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

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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: Partial Section, Rear Side Panel
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Fig 2: Mark On Severance Cuts
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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

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NOTE: The work step for the M5 ends here.

Open weld joints in areas (1).

Open brazed joints in areas (2).

Fig 4: Open Weld And Brazed Joints Areas

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Right side of vehicle only:

If necessary, open weld joints in area (1).

Fig 5: Locating Right Side Weld Joints

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Installation:

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

Fig 6: Seal Component From Inside Area

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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 surface of reinforcement (1). Adjust side panel to fit and weld holes above wheel arch.

Fig 7: Contact Surface Of Reinforcement

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NOTE: Following work steps apply to M5 only.

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

1 = Body outer side

Fig 8: Body Outer Side

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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 9: Mark On Severance Cut

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View of trimmed rear side panel.

1 = Body outer side

2 = Radius of trimmed side panel

Fig 10: Locating Radius Of Trimmed Side Panel

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Installation:

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

Dimension a = 10 mm

Fig 11: Adhesive Applying Area

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Installation:

Apply adhesive in area (1).

Flange edge of side panel in area (1) flush to outer wheel arch section.

Fig 12: Flange Edge Of Side Panel Area

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Flange edge of wheel arch (3) of rear side panel flush to outer wheel arch section.

Do not flange sharp edges as the flange edge may begin breaking!

Measurement a=4.5 mm

Adhesive
Side panel, rear

Fig 13: Flange Edge Of Wheel Arch, Adhesive And Side Panel
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NOTE: Additional work steps for M5 end here.