41 35 101 Replacing Rear Left Side Panel

Read contents of BODY, GENERAL .

STRIP DOWN VEHICLE 

Observe procedure for REPAIR STAGE 2 .

The following new body parts are required:

• (1) Side frame, rear
• (2) Reinforcement plates (not pictured)
• (3) Lock nuts (not pictured)

Following CONSUMABLES  are required:

Fig 1: Identifying New Body Parts Required

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Removing side wall: 

Mark severance cut in accordance with dimension and cut.

Dimension "a" = approx. 120 mm from corner of roof outer skin.

Open welded connections in area (1).

Fig 2: Identifying Welded Connections And Severance Cut Dimension

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Fig 3: Identifying Template

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Fig 4: Identifying Severance Cut Dimensions, Welded Connections, Adhesive Bonded Area, And Cavity Sealing

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Mark severance cuts in accordance with specified dimensions and cut.

Open welded connections in areas (1) and (2).

Fig 5: Identifying Welded Connections And Welding Spots

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Open welded connections in area (1).

Take off side panel.

Fig 6: Identifying Welded Connections

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Preparation of new part: 

Mark severance cuts on new part in accordance with severance cuts on vehicle and cut.

Prepare REINFORCEMENT PLATES  at severance cuts.

Open welded connections in area (1).

Remove sill section.

Fig 7: Identifying Welded Connections

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Adjust new part to fit and secure.

In area (1) create eight 4.2 mm dia. bore holes for blind rivets:

Fig 8: Identifying Area For Blind Rivet Bore Holes

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

Area (1): 2 bore holes

Area (2): 1 bore hole

Fig 9: Identifying Areas For Blind Rivet Bore Holes

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In areas (1) and (2), create four 4.2 mm dia. holes for blind rivets in each area

Remove new part again and deburr bore holes.

Fig 10: Identifying Areas For Blind Rivet Bore Holes

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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).

Apply adhesive to new part in area (3).

Fig 11: Identifying Sealant And Adhesive Application Areas

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Apply adhesive (1) to inside of side wall at distance "a".

Dimension "a" = approx. 5 mm.

Fig 12: Identifying Adhesive Application Dimension

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Install side panel with a second person helping.

Fig 13: Identifying N4/N5 Punch Rivet Areas

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

Fig 14: Identifying Punch Rivets Areas (N4)

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

1. (1) Rear side wall.
   Fig 15: Identifying Rear Side Wall, Outer Wheel Arch Section, And Adhesive Application Area

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Installation note: 

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.

Dimension (A) = 5 mm.

1. (1) Adhesive
2. (2) Rear side wall
   Fig 16: Identifying Rear Side Wall, Adhesive Area, And Flanging Dimension

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Also seal in area (3) according to standard.

Fig 17: Identifying Areas For EMC Screws

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