Replacing Rear Left Side Panel (M4 Coupe)

Read contents of Body, General.

Procedure OBSERVE repair stage 2!

Strip down vehicle.

Example figure.

Due to the constantly increasing levels of geometric complexity and the demanding pre-processing steps on visible separating cuts, the choice of joining technology for the reinforcing plate is switched from bonding to welding. This change applies for all BMW and MINI series.

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

Bonding is done in areas (2).

Note changed procedure (See REINFORCEMENT PLATE WITH STUD BOLT (BONDED OR WELDED) .

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Courtesy of BMW OF NORTH AMERICA, INC.

Following new body parts are required (see applicable BMW Parts Catalog):

(1) Rear side wall
Reinforcement plate, side sill
Reinforcement, B-pillar
Reinforcement plate, C-pillar
Mounting nuts

Following CONSUMABLES are required:

Material	Quantity
Adhesive K5b	1
Adhesive K5a	1
Blind rivet N3	11
Punch rivet N4	27
Punch rivet N5	6
EMC screws	3
Cleaning agent R1	1
Cavity sealing wax remover	1
Sealant D1	1

Removal

Mark severance cut in accordance with dimension and cut.

CAUTION: Cut outer panel only.

Compare position of separating cut with reinforcement plate.

Dimension a = approx. 220 mm from corner of roof outer skin.

Open welded connections in area (1).

NOTE: In addition to the dimensions, the position of the separating cut can be determined with a TEMPLATE (1).

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Courtesy of BMW OF NORTH AMERICA, INC.

Courtesy of BMW OF NORTH AMERICA, INC.

Mark severance cuts in accordance with specified dimensions and cut.

CAUTION: Cut outer panel only.

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

Dimension a = approx. 10 mm from center point of 15 mm dia. hole.

Dimension b = approx. 225 mm from the edge of side frame.

Open welded connections in areas (1).

Open seam adhesive bond in area (2).

Release side wall from cavity acoustic baffles (3).

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

CAUTION: In area (2), the welding spots must be detached from the side wall.

Take off side panel.

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New part preparation

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

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

Adjust new part to fit and secure.

Prepare area (1) for 4 x 15 mm long metal active gas weld seams (2).

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, 4 spot welds can be made in area (1) instead of metal active gas weld seams.

Courtesy of BMW OF NORTH AMERICA, INC.

Courtesy of BMW OF NORTH AMERICA, INC.

In areas (1) and (2), drill 0 4.2 mm bore holes for blind rivet:

Area	Number
1	1
2	10

Remove new part again and deburr bore holes.

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

Installation

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

Apply adhesive to reinforcement plates (side sill, B-pillar). Install reinforcement plates.

Coat CAVITY SEALINGS with sealant.

Apply adhesive to bonding surfaces on vehicle.

CAUTION: In the area around the B-pillar, adequate distance must be provided between the adhesive applied and the upcoming metal active gas welded connections. Distance depending on the adhesive 2 - 3 centimeter.

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.