41 35 101 Rear Left Side Panel Replacement

The following body new parts are required

• (1) Rear side wall
• (2) Attachment, entrance, outer
• Reinforcement plate, side sill
• Reinforcement plate, C-pillar
• Shaped part entrance, rear
• Mounting nuts

Fig 1: Side Panel, Rear And Attachment, Entrance, Outer

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Removing side panel 

Mark severance cut (1) at outer entrance attachment (2) in accordance with dimension a and cut. Dimension a = 100 mm in front of 20 mm dia. hole. Open weld joints on entrance attachment (2) and remove component.

Fig 2: Opening Weld Joints On Outer Entrance

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Fig 3: Severance Cuts And Specified Dimensions

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Mark severance cuts in accordance with specified dimensions and cut. Important! Cut outer panel only. Compare position of severance cuts with reinforcement plates. The slide/tilt sunroof water drain hose is located behind severance cut b! Before detaching the wheel arch weld connections, straighten the wheel arch edge in accordance with the new part.

Dimension a = approx. 25 mm from center point of 20 mm diameter hole. (left side of vehicle only) Dimension b = approx. 100 mm from roof edge. Dimension c = approx. 20 mm from outer edge of sill. Open welded connections in areas (1). Open weld connections on bulkhead in area (2). Release side wall from cavity sealing (3).

Fig 4: Using Template

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Right side of vehicle only:  Mark severance cut (1) in accordance with dimension and cut. Dimension a = approx. 20 mm before center of 20 mm dia. hole.

Separation cut (2) analogous with left side of vehicle.

Fig 5: Dimension "A"

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Open welded connections in areas (1). Open brazed connections in areas (2). Take off side panel.

Fig 6: Brazed Joints Areas

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Right side of vehicle only: If necessary, open weld joints in area (1).

Fig 7: Locating Right Side Weld Joints

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New part preparation  Mark severance cuts on the new part according to vehicle and cut. Prepare reinforcement plates (bonded) at all severance cuts.

Fig 8: Cutting New Part On Sill Outer Edge Radius

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Cut new part on sill outer edge radius (1).

Open welded connections in areas (1). Centre punch the welded connections in area (2) in the middle and drill through with a drill diameter of 6.8 mm. Then sand off the remaining welding spots with a belt sander from inside and take off section (3).

Fig 9: Open Welded Connections In Area 1

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Fig 10: Adjusting New Part To Fit And Secure

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Adjust new part to fit and secure. In areas (1) and (2) set five 4.2 mm dia. holes for blind rivets in each area. in the reinforcement plate of jacking point (3) in area (4): set 6.8 mm dia. bore holes for N1 blind rivets.

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

Fig 11: Set Three 4.2 mm Diameter Holes For Blind Rivets

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Severance cut (2) at entrance attachment (1). Mark severance cut with extra material in accordance with dimension a and cut. Dimension a = 50 mm from severance cut on vehicle. Entrance attachment section is installed overlapping by dimension a.

Fig 12: Severance Cut (2) At Entrance Attachment (1)

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Adjust new entrance attachment part (1) to fit and secure. Set ten 4.2 mm dia. holes for blind rivets in areas (2). Area (3): 1 hole Remove new parts and deburr bore holes.

Fig 13: Installing Entrance Attachment And Rivets

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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.

Fig 14: Applying Adhesive In Areas

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Apply adhesive in areas (1). Adhesive must be applied to new part in area (2). Apply sealant D1 to cavity sealings in areas (3).

Apply adhesive (1) to inside of side wall (2) at distance a. Dimension a = 10 mm

Fig 15: Applying Adhesive To Inside Of Side Panel At Distance A

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Fig 16: Ensure Sufficient Adhesive Is On Bonding Surfaces

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Install side wall with a second person helping.

Rivet side wall in area (1) with blind rivets. In areas (2) to (4) use punch rivets N4.

Fig 17: Punch Rivet Area

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Fig 18: Riveting Reinforcement Of Jacking Point (1) With Side Wall (2)

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Rivet reinforcement of jacking point (1) with side wall (2).

Entrance attachment: Clean bonding surface (1) with cleaning agent R1. Apply adhesive to bonding surface.

Fig 19: Cleaning Bonding Surface (1) With Cleaning Agent

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Install entrance attachment (1) and rivet in areas (2) and (3). No riveting in area (4). After adhesive has hardened in the lower sill area, install an EMC screw.

Fig 20: Installing Entrance Attachment And Rivets

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Seal new component from inside in area (1) with sealing compound.

Fig 21: Component Sealing Area

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