41 35 105 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) Rear side wall

The following CONSUMABLES are required:

Fig 1: Identifying Rear Side Wall

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MATERIAL QUANTITY SPECIFICATION

Material	Quantity
Adhesive K5b	1
Blind rivets N3	10
Punch rivets N4	20
EMC screws	1
Cleaning agent R1	1
Cavity sealing wax remover	1
Sealant D1

Removing side wall:

Open welded connections in areas (1).

Open brazed connections 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 Cavity Sealing, Brazed Connection Areas, And Welded Connection 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: Identifying Areas For Blind Rivet Bore Holes

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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.

Fig 4: Identifying Area For Blind Rivet Bore Holes

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CAUTION: Pay attention to hinge mount on split door.

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 to bonding surfaces.

Fig 5: Identifying Bonding Surfaces

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Apply sealant to cavity sealing (1). See 4100... INSTALLING CAVITY SEALING (EXPANDED) or 4100... INSTALLING CAVITY SEALING (NOT EXPANDED) .

Fig 6: Identifying Sealant Application Area

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

Fig 7: Identifying Areas For Blind Rivets

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

Fig 8: Identifying Area For Blind Rivets

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

NUMBER SPECIFICATION

Area	Number
1	8
2	6
3	6

Fig 9: Identifying Areas For 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 Area

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