41 35 105 Replacing rear left side panel

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

NOTE: Observe new procedure for bonding and riveting (REPAIR STAGE 2) .

Following new body parts are required:

(1) Rear side panel

Following CONSUMABLES are required:

CONSUMABLES MATERIAL REFERENCE CHART

Material	Quantity
Adhesive K5b	1
Blind rivets N3	8
Punch rivets N4	21
Punch rivets N5	3
EMC screws	1
Cavity sealing wax remover
Cleaning agent R1	1
Sealant D1

Fig 1: Identifying Rear Side Panel

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Removing side panel

Open welded connections in areas (1).

Open brazed joint in area (2) by grinding.

Heat cavity acoustic baffle (4) with hot-air blower and detach from side panel.

Fig 2: Identifying Welded Connections, Brazed Joint Areas And Cavity Acoustic Baffle

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Open welded connections in areas (1).

Open brazed joint in area (2) by grinding.

Fig 3: Identifying Welded Connections, Brazed Joint Areas

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Open welded connections in areas (1).

Fig 4: Identifying Welded Connections Areas

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Open brazed joint in area (2) by grinding.

Take off side panel.

Fig 5: Identifying Brazed Joint Area

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Preparation of new part

Fig 6: Identifying Holes For Blind Rivets Areas

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Adjust side panel and secure.

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

Remove new part again and deburr bore holes.

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

Remove new part again and deburr bore holes.

Fig 7: Identifying Holes For Blind Rivets Areas

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

Installing side wall

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

Apply adhesive K5b to bonding surfaces (1).

Fig 8: Identifying Bonding Surfaces

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Apply sealing compound to cavity acoustic baffle. See 4100... INSTALLING A CAVITY ACOUSTIC BAFFLE (EXPANDED) or 4100... Installing a cavity acoustic baffle (not expanded) (1).

Apply sealing compound in area (2).

Fig 9: Identifying Cavity Acoustic Baffle And Sealing Compound Area

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Fig 10: Identifying Side Panel And Rivet With Blind Rivets

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

Rivet side panel with blind rivets (1).

In area (2) secure side panel until adhesive has hardened.

Fig 11: Identifying Rivet Side Panel With Blind Rivets

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Fig 12: Riveting Side Panel With Punch Rivets

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In areas (1) to (5) rivet side panel with punch rivets.

Refer to table below for number.

RIVET NUMBERS REFERENCE CHART

Area	Remarks	Number
1	Punch rivet N5	3
2	Punch rivet N4	5
3	Punch rivet N4	6
4	Punch rivet N4	3
5	Punch rivet N4	7

Apply sealant in area (1) in same way as on opposite side.

Fig 13: Identifying Sealant Applying Area

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

Fig 14: Identifying Adhesive Hardened Area

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