41 35 251 Replacing rear left side wall and tail panel

WARNING: This page is about a different variant/trim than selected.

Read contents of BODY, GENERAL .

STRIP DOWN VEHICLE .

Procedure OBSERVE repair stage 2!

Removal of side wall described under 41 35 105 .

Following new body parts are required:

(1) Rear trim, inner
(2) Rear trim, outer skin
(3) Reinforcement, D-pillar, inner

Following CONSUMABLES are required:

Fig 1: Identifying Rear Trim And Reinforcement

Courtesy of BMW OF NORTH AMERICA, INC.

Material	Quantity
Adhesive K5b	1
Blind rivets N3	24
Punch rivets N4	28
EMC screws	11
Cavity sealing wax remover
Cleaning agent R1	1
Sealant D1

Removing rear trim panel

Left side of vehicle:

Open welded connections in areas (1).

Fig 2: Identifying Rear Trim Panel And Welded Connections Areas

Courtesy of BMW OF NORTH AMERICA, INC.

Right side of vehicle:

Mark severance cut (1) as pictured and cut.

Open brazed joint in area (2) by grinding.

Open welded connections in area (3).

Fig 3: Identifying Severance Cut Area, Brazed Joint Area, And Welded Connections Area

Courtesy of BMW OF NORTH AMERICA, INC.

View from vehicle interior left side.

Open welded connections in area (1).

Fig 4: Identifying Welded Connections Area

Courtesy of BMW OF NORTH AMERICA, INC.

View from vehicle interior right side.

Open welded connections in area (1).

Remove rear trim panel.

Fig 5: Identifying Connections Area

Courtesy of BMW OF NORTH AMERICA, INC.

New part preparation

NOTE: New parts tail panel and side wall must be adjusted in combination.
New part preparation of the side panel described in 41 35 101 .

Right side only, rear trim panel outer skin:

Mark severance cut (1) on new part in accordance with shape of side panel and cut.

Severance cut (2) of rear trim panel on car .

Open weld joints and remove component (3).

Fig 6: Identifying Severance Cut Marks

Courtesy of BMW OF NORTH AMERICA, INC.

Right side only, rear trim panel inner part:

Open weld joints in area (1) and remove component (2).

Fig 7: Identifying Weld Joints Area

Courtesy of BMW OF NORTH AMERICA, INC.

Adjust new parts to fit and secure.

In areas (1) to (5), set 4.2 mm dia. holes for blind rivets.

Fig 8: Locating Holes For Blind Rivets

Courtesy of BMW OF NORTH AMERICA, INC.

Area	Number
1	9
2 2	of
3	2
4	2
5	1

Left side of vehicle reinforcement D-pillar (1):

Set two 4.2 mm bore holes for blind rivets in each of areas (2).

Installation note:

The new parts will be welded according to the series during installation in area (3).

Fig 9: Identifying Reinforcement D-Pillar And Areas For Blind Rivet Bore Holes

Courtesy of BMW OF NORTH AMERICA, INC.

Set one 4.2 mm bore hole for blind rivets in each of areas (1).

Remove new parts again and deburr holes.

Fig 10: Identifying Blind Rivets Bore Hole Areas

Courtesy of BMW OF NORTH AMERICA, INC.

Bend adhesive flange (1) approx. 30° inwards.

Graphic representation similar.

NOTE: Apply adhesive to this adhesive flange only after installing rear trim panel.

Fig 11: Identifying Adhesive Flange

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT: Do not grind new parts and body in area of bonding surfaces.

Installing rear trim panel

Clean all bonding surfaces on new part and on vehicle with cleaning agent R1.

Apply adhesive to bonding surfaces.

NOTE: When inserting rear trim panel, make sure there is sufficient adhesive on bonding surfaces.

IMPORTANT: Due to the application time of 2 hours for the adhesive, the tail panel and side wall must be installed in a single work step!

Install rear trim panel inner section and rivet with blind rivets.

Install rear trim panel outer skin and rivet with blind rivets.

In areas (1) to (6) rivet rear trim panel with punch rivets N4.

Fig 12: Identifying Punch Rivet Areas And New Parts Welding Area

Courtesy of BMW OF NORTH AMERICA, INC.

Area	Number
1	3
2	3
3	3
4	6
5	3
6	10

Weld new parts in area (7) same as the series.

Deviating procedure to install the side wall:

IMPORTANT: Three-sheet-metal combination in area (1)!
In area (1) rivet new parts on both sides offset with 4 punch rivets N4.

Fig 13: Identifying Area For Riveting

Courtesy of BMW OF NORTH AMERICA, INC.

Mount carrier for bumper trim to secure rear trim panel.

IMPORTANT: Prevent emerging adhesive from coming into contact with support.
Remove emerging adhesive.
Do not use any cleaning agents containing solvents.

Fig 14: Identifying Installation Areas For EMC Screws

Courtesy of BMW OF NORTH AMERICA, INC.

After hardening of the adhesive install 6 EMC SCREWS in the areas shown.

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

Fig 15: Identifying EMC Screw Areas

Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 16: Identifying Installation Areas For EMC Screws

Courtesy of BMW OF NORTH AMERICA, INC.