41 35 101 Replacing Rear Left Side Panel

Read contents of Body, General.

Follow procedure for REPAIR TECHNIQUES, REPAIR STAGE 2 .

Strip down vehicle.

Example figure.

Due to the ever-increasing geometric complexity as well as the demanding post-processing steps on visible severance cuts, the joining technology of the reinforcement plate is to be changed from adhesive bonding to welding. This change applies across all BMW and MINI models.

Welding is done in area (1) (incl. water channel).

Bonding is done in areas (2).

Note changed procedure! Refer to REINFORCEMENT PLATE WITH STUD BOLT (BONDED OR WELDED) .

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The following new body parts are required (refer to appropriate parts information ).

(1) Rear side wall
(2) Reinforcement plate, side sill (not shown)
(3) Reinforcement plate, C-pillar (not shown)
(3) Lock nuts (not pictured)

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The following consumables are required (refer to OVERVIEW OF CONSUMABLES (ELECTRONIC PARTS CATALOG) .

Material	Quantity
Adhesive K5b	1
Adhesive K5a	1
Blind rivets N3	12
Punch rivets N4	39
EMC screws	3
Cleaning agent R1	1
Cavity sealing wax remover	1
Sealant D1	1

Removing side panel:

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Mark severance cuts in accordance with specified dimensions and cut.

Attention!

Cut outer panel only.

Compare position of severance cuts with reinforcement plates; refer to REINFORCEMENT PLATE WITH STUD BOLT (BONDED OR WELDED) .

Measurement a = approx. 20 mm from the centerpoint of 20 mm dia. hole.

Dimension b = approx. 105 mm from corner of roof outer skin.

Open welded connections in areas (1).

Open seam adhesive bond in area (2).

Release side wall from cavity sealing (3) and bonded connection (4).

NOTE: Bonded connection (4) is replaced with sealant during installation.

NOTE: In addition to the dimensions, the position of the separating cut can be determined with a template (1); refer to SEPARATING CUT DETERMINATION WITH A TEMPLATE .

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

Attention!

In areas (2), the welding spots must be released from the side wall.

Take off side panel.

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Preparation of new part:

Mark severance cuts on the new part according to vehicle and cut.

Prepare reinforcement plates at severance cuts; refer to REINFORCEMENT PLATE WITH STUD BOLT (BONDED OR WELDED) .

Adjust new part to fit and secure.

Attention!

Adjust new part to fit without strain particularly in area of C-pillar. Straightening after the adhesive has hardened is not possible.

In areas (1) to (3), set 4.2mm dia. bore holes for blind rivets N3:

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Area	Number
1	2
2	3
3	7

For vehicles with trim at the entrance:

Mark bore holes for the trim and drill.

Prepare area (1) for bonded connection with sealant.

Remove new part again and deburr bore holes.

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Attention!

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

Installing side panel:

Clean all bonding surfaces on vehicle, on the new part and on the reinforcement plate with cleaning agent R1.

Apply adhesive to the reinforcement plate. Install the reinforcement plate on the side sill.

Apply sealant to cavity sealing; refer to INSTALLING CAVITY SEALING (EXPANDED) .

Apply adhesive to bonding surfaces on vehicle.

Apply adhesive to new part in area of wheel arch.

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

Measurement a = approx. 5 mm.

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Install side panel with a second person helping.

NOTE: When installing side panel, make sure there is sufficient adhesive on bonding surfaces.

After adjusting side wall to fit, tighten nuts of reinforcement plates.

Secure side panel in area of reinforcement plates with gripping pliers.

Rivet side panel with blind rivets.

In areas (1) to (4), use N4 punch rivets.

Area	Number
1	12
2	11
3	3
4	2

Weld the separation point to the C-pillar.

In areas (1) to (3), use N4 self-pierce rivets.

Area	Number
1	5
2	2
3	4

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Also apply adhesive (2) to outer wheel arch section (3).

(1) Rear side wall.

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

Do not create sharp edges when flanging as otherwise the flange edge may begin to tear.

Dimension (A) = 5 mm.

Adhesive
Rear side wall

Also seal in area (3) according to standard.

Attention!

Flange edge must be completely filled with adhesive!

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After adhesive has hardened, install one EMC screw in each case in areas (1); refer to EMC SCREWS .

Additionally, install EMC screw in sill area.

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