41 35 401 Replacing Rear Left Side Panel (Partial Replacement, Door Opening)

Read contents of BODY, GENERAL .

Spot-weld bonding is used on this vehicle. Observe specific procedure  .

Use only approved spot-welding apparatus  for repairs, see WORKSHOP EQUIPMENT !

Remove or cover those vehicle components in the repair area which are susceptible to heat or dust.

Following new body parts are required:

• (1) Side frame, rear
• (2) Shaped part, entrance, outer (not shown)

Fig 1: Identifying Side Frame, Rear

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Mark severance cuts in accordance with specified measurements and cut.

Measurement a = approx. 190 mm from middle of lower lock striker screw point.

Measurement b = approx. 320 mm from centerpoint of hole dia. 20 mm

Open weld joints in areas (1).

Open spot-weld bonded joints in area (3)

Fig 2: Identifying Cut Mark Area

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Installation information: 

• Apply window glass adhesive to cavity acoustic baffle  (2).
• Weld in reinforcing panels  at all severance cuts, see 41 00... Welding in reinforcement plate (steel plate) .
• Bond  and rivet new part in area (3), see 41 00... Bonding steel on steel .

Use Hemlock 813 blind rivet (sourcing reference: BMW Parts Service picture board - Aluminum and steel/bonding and welding).

Double number of rivets with respect to welding spots in area (3).

Open adhesive joints in areas (1) and (2).

Open weld joint in area (1).

Installation information: 

Welding spot is omitted from area (1).

Glue  new part in areas (1) and (2).

Apply window glass adhesive to cavity acoustic baffle  (3).

Fig 3: Identifying Cavity Acoustic Baffle & Area

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Installation: 

Apply adhesive  in areas (1).

Fig 4: Identifying Adhesive Areas

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