Removing side wall

Mark severance cuts in accordance with specified dimensions and cut.

Compare position of severance cuts with REINFORCEMENT PLATES .

Dimension a = approx. 200 mm from center point of 25 mm dia. hole

Dimension b = approx. 115 mm from roof edge.

Open welded connections in areas (1).

Open spot-welded adhesive joints in area (2)

Open FOLDED BONDED CONNECTION  in area (3).

Loosen side wall of cavity sealing (4).

Fig 1: Identifying Rear Left Side Panel Side Wall Cavity Sealing And Welded Connections Areas

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Fig 2: Identifying Rear Left Side Panel Template

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

Take off side panel.

Fig 3: Identifying Welded Connections Areas

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Open welded connections in area (1).

Release bonded joint (2).

Remove lock striker reinforcement.

Fig 4: Identifying Welded Connections Area And Bonded Joint

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Preparation of new part: 

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

Prepare REINFORCEMENT PLATES  (bonded) at all severance cuts.

Separate weld joints in area (1) from inside.

Remove sill section (2).

Fig 5: Identifying Weld Joints Area And Sill Section

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Adjust new part to fit and secure.

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

Area (1): 5 bore holes

Area (2): 4 holes

F02 only: 

In area (1) 6 holes

Fig 6: Identifying Rear Left Side Panel Bore Holes Areas

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

Area (1): 3 holes

Area (2): 1 bore holes

Remove new part again and deburr bore holes.

Fig 7: Identifying Rear Left Side Panel Bore Holes Areas

Courtesy of BMW OF NORTH AMERICA, INC.