41 35 101 Replacing Rear Left Side Panel: Notes

Read contents of BODY, GENERAL .

STRIP DOWN VEHICLE 

Observe procedure for REPAIR STAGE 2 .

The following body new parts are required (refer to BMW ELECTRONIC PARTS CATALOGUE )

• (1) Side frame, rear
• Reinforcement plate, side sill
• Reinforcement plate, C-pillar
• Reinforcement plate, D-pillar
• Mounting nuts
  Fig 1: Identifying Rear Side Frame

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Following CONSUMABLES  are required:

Removing side panel 

Fig 2: Identifying Severance Cut Dimensions

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Mark severance cuts in accordance with specified dimensions and cut.

Fig 3: Identifying Template

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Open welded connections in areas (1).

Take off side panel.

Fig 4: Identifying Welded Connections Areas

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Open welded connections in area (1).

Release bonded joint (2).

Fig 5: Identifying Bonded Joint And Welded Connections Area

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New part preparation 

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 6: Identifying Sill Section And Weld Joints Area

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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): 4 bore holes

Area (2): 4 bore holes

Fig 7: Identifying Bore Holes Area Of Blind Rivets

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

Area (1): 2 bore holes

Area (2): 7 bore holes

Remove new part again and deburr bore holes.

Fig 8: Identifying Deburr Bore Holes Areas

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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 9: Identifying Adhesive 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 CAVITY SEALING (EXPANDED)  and INSTALLING CAVITY SEALING (NOT EXPANDED) .

Apply adhesive to inside of side wall (in wheel arch area) at spacing a.

Dimension a = approx. 5 mm.

Fig 10: Identifying Wheel Arch Dimension

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Fig 11: Identifying Nuts Of Reinforcement Plates And Blind Rivets Areas

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Install side panel with a second person helping.

In areas (1), rivet side wall with blind rivets.

Use 4 N4 punch rivets in area (2).

Fig 12: Identifying Blind Rivets And N4 Punch Rivets Area

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

(1) Rear side wall.

Fig 13: Identifying Adhesive At Outer Wheel Arch Section

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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.

1. Adhesive
2. Rear side wall

Also seal in area (3) according to standard.

Fig 14: Identifying Flange Edge Of Wheel Arch And Seal Area

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After adhesive has hardened, install one EMC SCREW  in each case in areas (1).

Additionally, install EMC screw in sill area.

Graphic representation similar.

Fig 15: Identifying EMC Screw Case Areas

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