41 35 101 Replacing Rear Left Side Panel

WARNING: This page is about a different car, the 2011 BMW X6 and 2010 BMW X6. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: High-voltage system - danger to life!

WARNING: The following points must be strictly observed prior to starting work :

DE-ENERGIZE THE HIGH-VOLTAGE SYSTEM
Observe SAFETY INSTRUCTIONS for handling with hybrid cars

Read contents of BODY .

STRIP DOWN VEHICLE

Procedure observe REPAIR STAGE 2 !

Following new body parts are required (refer to ELECTRONIC PARTS CATALOGUE ):

Fig 1: Identifying Rear Side Frame

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(1) Side frame, rear
Reinforcement plate, side sill
Reinforcement plate, C-pillar
Reinforcement plate, D-pillar
Shaped part entrance, outer
Shaped part, C-pillar
Shaped part, D-pillar, outer
Mounting nuts

Following CONSUMABLES are required:

Material	Quantity
Adhesive K5b	1
Adhesive K5a	1
Blind rivets N3	19
Blind rivets N1	3
Punch rivets N4	34
EMC screws	2
Cleaning agent R1	1
Cavity sealing wax remover	1
Sealant D1

Removing side panel:

Mark severance cut (1) in accordance with dimension and cut.

Mark severance cut (2) at component edge and cut.

IMPORTANT: Cut outer panel only.
Compare position of severance cut (1) with REINFORCEMENT PLATE (bonded).

Measurement a = approx. 90 mm from center point of 20 mm dia. hole.

Open weld joint in areas (3).

Fig 2: Identifying Component Edge Severance Cut And Weld Joint Areas

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Fig 3: Identifying Welded Connections Areas And Position Of Cavity Acoustic Baffles

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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. Correct position if necessary.

Measurement a = approx. 130 mm from roof edge

Measurement b = approx. 95 mm

Open welded connections in areas (1).

(2) Position of cavity acoustic baffles

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

Fig 4: Identifying Template

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Open welded connections in areas (1).

Open brazed connections in areas (2).

Fig 5: Identifying Welded Connections Areas And Brazed Connections Areas

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Open welded connections in area (1).

Take off side panel.

Fig 6: Identifying Welded Connections Area

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New part preparation:

Prepare REINFORCEMENT PLATES (bonded) at all severance cuts.

Mark severance cut (1) in accordance with vehicle and cut.

Mark severance cut (2) at component edge and cut.

Open weld joints in areas (3) and remove components (4).

Mark further severance cuts in accordance with vehicle and cut.

Fig 7: Identifying Severance Cut, Weld Joints Areas And Components

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Adjust new part to fit and secure.

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

In area (4), set 6.8 mm dia. holes for N1 blind rivets :

IMPORTANT: When introducing holes in the area of the sill, watch out for the add-on parts.

Fig 8: Identifying Blind N3 Rivets Area And N1 Blind Rivets Area

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Area	Number
1	4
2	3
3	4
4	3

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

Area	Number
1	4
2	2

Remove new part again and deburr bore holes.

Fig 9: Identifying Bore Holes Area For Blind Rivets

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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 plates with cleaning agent R1.

Apply adhesive to reinforcement plates. Install reinforcement plates.

Fig 10: Identifying Adhesive Areas And Cavity Acoustic Baffles Areas

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Apply adhesive in areas (1).

Apply sealant to cavity acoustic baffles in areas (2). See INSTALLING A CAVITY ACOUSTIC BAFFLE (EXPANDED) or INSTALLING A CAVITY ACOUSTIC BAFFLE (NOT EXPANDED) .

Fig 11: Identifying Adhesive Areas And Punch Rivets N4 Area

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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 panel to fit, tighten nuts of reinforcement plates (1).
Secure side panel in area of reinforcement plates with gripping pliers and rivet with blind rivets.

In areas (2) to (4) use punch rivets N4.

Area	Number
2	10
3	11
4	5

In areas (5), screw in the screws before the adhesive hardens.

NOTE: When fastening in the screws, ensure that no adhesive reaches the screw connection!
Tighten screws hand-tight.

Use 8 N4 punch rivets in area (1).

Fig 12: Identifying N4 Punch Rivets Area

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Once the adhesive has hardened in area (1) and in the area of the side sill, fit one EMC SCREW .

Fig 13: Identifying Adhesive Hardened Area

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