41 35 102 Rear Left Side Panel Replacement (Partial Replacement Before Longitudinal Member Cover)

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Spot-weld bonding is used for the first time on the E65. A specific procedure must be followed here.

Following new body parts are required:

Partial section, rear side panel

Fig 1: Rear Side Panel Partial Section
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Mark severance cuts in accordance with specified measurements and cut.

CAUTION: Cut outer metal sheet only.

Sunroof water drain hose is located behind severance cut a.

Measurement a = approx. 100 mm from roof edge.

Measurement b = approx. 200 mm from lower latch striker screwing point.

Open weld joints in areas (1).

Installation information:

Apply window glass adhesive to cavity acoustic baffle (2).
Weld in reinforcing plates approx. 30 mm long at severance cuts.

Fig 2: Open Weld Joint Areas, Cavity Acoustic Baffle And Measurement Areas

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Open weld joints in areas (1).

Open brazed joints in areas (2).

Fig 3: Open Weld Joint Areas And Open Brazed Joints Areas

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Installation:

Make a metal angle bracket (1) to protect water drain hose against welding heat. Length a = 30 mm. Attach metal angle bracket (1) to hose and secure centrally under cutting edge through welding spots.

Fig 4: Metal Angle Bracket And Length Measurement

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Installation:

Reinforcement of C-pillar latch striker is originally bonded to outer wheel arch. Drill holes for spot welding in contact area of reinforcement (1). Adjust side panel to fit and weld holes above wheel arch.

Fig 5: Reinforcement Spot Welding Holes

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