41 35 101 Replacing Left Rear Side Panel M3

WARNING: This page is about a different car, the 2011 BMW M3, 2010 BMW M3, 2009 BMW M3, and 2008 BMW M3. However, it is still accessible from the selected car via links, so may be relevant.

Read general service information under BODY, GENERAL .

STRIP DOWN vehicle.

NOTE: Observe procedure for bonding and riveting (REPAIR STAGE 2) .

The following new body parts are required:

(1) Rear side wall
(2) Reinforcement plates (not pictured)
(3) Lock nuts (not pictured)

Following CONSUMABLES are required:

CONSUMABLES REFERENCE CHART

Material	Quantity
Adhesive K5b	1
Adhesive K5a	1
Sealant D1
Blind rivets N3	17
Punch rivets N4	19
EMC screws	1
R1 cleaning agent	1

Fig 1: Identifying Rear Side Panel

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Removing side wall

Fig 2: Identifying Weld Areas And Severance Cut Position

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Mark severance cuts in accordance with specified dimensions and cut.

IMPORTANT: Cut outer panel only.

Compare position of severance cuts with REINFORCEMENT PLATES .

Dimension a = approx. 110 mm from roof edge.

Dimensions b = approx. 250 mm from centerpoint of hole diameter 25 mm

Open welded connections in areas (1).

Undo FOLD BONDED CONNECTION . in the area (2).

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

Fig 3: Identifying Template

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Open welded connections in areas (1).

Open brazed connections in areas (2).

Fig 4: Identifying Welded And Brazed Connection Areas

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Preparation of new part

IMPORTANT: Release entrance section from new part.

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

Prepare REINFORCEMENT PLATES at all severance cuts.

Adjust new part to fit and secure.

Set 4.2 mm diameter bore holes for blind rivets in areas (1) and (2).

Area (1): 5 bore holes

Area (2): 6 bore holes

Fig 5: Identifying Rivet Areas

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Set 4.2 mm diameter bore hole for blind rivets in bulkhead of jacking point in the area (1):

Fig 6: Identifying Rivets Areas In Jacking Point Bulkhead

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Set 4.2 mm diameter bore holes for blind rivets in areas (1) and (2).

Area (1): 4 bore holes

Area (2): 1 bore hole

Remove new part and deburr bore holes.

Fig 7: Identifying Rivet Areas

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

Installing side wall

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

Apply adhesive to reinforcement plates. Install reinforcement plates.

Fig 8: Identifying Adhesive Applying Areas On Rear Side Panel

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Apply adhesive in areas (1).

Adhesive must be applied to new part in area (2).

Apply sealant D1 to cavity sealing in areas (3).

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

Dimension a = approx. 10 mm

Fig 9: Identifying Side Wall Adhesive Applying Area

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Fig 10: Identifying Blind Rivets And N4 Rivets Areas

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Install side wall with a second person helping.

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

Secure side wall next to reinforcement plates with gripping pliers.

Rivet side wall with blind rivets in areas (1).

Use punch rivets N4 in areas (2) and (3):

RIVETS AREAS REFERENCE CHART

Area	Number
2	10
3	2

Side wall is glued and bordered in area (4).

Rivet side wall with blind rivets in areas (1).

Use punch rivets N4 in areas (2) and (3).

RIVETS AREAS REFERENCE CHART

Area	Number
2	3
3	4

Fig 11: Identifying Rivet Areas

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

Rear side wall.

Fig 12: Identifying Outer Wheel Arch Section Adhesive Applying Area

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Installation note:

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.

Fig 13: Identifying Rear Side Wall Adhesive Applying Area

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IMPORTANT: Flange edge must be completely filled with adhesive (1).

IMPORTANT: The wheel arch must be flanged immediately after riveting before the adhesive hardens.
After adhesive has hardened in the lower sill area, install an EMC SCREW .