41 35 101 Replacing rear left side panel: Notes

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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: Rear Side Wall

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Material	Quantity
Adhesive K5b	1
Blind rivet N3	12
Punch rivet N4	32
EMC screw	2
Cavity sealing wax remover	1
Cleaning agent R1	1
Sealant D1	1

Removal

Open WELDED CONNECTIONS in areas (1).

Heat cavity sealing (2) with hot air blower and release from side wall.

Fig 2: Welded Connections Areas And Cavity Sealing

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Open WELDED CONNECTIONS in areas (1) and (2).

Take off side panel.

Attention !

In area (1), the WELDED CONNECTIONS must be detached from the side wall.

Fig 3: Welded Connections Areas

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New part preparation

Adjust side panel and secure. Feed in the side panel, starting at the C-pillar.

Prepare area (1) for three 15 millimeter long metal active gas weld seams (2).

Fig 4: MAG Weld Seams Area

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Installation note:

The metal active gas weld seams (2) will be placed on the front side of the 3-sheet metal flange.

If an approved spot-welding apparatus is available, spot welding can also be set in area (1) instead of the metal active gas weld seams.

Drill bore holes 4.2 mm for blind rivet in areas (1) and (2).

Area	Number
1	1
2	4

In areas (1) and (2), set bore holes of 4.2 mm for blind rivet.

Fig 5: Rivet Areas

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Area	Number
1	2
2	1
3	4

Remove new part again and deburr bore holes.

Attention !

Do not grind/sand new part in area of bonding surfaces.

Installation:

Clean all bonding surfaces (1) and (2) on new part and on vehicle with cleaning agent R1!

Apply adhesive to bonding surfaces.

Also apply adhesive to the new part in the areas (2).

Coat CAVITY SEALINGS (3) with sealant.

Fig 6: Bonding Surfaces And Cavity Sealings

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Attention !

The area around the B-pillar requires a sufficient distance between the adhesive application and the subsequent welded connections. Distance depending on the adhesive 2 - 3 centimeter.

Install the side panel and rivet areas (1) and (2) with the blind rivet N3.

Fig 7: Rivet Areas

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Fig 8: Bonding Surfaces On New Part And Cavity Sealings

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Rivet the side panel with the blind rivet N3 in areas (1) to (3).

Fig 9: Bonding Surfaces And Cavity Sealings

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In areas (1) to (3), rivet the side panel with punch rivets N4.

Attention !

Punch rivets N4 may only be installed in area (3) at the three moldings in the wheel arch panel!

Fig 10: Side Panel With Punch Rivets N4 Areas

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Area	Number
1	5
2	5
3	3

In area (4), set three 15 mm long metal active gas weld seams or three spot welding according to the new part preparation.

In area (5), secure side panel with gripping pliers until adhesive has hardened.

In areas (1) to (3), rivet the side panel with punch rivets N4.

Fig 11: Side Panel With Punch Rivets N4 Areas

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Area	Number
1	8
2	4
3	2

Fit an EMC SCREW after adhesive has hardened in area (1).

Fig 12: EMC Screw Area

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Fit an EMC screw after adhesive has hardened in area (1).

Fig 13: EMC Screw Area

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