41 35 120 Partially Replace Rear Left Side Wall: Notes

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

Strip down vehicle. See 41 35 120 STRIPPING OPERATION - PARTIAL REPLACEMENT OF LEFT REAR SIDE PANEL LEFT .

Observe (repair stage 2) procedure. 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
(2) Reinforcement plate (not shown)
(3) Lock nuts (not pictured)

Following consumables are required:

Fig 1: Identifying Rear Side Wall

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Material	Quantity
Adhesive K5b	1
Blind rivets N3	10
Punch rivets N4	18
R1 cleaning agent	1
Sealant D1
EMC screws	1

Removing side wall:

Fig 2: Identifying Side Wall Corner Of Wheel Arch Dimension

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Mark severance cuts in accordance with specified dimensions and cut.

IMPORTANT: Cut outer panel only.
Compare position of severance cut with reinforcement plate. See 41 00... REINFORCEMENT PLATE WITH STUD BOLT (BONDED) .

Dimension a = approx. 115 mm from soft top compartment radius.

Dimension b = approx. 130 mm to corner of wheel arch.

Open welded connections in area (1).

Fig 3: Identifying Welded Connections Area

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Open welded connections in area (1).

Remove section of side wall.

Fig 4: Identifying Side Wall Section Welded Connections Area

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Preparation of new part:

Mark and cut the severance cut on new part as per the severance cut on the vehicle.

Prepare reinforcement plate at severance cut. See 41 00... WELDING IN REINFORCEMENT PLATE (SHEET STEEL) .

Mark severance cut (1) as pictured and cut.

Remove section (2).

Fig 5: Identifying Side Wall Section And Mark Severance Cut

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Mark severance cuts (1) and (2) on the reinforcement plate as shown and cut.

Remove sections.

Fig 6: Identifying Mark Severance Cuts On Reinforcement Plate

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Adjust new part to fit and secure.

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

Fig 7: Identifying Blind Rivets Bore Holes Area

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In areas (1) to (3) set 4.2 mm dia. holes for blind rivets:

Area	Number
1	4
2	3
3	1

Fig 8: Identifying Blind Rivets Holes Areas

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Fig 9: Identifying Reinforcement Plate

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Produce a reinforcement plate (1) at the severance cut of the water channel.

Installation note:

The reinforcement plate is installed during the installation of the side of the soft top compartment with two rivets N4.

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 and on new part with cleaning agent R1.

Apply adhesive to bonding surfaces.

Attach section of side wall and rivet with blind rivets N3.

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

Fig 10: Identifying Side Panel Rivet Areas

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In areas (1) to (3) rivet side panel with punch rivets N4.

Area	Number
1	7
2	6
3	1

In area (1), rivet section of side wall with 2 punch rivets N 4.

After adhesive has hardened, fit an EMC screws below taillight holder. See 41 00... EMC SCREWS .

Fig 11: Identifying Side Wall Section Rivet Area

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