm from corner of roof frame.

Carry out severance cut (1).

IMPORTANT: Cut outer panel only.

Fig 3: Identifying Severance Cutting Dimension On D-Pillar

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

Fig 4: Identifying D-Pillar Template

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Fig 5: Identifying D-Pillar Welded Connections Areas

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

Dimension a = approx. 60 mm from center point mounting bore for damper holder.

IMPORTANT: Cut outer panel only.

Severance cut (1) must be partially executed using a belt sander.

Open welded connections in areas (2).

Fig 6: Identifying Side Wall Component Edge Dimension

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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. 65 mm before center of 22 mm dia. hole.

Dimension b = approx. 20 mm from sill edge.

Dimension c = approx. 155 mm from side wall component edge.

Open welded connections in areas (1).

Release side wall from cavity sealing (2).

Open welded connections in areas (1).

Take off side wall.

Fig 7: Identifying Side Wall Welded Connections Areas

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New part preparation

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

Prepare REINFORCEMENT PLATES (bonded) at all severance cuts.

Mark severance cut (1) in accordance with vehicle and cut.

Mark severance cut (2) at sill edge and cut.

Mark further severance cuts in accordance with vehicle and cut.

Fig 8: Identifying Severance Cut Mark At Sill Edge

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D-pillar water channel severance cut area:

Make an additional 2 shims (1) and (2) in the severance cut area.

NOTE: Before installing the side wall:

Coat shim (1) with adhesive and slide in.

Coat shim (2) with adhesive and secure with a punch rivet N4.

Fig 9: Identifying Shims In Severance Cut Area

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Adjust new part to fit and secure.

Set three 4.2 mm dia. holes for blind rivets in area (1).

Fig 10: Identifying Blind Rivets Holes Area

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In areas (1) to (4), set 4.2 mm dia. bore holes for blind rivets.

Area	Number
1	3
2	2
3	2
4	1

Fig 11: Identifying Bore Holes Area For Blind Rivets

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Remove new part again and deburr bore holes.

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 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).

Fig 12: Identifying Sealant Applying Area On Cavity Acoustic Baffles

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Fig 13: Identifying Rivet Side Panel Area With Punch Rivets N4

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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.

Align side wall in areas of severance cuts and fix with gripping pliers.

Rivet side wall with blind rivets N3.

In areas (1) to (4) rivet side panel with punch rivets N4.

Area	Number
1	12
2	7
3	5
4	11

Rivet side wall with blind rivets N3.

In areas (1) and (2) rivet side panel with punch rivets N4.

Area	Number
1	5
2	5

Fig 14: Identifying Rivet Side Panel Area With Punch Rivets N4

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Once the adhesive has hardened in area (1) and in the area of the side sill, fit one EMC SCREW in each area.

Fig 15: Identifying EMC Screw Area

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