41 35 401 Rear Left Side Panel Replacement (Partial Replacement, Door Opening)

WARNING: This page is about a different car, the 2010 BMW 550i, 2009 BMW 550i, and 2008 BMW 550i. However, it is still accessible from the selected car via links, so may be relevant.

Spot-weld bonding is used on this vehicle. Observe specific procedure .

Use only approved spot-welding apparatus for repairs!

Following new body parts are required:

Side panel, rear
Attachment, entrance, outer
Shaped part, entrance, rear (not shown)

Fig 1: Identifying Side Panel And Attachment
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Mark severance cut (1) at outer entrance attachment (2) in accordance with measurement a and cut.

Measurement a = approx. 60 mm behind hole dia. 15 mm.

Open weld joints on outer entrance attachment (2) and remove component.

Installation:

Weld in reinforcement plate at severance cut (1).

Fig 2: Severance Cut At Outer Entrance Attachment

Courtesy of BMW OF NORTH AMERICA, INC.

Fig 3: Severance Cut Measurements

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Mark severance cuts in accordance with specified measurements and cut.

IMPORTANT: Cut outer metal sheet only.

Distance a = approx. 150 mm behind bore dia. 6 mm.

Measurement b = approx. 120 mm from middle of lower lock striker screw point.

Open weld joints in areas (1) and (3).

NOTE: Side frame is bonded and welded to longitudinal member in area (2).

Installation information:

Weld in reinforcement plates at severance cuts.
Bond and rivet new part in area (3).
Use Hemlock 813 blind rivet

Double number of rivets with respect to welding spots in area (3).

Installation information:

Apply adhesive in areas (1).

Apply window glass adhesive to cavity acoustic baffle (2).

Fig 4: Apply Window Glass Adhesive To Cavity Acoustic Baffle
Courtesy of BMW OF NORTH AMERICA, INC.