41 35 101 Replacing rear left side panel: Notes

Read contents of BODY, GENERAL .

STRIP DOWN VEHICLE .

Follow procedure for REPAIR STAGE 2 .

The following new parts are required:

• Rear wall (1)
• Reinforcement plate, door sill
• Reinforcement plate, C-pillar
• Reinforcement plate, D-pillar
• Reinforcement plate, universal

Fig 1: Rear Wall

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The following CONSUMABLES  are required:

Removal: 

Mark severance cuts in accordance with specified dimensions and cut.

Compare position of severance cuts with REINFORCEMENT PLATES .

Dimension "a" = approx. 80 mm from the center point of 25 mm dia. hole.

Dimension "b" = approx. 150 mm from component edge of the window frame.

Dimension "c" = approx. 60 mm from the center point of the hole in the molding.

Open welded connections in areas (1).

OPEN  spot-welded adhesive joints in area (2).

Loosen side wall of cavity sealing (3).

Fig 2: Welded Connections Areas, Spot-Welded Adhesive Joints Area, And Cavity Sealing

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Fig 3: Template

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Cut the separating cut (1) in the water channel in the center between the welded connections (2) and sever.

Open the lower welding spot (2) and welded connections in the area (3).

(4) = Severance cut, C-pillar.

Fig 4: Cutting Areas, Welded Connections, And Lower Welding Spot

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Open welded connections in areas (1) and (2).

Take off side panel.

Fig 5: Welded Connections Areas

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Preparation of new part: 

Mark severance cuts on new part in accordance with severance cuts on vehicle and cut.

For severance cuts, prepare reinforcement plates.

Area of water channel:

Adjust the universal reinforcement plate (1) for the severance cut in the water channel as shown.

Installation note: 

Close the hole (2) with adhesive tape before applying the adhesive. Top the area (3) with adhesive for installation.

Fig 6: Adjusting Universal Reinforcement Plate For Severance Cut In Water Channel

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Fit in new part.

In area (1), set three bores with a 4.2 mm dia. for the blind rivets.

Fig 7: Blind Rivet Bore Holes Area

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Remove new part and deburr holes.

Installation: 

Clean all  bonding surfaces (1) on the new part, vehicle and reinforcement plates with cleaning agent R1!

Apply adhesive to reinforcement plates. Install reinforcement plates.

Apply adhesive to bonding surfaces on vehicle.

Apply sealant to CAVITY SEALING  (2).

Fig 8: Areas For Applying Adhesive And Sealant

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Install the side panel and rivet with blind rivets N3 in the area (1).

Fig 9: Blind Rivet Bore Holes Area

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In areas (1) to (4), rivet side panel with punch rivets N4.

Fig 10: Rivet Areas

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

In areas (1) to (4), rivet side panel with punch rivets N4.

Fig 11: Rivet Areas

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After adhesive has hardened, install one EMC SCREW  in each case in areas (1).

Fig 12: EMC Screw Installation Areas

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