41 35 101 Rear Left Side Panel Replacement (Convertible)

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Read contents of Body, General .

Strip down vehicle .

Place vehicle on straightening bench.

Observe repair stage 3 !

Following new body parts are required:

(1) Side panel, rear

Following consumables are required:

Material	Quantity
Adhesive K5b	1
Blind rivets N3	25
Punch rivets N4	22
Punch rivets N5	5
Cleaning agent R1	1
Sealant D1
EMC screws	3

Fig 1: Rear Side Panel

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Removing side wall:

IMPORTANT:

Before loosening the wheel arch welding connections:

Straighten wheel arch edge similarly to new part.

Open weld joints in area (1).

Open brazed joint in area (2).

Spot-weld bonding is used on this vehicle. Observe specific procedure .

Fig 2: Identifying Weld Joint Areas And Brazed Joint Area

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Open weld joints in areas (1).

Open brazed joints in areas (2).

Fig 3: Identifying Weld Joint Areas And Brazed Joint Area

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Open weld joints in area (1).

Open brazed joints in areas (2).

Fig 4: Identifying Weld Joint Areas And Brazed Joint Area

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Open MIG soldered joints in area (1).

Installation:

MAG-weld new part in area (1).

Fig 5: Identifying MAG-Weld Area

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Open brazed joint in area (1).

Installation:

When sealing in area (2), ensure sufficient clearance for outer window cavity cover strip.

Fig 6: Identifying Brazed Joint Area And Sealing Area

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Preparation of new part:

Adjust new part to fit with alignment bracket or universal mount and secure.

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

Area	Number
1	6
2	4

Fig 7: Identifying Bore Hole Areas For Blind Rivets

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Set two 4.2 mm diameter bore holes for blind rivets in area (1).

Fig 8: Identifying Bore Hole Area For Blind Rivets

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

Area	Number
1	6
2	1

Fig 9: Identifying Bore Hole Areas For Blind Rivets

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Set six 4.2 mm diameter bore holes for blind rivets in area (1).

Remove new part again and deburr bore holes.

Fig 10: Identifying Bore Hole Area For Blind Rivets

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IMPORTANT: Do not grind/sand new part in area of bonding surfaces.

Apply adhesive in areas (1).

Adhesive must be applied to new part in area (2).

Fig 11: Identifying Adhesive Application Areas

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Fit the side wall with alignment bracket or universal mount.

Install side panel with a second person helping.

NOTE:

When installing side panel, make sure there is sufficient adhesive on bonding surfaces.

Secure side wall with gripping pliers.

Rivet side wall with blind rivets in areas (1).

Use punch rivets in areas (2) and (3).

In area (4), secure side wall with gripping pliers until adhesive has hardened.

Area	Number	Remarks
2	5	Punch rivet N5
3	10	Punch rivet N4

Fig 12: Identifying Rivet Areas (1 Of 2)

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Rivet side wall with blind rivets in areas (1).

In areas (2) to (4) use punch rivets N4.

Fig 13: Identifying Rivet Areas (2 Of 2)

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Area	Number
2	4
3	2
4	3
5	3

IMPORTANT: The wheel arch must be flanged immediately after riveting before the adhesive hardens.

After adhesive has hardened, install one EMC screw in each case in areas (1).

Additionally, install EMC screw in sill area.

Fig 14: Identifying Areas For EMC Screws

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