4100... Reinforcement Plate With Stud Bolt (Bonded)

In the case of a partial replacement piece, a body component is cut at a point described in the repair instructions.

A reinforcement plate is bonded in to ensure sufficient strength.

Reinforcement plates are available as new parts and must also be used

NOTE: The following graphics serve as general illustrations of reinforcement plate repair work. They are applicable to sectional repairs in the outer skin area.

Overview of reinforcement plates:

Reinforcement plate, sill
Reinforcement plate, C-pillar
Reinforcement plate, universal
Reinforcement plate, C- or D-pillar
Lock nuts (not pictured)
- Plastic nut.18 mm, part number 1 943 122
- Clip nut.30 mm, part number 7 139 081
  
  Fig 1: Overview Of Reinforcement Plates
  Courtesy of BMW OF NORTH AMERICA, INC.

Mark component in accordance with dimension a and cut.

Fig 2: Identifying Cutting Dimension

Courtesy of BMW OF NORTH AMERICA, INC.

Preparation of new part

The reinforcement plates must if necessary be reworked and cut to size.

Adjust reinforcement plate (1) to fit in component (2) on vehicle.

Make recesses (3) for stud bolts (4) in a semicircular shape.

Diameter of recesses approx. 10 - 12 mm.

Fig 3: Fitting Reinforcement Plate In Components

Courtesy of BMW OF NORTH AMERICA, INC.

Secure reinforcement plate by screwing on lock nuts (1).

Fit new part (2). Make recesses (3) in new part in a semicircular shape.

Diameter of recesses approx. 10 - 12 mm.

Remove reinforcement plate again.

NOTE: Width of joint between new part and component on vehicle approx. 3 - 8 mm (at least 30 mm flange width per side).
Plastic nuts should be screwed on once before applying adhesive (no thread in new plastic nut)!

Fig 4: Identifying Lock Nut And Recesses

Courtesy of BMW OF NORTH AMERICA, INC.

Round off cutting edges (1) on joint by grinding.

(2) Component on vehicle

(3) New part

Fig 5: Identifying Cutting Edges, Component On Vehicle And New Part

Courtesy of BMW OF NORTH AMERICA, INC.

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

Procedure for using universal reinforcement plate

The universal reinforcement plate needs to be adapted. The plate must be divided if the distance between the pins is too great.

Dimension a is between 40 and 80 mm depending on the space available.

Secure plates with N4 punch rivets.

NOTE: Ensure the rivet is positioned correctly! Rivet head is on the adhesion side!
Rivet the plate to the inside of the flange!

Fig 6: Identifying Universal Reinforcement Plate Dimension

Courtesy of BMW OF NORTH AMERICA, INC.

Installing reinforcement plate

Clean all bonding surfaces.

Apply adhesive to reinforcement plate in area (1). Apply more adhesive in the radii to avoid air pockets.

Carefully slide reinforcement plate into component on vehicle and secure by screwing on nuts (2). Screw on nuts a few turns only.

IMPORTANT: When joining reinforcement plate, make sure there is sufficient adhesive on bonding surfaces.

Fig 7: Identifying Adhesive Applying Areas On Reinforcement Plate With Mounting Nuts

Courtesy of BMW OF NORTH AMERICA, INC.

Apply adhesive to reinforcement plate bonding surface (1). Apply more adhesive in the radii to avoid air pockets.

Fit new part (2).

Align new part to adjoining component and secure with gripping pliers.

Tighten nuts.

Tightening torque 41 14 1AZ.

IMPORTANT: Check that the transition of the components is OK at the separation point. Corrections can only be made before the adhesive has hardened. Straightening at a later stage is not possible.

Fig 8: Identifying Adhesive Applying Areas On Reinforcement Plate Bonding Surface

Courtesy of BMW OF NORTH AMERICA, INC.

Concluding tasks at separation point:

After adhesive has hardened:

In area visible to customer:

Cut off stud bolts with bodywork saw.

Completely remove adhesive residue in joint (1).

Round off sharp edges by grinding.

IMPORTANT: Avoid heating the separation point by excessive grinding.
Reworking by pressing not permitted!

Fig 9: Identifying Joint

Courtesy of BMW OF NORTH AMERICA, INC.

Only the BMW-approved METAL FILLER should be used on the joint.

METAL FILLER-INSTRUCTIONS FOR USE

Not in area visible to customer:

Examples: The joint is covered by sill trim panel, windows, seals, etc.

Grind off stud bolts and surplus adhesive flush. Do not use metal filler. Paint area as specified in BMW Painting Handbook.

NOTE: After painting, the joint becomes visible as the adhesive shrinks. This has no affect on the quality.