41 35 101 Replacing Left Rear Side Wall

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	26
EMC screws	1
R1 cleaning agent	1

Fig 1: Identifying Rear Side Panel

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Removing side wall

Fig 2: Identifying Welding Areas With Dimension a And b On Left Rear Side Panel

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Mark severance cuts in accordance with specified dimensions and cut.

IMPORTANT: Cut outer panel only.

Before loosening the wheel arch welding connections:

Straighten wheel arch edge similarly to new part.

Compare position of severance cuts with REINFORCEMENT PLATES .

Dimension a = approx. 110 mm from roof edge.

Dimension b = approx. 250 mm to centerpoint of 25 mm diameter hole.

Open welded connections in areas (1).

NOTE: In addition to the dimensions, a TEMPLATE (1) may be used to determine the position of the separating cut.

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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In areas (1) and (2) set 4.2 mm diameter bore holes for blind rivets.

Area (1): 4 bore holes

Area (2): 1 bore hole

Remove new part again 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).

Fig 9: Identifying Rivet Areas On Left Rear Side Panel

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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.
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	6

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	5
3	5

Fig 10: Identifying Rivet Areas

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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 .