41 35 101 Replacing rear left side panel
Read contents of BODY, GENERAL .
Follow procedure for REPAIR STAGE 2 .
The 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
- Attachment nut
The following CONSUMABLES are required:
| Material | Quantity |
|---|---|
| Adhesive K5b | 1 |
| Adhesive K5a | 1 |
| Blind rivets N3 | 13 |
| Punch rivets N4 | 35 |
| Punch rivets N5 | 6 |
| EMC screws | 4 |
| Cleaning agent R1 | 1 |
| Cavity sealing wax remover | 1 |
| Sealant D1 |
Removal:
Mark severance cuts (1) and (3) according to specification and cut.
Compare position of severance cuts with REINFORCEMENT PLATES .
The severance cut (1) runs through the center between stiffening impressions (2).
Severance cut (3) in accordance with dimension a = approx. 25 mm from weld point connection (4).
Open welded connections in areas (4) and (5).
Open welded connections in area (1).
Mark severance cuts in accordance with specified dimensions and cut.
Compare position of severance cuts with reinforcement plates.
Dimension a = approx. 52 mm from center point of 8 mm dia. hole.
Dimension b = approx. 215 mm from component edge of side frame.
Dimension c = approx. 20 mm from outer edge of sill
Open welded connections in areas (1).
Release side wall from cavity sealings (2) and remove.
Preparation of new part:
Cut new part on sill outer edge (1).
Mark severance cut (2) and the other severance cuts according to vehicle and cut.
Prepare REINFORCEMENT PLATES (bonded) at all severance cuts.
Open welded connections in areas (1).
Release reinforcement B-pillar from cavity sealing (2) and remove.
Removed foamed material of cavity sealings in areas (2) and (3).
General view of C-pillar:
Make universal reinforcement plate (1) in area of water channel according to schematic diagram and adjust.
Dimension a = approx. 60 mm.
Adjust new part to fit and secure.
Set three 4.2 mm dia. bore holes for blind rivet in area (1).
Set four 4.2 mm dia. bore holes for blind rivet in area (1).
Prepare area (1) for 5 x 10 mm long metal active gas weld seams (2).
Installation note:
The metal active gas weld seams (2) will be placed at equal distances on the front side of the 3 - sheet metal flange.
The area (1) corresponds to the flange surface of the B-pillar reinforcement.
Set six 4.2 mm dia. bore holes for blind rivet in area (1).
Remove new part again and deburr bore holes.
Installation:
Clean all bonding surfaces on vehicle, on the new part and on the reinforcement plates with cleaning agent R1.
Install universal reinforcement plate:
Area (1) between water channel (2) and C-pillar (3) must be completely filled with adhesive.
Then install universal reinforcement plate by screwing it in direction of arrow.
Apply adhesive to further reinforcement plates and install reinforcement plates.
Apply adhesive in areas (1).
New part in areas B- and C-pillars: Apply sealant to cavity sealings on new part. See INSTALLING CAVITY SEALING (EXPANDED) , INSTALLING CAVITY SEALING (NOT EXPANDED) , and EMC SCREWS .
Apply additional sealant for cavity sealing in area (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 punch rivets N4 and N5 areas (1) to (5).
| Area | Number | Remarks |
|---|---|---|
| 1 | 10 | Punch rivetN4 |
| 2 | 2 | Punch rivet N5 |
| 3 | 4 | Punch rivet N5 |
| 4 | 14 | Punch rivetN4 |
| 5 | 2 | Punch rivetN4 |
In the area (6) set 5 metal active gas welding seams according to the preparation of new part. In area (7), secure side wall with gripping pliers until adhesive has hardened.
Use 9 punch rivets N4 in area (1).
Use one punch rivet N4 in each area (2).
Remove excess adhesive.
After hardening of the adhesive install 3 EMC SCREWS in areas (1).
Additionally, install one EMC screw in sill area (2).