Installing The Rear Left Side Panel
- Install reinforcement plate (1) and tack by welding.
- Pre-clean the bonding surfaces of the reinforcement plate (1) and the body.CONSUMABLE SPECIFICATION
Cleaning agent R2 500 ml 83190417324 - Clean bonding surfaces of reinforcement plate (1) and the body.CONSUMABLE SPECIFICATION
Cleaning agent R1 100 ml, Bottle 83192211217 - Apply adhesive on to the reinforcement plate (1).ADHESIVE SPECIFICATION
Body adhesive K5 195 ml 83195A59935 - Install reinforcement plate (1).
- Pre-clean the bonding surfaces (1) on the vehicle and new part.CONSUMABLE SPECIFICATION
Cleaning agent R2 500 ml 83190417324 - Pre-clean the bonding surfaces (1) on the vehicle and new part.CONSUMABLE SPECIFICATION
Cleaning agent R1 100 ml, Bottle 83192211217 - Apply adhesive on the bonding surfaces (1).NOTE: TECHNICAL INFORMATION
For additional information see: 41 00... Installation of cavity sealing (expanded) - Apply sealant to cavity sealing (2).CONSUMABLE SPECIFICATION
Sealant D2 290 ml83425A547B9 - Pre-clean the bonding surface (1) on the vehicle and on the new part.
Clean the bonding surface (1) on the vehicle and on the new part.
In area (1), apply adhesive on the reinforcement of the lock striker.
- Install the side panel with the help of a second person.
During installation, ensure that sufficient adhesive has been applied to all bonding surfaces.
- Align the side wall in the areas of the separating cuts and secure it with locking pliers.
- Tighten the nuts on the reinforcement plate.CONSUMABLE SPECIFICATION
Plastic nut 018 mm 51161943122 CONSUMABLE SPECIFICATIONPlastic nut 022 mm 07147169847 - Rivet the side panel in the areas (1) to (3) with blind rivets.CONSUMABLE SPECIFICATION
Blind rivet N3 83190301421 Ø 4 mm; clamping area 1-3 mm - Install a punch rivet in the areas (2).CONSUMABLE SPECIFICATION
Punch rivet N4 83192457307 Ø 3 mm; 4 mm long - Rivet the side panel in the areas (1) and (2) with blind rivets.CONSUMABLE SPECIFICATION
Blind rivet N3 83190301421 Ø 4 mm; clamping area 1-3 mm - Rivet the side panel in the areas (3) and (4) with punch rivets.
Area Number Punch rivet 3 1 N4 4 7 N5 CONSUMABLE SPECIFICATIONPunch rivet N4 83192457307 Ø 3 mm; 4 mm long CONSUMABLE SPECIFICATIONPunch rivet N5 83192158079 Ø 5 mm; 5 mm long - Attach separating cut (1) and reinforcement plate (2) through welding.
Only finish welding the separating cut and reinforcement plate after installation of the punch rivets.
- On the separating cut (1), tighten the nuts of the reinforcement plate (2).
- Rivet the side panel in the areas (1) to (5) with punch rivets.
Area Number Punch rivet 1 5 N5 2 2 N5 3 8 N5 4 7 N5 5 3 N4 - Set the 2 punch rivets from the inside in the area (2) of reinforcement of wear wedge.
Do not damage the spot weldings of the new part in the process.
- Rivet the side panel in the area (1) with 7 punch rivets.CONSUMABLE SPECIFICATION
Punch rivet N5 83192158079 Ø 5 mm; 5 mm long - Also apply adhesive (2) to the outer wheel arch section (3).
(1) = rear quarter panel.
- Flange the edge of wheel arch (3) of the side panel flush to the outer wheel arch section.
- Do not create sharp edges when flanging because the crimping edge may otherwise begin to tear.
- Fill crimping edge fully with adhesive.
Dimension (a) = 5 mm
(1) = adhesive.
(2) = rear quarter panel.
- Seal the new part with sealant in the same way as for standard production.
Seal with sealant in the area (3) according to the standard.
CONSUMABLE SPECIFICATIONSealant D2 290 ml83425A547B9 - Weld the separating cut (1) and the reinforcement plate (2).
Avoid excessive heat input on the adjacent adhesive areas.
Installing the EMC screw
- Drill the hole with a diameter of 4.2 mm after the adhesive completely hardens.
- Screw in the EMC screw.CONSUMABLE SPECIFICATION
screw 83190301639 EMC screw, SF Plus, M5x15 - Seal the EMC screw with the sealant.CONSUMABLE SPECIFICATION
Sealant D2 290 ml83425A547B9 - After the adhesive has hardened, install 2 EMC screws in the areas (1).CONSUMABLE SPECIFICATION
screw 83190301639 EMC screw, SF Plus, M5x15