41 35 101 Replacing rear left side panel
Read contents of BODY, GENERAL .
Procedure OBSERVE repair stage 2!
Following new body parts are required:
- (1) Rear side wall
Following CONSUMABLES are required:
| Material | Quantity |
|---|---|
| Adhesive K5b | 1 |
| Blind rivets N3 | 7 |
| Punch rivets N4 | 25 |
| Punch rivets N5 | 9 |
| EMC screws | 3 |
| Cavity sealing wax remover | |
| Cleaning agent R1 | 1 |
| Sealant D1 |
Removing side wall
Open welded connections in area (1).
Open brazed joint in area (1) by grinding.
Open welded connections in areas (2) and (3).
Installation note:
New part is joined in areas (1) and (2) by means of welding method.
Open welded connections in areas (1).
Heat cavity sealing (2) with hot air blower and release from side wall.
Remove side wall.
New part preparation
Open welded connections in area (1).
Release bonded connection (2) and remove inner side wall reinforcement (3).
Adjust side panel and secure.
In areas (1) and (2) set 7 4.2 mm dia. bore holes for blind rivets.
Prepare new part and vehicle in area (1) for joining by welding.
Remove new part again and deburr bore holes.
Installing side wall
Clean all bonding surfaces on new part and on vehicle with cleaning agent R1.
Apply adhesive to bonding surfaces.
Coat cavity sealings with sealant. See INSTALLING CAVITY SEALING (EXPANDED) or INSTALLING CAVITY SEALING (NOT EXPANDED) .
Mount side wall and rivet with blind rivets.
In areas (1) and (5) rivet side wall with punch rivets N4 and N5.
| Area | Punch rivet N4 | Punch rivet N5 |
|---|---|---|
| 1 | 5 | |
| 2 | 6 | |
| 3 | 3 | |
| 4 | 5 |
In areas (1) and (2) rivet side panel with punch rivets N4.
| Area | Number |
|---|---|
| 1 | 2 |
| 2 | 3 |
Weld new part in area (3).
In areas (1) and (2) rivet side panel with punch rivets N4.
| Area | Number |
|---|---|
| 1 | 4 |
| 2 | 3 |
After adhesive has hardened in area (2), fit an EMC SCREW .
After hardening of the adhesive in area (1), install 2 EMC screws.