41 35 101 Replacing rear left side panel
Read contents of SAFETY INFORMATION and BODY, GENERAL .
Procedure OBSERVE repair stage 2.
Following new body parts are required:
- (1) Side frame, outer, left
- Reinforcement plate, side sill
- Reinforcement plate, C-pillar
- Reinforcement plate, D-pillar
- Reinforcement plate, universal
- Mounting nuts
Following CONSUMABLE are required:
| Material | Quantity |
|---|---|
| Adhesive K5b | 1 |
| Adhesive K5a | 1 |
| Blind rivets N3 | 6 |
| Punch rivets N4 | 35 |
| Punch rivets N5 | 10 |
| EMC screws | 3 |
| Cleaning agent R1 | 1 |
| Cavity sealing wax remover | 1 |
| Sealant | D1 |
Removing side panel
Mark severance cuts in accordance with specified dimensions and cut.
Compare position of severance cuts with REINFORCEMENT PLATES .
Dimension "a" = approx. 135 mm from component edge of roof skin.
Dimension "b" = approx. 115 mm from component edge of roof skin.
Dimension "c" = approx. 125 mm from corner of roof outer skin.
Mark severance cuts in accordance with specified dimensions and cut.
Compare position of severance cuts with reinforcement plates.
Dimension "a" = approx. 185 mm from center point of 20 x 25 mm diameter hole.
Dimension "b" = approx. 20 mm from outer edge of sill.
Open welded connections in areas (1).
Release side wall from cavity sealing (2).
Open welded connections in areas (1) and (2).
Take off side panel.
New part preparation
Cut new part on sill outer edge (1).
Mark severance cut (2) and the other severance cuts according to vehicle and cut.
Open weld joint in area (3).
Prepare REINFORCEMENT PLATES (bonded) at all severance cuts.
View of D-pillar:
(1) Reinforcement plate, D-pillar
(2) Reinforcement plate, universal
Adjust universal reinforcement plate (2) in area of water channel.
In the universal reinforcement plate, introduce a recess (3) of approx. Ø 20 mm.
Adjust new part to fit and secure.
Set three 4.2 mm dia. holes for blind rivets in area (1).
Set three 4.2 mm dia. holes for blind rivets in area (1).
Remove new part again and deburr bore holes.
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 area (1).
Apply sealant to CAVITY ACOUSTIC BAFFLES in areas (2).
Install side panel with a second person helping.
After adjusting side wall to fit, tighten nuts of reinforcement plates.
Secure side wall in area of reinforcement plates with gripping pliers.
Rivet side panel with blind rivets N3.
Use N5 punch rivets in areas (1) and (6).
Use N4 punch rivets in areas (2) to (5).
| Area | Number | Remarks |
|---|---|---|
| 1 | 6 | Punch rivet N5 |
| 2 | 8 | Punch rivet N4 |
| 3 | 8 | Punch rivet N4 |
| 4 | 6 | Punch rivet N4 |
| 5 | 3 | Punch rivet N4 |
| 6 | 4 | Punch rivet N5 |
In area "a", the rivet tool may only be used in the interior of the vehicle.
Dimension "a" = approx. 350 mm.
Use 7 N4 punch rivets in area (1).
Use 3 N4 punch rivets in area (2).
Remove excess adhesive.
After hardening of the adhesive, install two EMC SCREWS in the areas (1).
Additionally, install one EMC screw in sill area (2).