41 35 105 Replacing rear left side panel

WARNING: This page is about a different variant/trim than selected.

Refer to relevant service information in BODY, GENERAL .

Strip down vehicle. See STRIPPING OPERATIONS .

Observe procedure for REPAIR STAGE 2 !

The following new body parts are required:

Rear side wall (1)

Fig 1: Identifying Side Panel - Rear

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Removing side wall:

Open weld joints in areas (1).

Open brazed joints in areas (2) by grinding.

Heat cavity sealing (4) with hot air blower and detach from side panel.

Take off side panel.

Fig 2: Identifying Open Weld Joints Areas

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Preparation of new part:

Adjust side panel and secure.

In areas (1), set 7 4.2 mm dia. holes for blind rivets.

Fig 3: Locating Blind Rivets

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Set three 4.2 mm dia. holes for blind rivets in area (1).

Remove new part again and deburr bore holes.

CAUTION: Pay attention to hinge mount on split door.

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

Fig 4: Locating Bore Holes For Blind Rivets

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Installing side wall:

Clean all bonding surfaces (1) on new part and on vehicle with cleaning agent R1!

Apply adhesive to bonding surfaces.

Fig 5: Identifying Bonding Surfaces

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Apply sealant to cavity sealing (1).

Fig 6: Identifying Cavity Acoustic Baffle

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Mount side panel and rivet with blind rivets (1).

Fig 7: Locating Blind Rivets

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Rivet side panel in area (1) with blind rivets.

Fig 8: Locating Blind Rivets

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

Area	Number
1	8
2	6
3	6

Fig 9: Locating Punch Rivets

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After completing work:

Remove excess adhesive in the entire adhesive area.

IMPORTANT: Do not use any cleaning agents containing solvents.

Seal adhesive area with sealant D1.

Fit an EMC SCREW after adhesive has hardened in area (1).

Fig 10: Identifying Adhesive Hardened Area

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