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

Read contents of Body, General  . See 41 0 CONTENTS OF BODY, GENERAL .

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:

• (1) Partial section, rear side panel
  Fig 1: Identifying Partial Section, Rear Side Panel

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  Fig 2: Identifying Weld Joints Areas And Measurements

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Mark severance cuts in accordance with specified measurements and cut.

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). See 41 00... INSTALLING A CAVITY BULKHEAD (EXPANDED)  or 41 00... INSTALLING A CAVITY BULKHEAD (NOT EXPANDED) .
• Weld in reinforcing plates  approx. 30 mm long at severance cuts. See 41 00... WELDING IN REINFORCEMENT PLATE (STEEL PLATE) .

Open weld joints in areas (1).

Open brazed joints in areas (2).

Fig 3: Identifying Weld Joints Areas And 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: Identifying Metal Angle Bracket And Length

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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: Identifying Spot Welding Contact Area Of Reinforcement

Courtesy of BMW OF NORTH AMERICA, INC.