41 35 101 Rear Left Side Panel Replacement: Notes

WARNING: This page is about a different car, the 2010 BMW 535xi, 2009 BMW 535xi, and 2008 BMW 535xi. However, it is still accessible from the selected car via links, so may be relevant.

Read contents of BODY, GENERAL .

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Observe relevant procedures in BODY, GENERAL .

The following new body parts are required:

Rear side wall
Attachment, entrance, outer
Shaped part, entrance, rear (not shown)
Reinforcement plate, universal (not shown)
Reinforcement plate, side sill (not shown)
Reinforcement plate, C-pillar (not shown)
Reinforcement plate, D-pillar (not shown)
Lock nut (not pictured)

Fig 1: Identifying Attachment, Entrance, Outer

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Removing side wall:

Mark severance cut (1) at outer entrance attachment (2) in accordance with dimension a and cut.

Dimension a = 100 mm in front of 20 mm dia. hole.

Open weld joints on entrance attachment and remove component.

Fig 2: Opening Weld Joints On Outer Entrance

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Fig 3: Identifying Severance Cuts Mark In Accordance With Specified Measurements And Cut

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Mark severance cuts in accordance with specified dimensions and cut.

IMPORTANT: Cut outer panel only.

Dimension a = approx. 170 mm from roof edge.

Dimension b = approx. 150 mm behind bore dia. 6 mm.

Dimension c = approx. 250 mm

Open welded connections in areas (1).

Release welded connections (2) at trailing link fixture.

Release side wall from cavity sealing (3).

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

Fig 4: Identifying Template

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Right side of vehicle only:

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

Dimension a = approx. 20 mm before center of 20 mm dia. hole.

IMPORTANT: Cut outer panel only.

Separation cut (2) analogous with left side of vehicle.

Fig 5: Identifying Dimension "A"

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Shown without side panel for purposes of clarity.

(2) Mounting, tension link

IMPORTANT: Do not release welded connections in area (1) for trailing link fixture (2) on inside sill!

Fig 6: Identifying Trailing Link Fixture And Area Of Welded Connections

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Open welded connections in areas (1).

Open brazed connections in areas (2).

Take off side panel.

Fig 7: Identifying Brazed Joints Areas

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Preparation of new part:

Mark severance cuts on the new part according to vehicle and cut.

Prepare REINFORCEMENT PLATES (bonded) at all severance cuts.

Sever new part just over the outer edge (1).

Fig 8: Identifying Outer Edge

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Centre punch the welded connections in areas (1) in the middle and drill through with a drill diameter of 6.8 mm.

Then sand off the remaining welding spots with a belt sander from inside and take off section (2).

Fig 9: Identifying Section And Areas Of Welded Connections

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Adjust new part to fit and secure.

In areas (1) and (2) set 4.2 mm diameter bore holes for N3 blind rivets:

Area (1): 5 bore holes

Area (2): 4 bore holes

Fig 10: Identifying Rivet Bore Hole Areas

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Set three 4.2 mm dia. holes for blind rivets in area (1).

Fig 11: Identifying Location For Rivets

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Special procedure for severance cut (1) in the area of the D-pillar water channel:

Another reinforcement plate (3) is needed in addition to the universal reinforcement plate (2).

Prepare reinforcement plate (3) as shown in the schematic diagram. Length a = approx. 60 mm.

NOTE: The reinforcement plate (3) is installed with punch rivets.

Fig 12: Identifying Severance Cut And Reinforcement Plates

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In the reinforcement plate of the jacking point (1) in area (2), set 6.8 mm dia. holes for N1 blind rivets.

In the fixture of the trailing link in area (3), set 6.8 mm dia. holes for N1 blind rivets.

Fig 13: Identifying Rivet Bore Hole Areas

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Cut new outer entrance attachment part (1).

Severance cut (2).

Area a is 50 mm.

Area a must overlap old part during installation.

Fig 14: Severance Cut (2) At Entrance Attachment (1)

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Adjust new entrance attachment part to fit and secure.

Set nine 4.2 mm dia. holes for N3 blind rivets in areas (1).

Area (2): 1 hole

Remove new parts and deburr bore holes.

NOTE: New entrance attachment part is not riveted in areas (3).

Fig 15: Identifying Rivet Bore Hole Areas And Non-Rivet Areas

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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.

Apply adhesive in area (1).

Adhesive must be applied to the new part in area (2).

Apply sealant D1 to CAVITY SEALINGS in areas (3).

Fig 16: Identifying Adhesive And Sealant Areas

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Apply adhesive (1) to inside of side wall (2) at distance a .

Dimension a = 10 mm

Fig 17: Apply Adhesive (1) To Inside Of Side Wall (2) At Distance A

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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.

Secure side panel next to reinforcement plates with gripping pliers.

Rivet side wall with blind rivets in areas (1).

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

Area	Number
2	10
3	8
4	9

Fig 18: Identifying Rivet Areas

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Rivet side wall in area (1) with blind rivets.

Use 7 punch rivets N4 in area (2).

Fig 19: Identifying Rivet Areas

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Clean bonding surface and apply adhesive

Install reinforcement plate (1) and rivet with 2 punch rivets.

Fig 20: Identifying Reinforcement Plate

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In the reinforcement plate of the jacking point (1) in area (2), set 6.8 mm dia. holes for N1 blind rivets.

In the fixture of the trailing link in area (3), set 6.8 mm dia. holes for N1 blind rivets.

Fig 21: Identifying Rivet Bore Hole Areas

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Entrance attachment:

Clean bonding surface (1) with cleaning agent R1.

Apply adhesive to bonding surface.

Fig 22: Cleaning Bonding Surface (1) With Cleaning Agent

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NOTE:

N1 blind rivets are already installed in areas (3).

Adjust entrance attachment in areas (3) if necessary.

Install entrance attachment (1) and rivet in areas (1) and (2).

Fig 23: Identifying Rivet Bore Hole Areas And Non-Rivet Areas

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IMPORTANT:

The wheel arch must be flanged immediately after riveting before the adhesive hardens.

After adhesive has hardened in the lower sill area, install an EMC SCREW .