41 35 102 Replacing Rear Left Side Panel (Partial Replacement Before Longitudinal Member Cover)

WARNING: This page is about a different car, the 2010 BMW M5, 2009 BMW M5, 2008 BMW M5, 2007 BMW M5, and 2006 BMW M5. However, it is still accessible from the selected car via links, so may be relevant.

Spot-weld bonding is used on the E60. Observe specific procedure .

Use only approved SPOT-WELDING APPARATUS for repairs!

Following new body parts are required:

Partial section, rear side panel

Fig 1: Identifying Partial Section, Rear Side Panel
Courtesy of BMW OF NORTH AMERICA, INC.

Fig 2: Mark Severance Cuts In Accordance With Specified Measurements And Cut
Courtesy of BMW OF NORTH AMERICA, INC.

Mark severance cuts in accordance with specified measurements and cut.

IMPORTANT: Cut outer metal sheet only.
Sunroof water drain hose is located behind severance cut a.

Measurement a = approx. 105 mm from roof edge.

Measurement b = approx. 120 mm from middle of lower lock striker screw point.

Open weld joints in areas (1).

Installation information:

Apply window glass adhesive to CAVITY ACOUSTIC BAFFLE (2).
Weld in REINFORCEMENT PLATES at severance cuts.
NOTE: The following work step applies to the M5 only.

The wheel arch connection area is partially glued on the M5!

Expose and detach wheel arch connection area.

Fig 3: Locating Wheel Arch Connection Area

G05503281

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: The work step for the M5 ends here.

Open weld joints in areas (1).

Open brazed joints in areas (2).

Fig 4: Identifying Brazed Joints Areas

G05503282

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

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

Fig 5: Identifying Component Seal Area

G05503283

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

Reinforcement of C-pillar latch striker is originally bonded to outer wheel arch. Drill holes for spot welding in contact surface of reinforcement (1). Adjust side panel to fit and weld holes above wheel arch.

Fig 6: Identifying Wheel Arch Cut Line

G05503284

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: Following work steps apply to M5 only.

Side panel, rear left and right, must be trimmed.

1 = Body outer side

Fig 7: Identifying Body Outer Side

G05503285

Courtesy of BMW OF NORTH AMERICA, INC.

Mark severance cut (1) in accordance with measurement and cut.

Measurement a = approx. 30 mm.

Measurement b = approx. 50 mm

IMPORTANT: Distance to outer edge (3) is 3 mm in area (2).
The trim must have a radius of approx. 4 mm in area (2).
Otherwise there is a risk that the metal plate of the rear side panel will begin breaking!

Fig 8: Mark Severance Cut (1) In Accordance With Measurement And Cut

G05503286

Courtesy of BMW OF NORTH AMERICA, INC.

View of trimmed rear side panel.

1 = Body outer side

2 = Radius of trimmed side panel

Fig 9: View Of Trimmed Rear Side Panel

G05503287

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

Apply adhesive (1) to inside of side panel (2) at distance a.

Dimension a = 10 mm

Fig 10: Identifying Adhesive Applying Distance Inside Of Side Panel

G05503288

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

Apply adhesive in area (1).

Flange edge of side panel in area (1) flush to outer wheel arch section.

Fig 11: Identifying Adhesive Applying Area

G05512271

Courtesy of BMW OF NORTH AMERICA, INC.

Flange edge of wheel arch (3) of rear side panel flush to outer wheel arch section.

Do not flange sharp edges as the flange edge may begin breaking!

Measurement a=4.5 mm

Adhesive
Side panel, rear

Fig 12: Identifying Side Panel, Rear
Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: Additional work steps for M5 end here.