41 35 101 Replacing Rear Left Side Panel: Notes

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Read contents of 41 00... 0 CONTENTS OF BODY, GENERAL .

Strip down vehicle. See 41 35 101 STRIPPING OPERATIONS - REPLACING REAR SIDE PANEL, LEFT .

Observe procedure repair stage 2. See 41 00... REPAIR TECHNIQUES, REPAIR STAGE 2 .

Following new body parts are required (refer to 41 00... OVERVIEW OF CONSUMABLES ):

(1) Rear side wall

Following consumables are required:

Fig 1: Identifying Rear Side Wall

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Material	Quantity
Adhesive K5a	1
Adhesive K5b	1
Blind rivets N3	19
Punch rivets N4	25
Punch rivets N5	12
Cleaning agent R1	1
Sealant D1
EMC screws	3

Removing side wall:

Open welded connections in areas (1).

Open spot-welded adhesive joints in area (2). See 41 00... OPENING BONDED CONNECTIONS

Open folded bonded connection in area (3). See 41 05 800 RELEASING BONDED FOLDED SEAM CONNECTIONS .

Fig 2: Identifying Side Wall Spot-Welded Adhesive Joints Area

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Open welded connections in areas (1).

Detach side wall.

Fig 3: Identifying Side Wall Welded Connections Areas

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Preparation of new part:

Fig 4: Identifying Blind Rivets Holes Areas

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Adjust new part to fit and secure.

In areas (1) to (3), set 4.2 mm Ø holes for blind rivets:

Area	Number
1	2
2	7
3	4

In areas (1) to (3), set 4.2 mm Ø holes for blind rivets:

Area	Number
1	2
2	1
3	3

Remove new part again and deburr bore holes.

Fig 5: Identifying Blind Rivets Holes Areas

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

Installing side panel:

Clean all bonding surfaces on vehicle and on new part with cleaning agent R1.

Apply adhesive to bonding surfaces.

Apply adhesive to the inside of the side wall in distance a in the area of the wheel arch.

Dimension a = approx. 10 mm

Fig 6: Identifying Adhesive Applying Area On Inside Of Side Wall

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Fig 7: Identifying Side Panel Punch Rivets Areas

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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.

Rivet side panel with blind rivets.

Use punch rivets in areas (1) to (5).

Area	Number	Remarks
1	8	Punch rivet N5
2	6	Punch rivet N4
3	2	Punch rivet N4
4	1	Punch rivet N5
5	3	Punch rivet N5

IMPORTANT: In the door sill area (5), the 2 punch rivets N5 may not be set onto the welding spots of the door sill!

Fig 8: Identifying Side Panel Punch Rivets Areas

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Rivet side panel with blind rivets.

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

Area	Number
1	5
2	5
3	7

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

(1) Rear side wall

Fig 9: Applying Adhesive To Outer Wheel Arch Section

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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.

Distance (A) = 5 mm.

Also seal in area (3) according to standard.

Adhesive
Rear side wall

NOTE: Flange edge must be completely filled with adhesive (1).

Fig 10: Identifying Rear Side Wall And Adhesive

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After the adhesive hardens, install two EMC screws in areas (1). See 41 00... EMC SCREWS .

Additionally, install EMC screw in sill area.

Fig 11: Identifying EMC Screws Areas

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