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

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2010 BMW 535xi, 2010 BMW 535i, 2009 BMW 535xi, 2009 BMW 535i, and 2008 BMW 535xi. However, it is still accessible from the selected car via links, so may be relevant.

Read contents of BODY, GENERAL .

Spot-weld bonding is used on the E60. Observe specific procedure.

Use only approved spot-welding apparatus for repairs!

Following new body parts are required :

Partial section, rear side panel

Fig 1: Identifying Partial Section, Rear Side Panel
Courtesy of BMW OF NORTH AMERICA, INC.

Fig 2: Identifying Mark Severance Cuts In Accordance With Specified Measurements And Cut
Courtesy of BMW OF NORTH AMERICA, INC.

Mark severance cuts in accordance with specified measurements and cut.

IMPORTANT: Cut outer metal sheet only.
Sunroof water drain hose is located behind severance cut a.

Measurement a = approx. 105 mm from roof edge.

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

Open weld joints in areas (1).

Installation information:

Apply window glass adhesive to cavity acoustic baffle (2).
Weld in reinforcement plates at severance cuts.
NOTE: The following work step applies to the M5 only.

The wheel arch connection area is partially glued on the M5!

Expose and detach wheel arch connection area.

Fig 3: Locating Wheel Arch Connection Area
Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: The work step for the M5 ends here.

Open weld joints in areas (1).

Open brazed joints in areas (2).

Fig 4: Identifying Brazed Joints Areas

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

Seal new component from inside in area (1) with sealing compound.

Fig 5: Identifying Component Seal Area

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

Reinforcement of C-pillar latch striker is originally bonded to outer wheel arch. Drill holes for spot welding in contact surface of reinforcement (1). Adjust side panel to fit and weld holes above wheel arch.

Fig 6: Identifying Wheel Arch Cut Line

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: Following work steps apply to M5 only.

Side panel, rear left and right, must be trimmed.

= Body outer side

Fig 7: Identifying Body Outer Side
Courtesy of BMW OF NORTH AMERICA, INC.

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

Measurement a = approx. 30 mm.

Measurement b = approx. 50 mm

IMPORTANT: Distance to outer edge (3) is 3 mm in area (2).
The trim must have a radius of approx. 4 mm in area (2).
Otherwise there is a risk that the metal plate of the rear side panel will begin breaking!

Fig 8: Identifying Severance Cut Mark In Accordance With Measurement And Cut