COLLISION - BODY PANEL REPAIR (F07) (GT Sedan) (535i GT)

• Body Panel Repair
  • 41 0 0 Contents Of Body General Information
  • 41... 0 Notes On The Repair Technique Used In The Main Group 41
  • 41 00... Blind Rivets
    • 1.0 Recommended tools and equipment
    • Setting blind rivets
  • 41 00... Bonding Aluminium On Steel
    • Notes
    • Overview of topics
    • 1.0 Equipment
    • 2.0 Preparation of surface
      • 2.1 Steel surface
      • 2.2 Aluminium surface
        • 2.2.1 Procedure for new aluminium component
        • 2.2.2 Procedure for previously bonded aluminium component
    • 3.0 Adhesive application
      • Notes
      • 3.1 Bonding in conjunction with repair elements (expanding elements)
      • 3.2 Bonding in conjunction with rivets
    • 4.0 Hardening times
    • 5.0 Subsequent treatment
  • 41 00... Bonding On Painted Surfaces
    • Notes
    • Overview of topics
    • 1.0 Equipment
    • 2.0 Expiry date of consumables
    • 3.0 Preparation of surface
      • 3.1 Preparation of the surface on the vehicle (series status)
      • 3.2 Preparation of the surface on the vehicle (replacement of a bonded component)
      • 3.3 Preparation of surface on new part
    • 4.0 Adhesive application
    • 5.0 Hardening times
    • 6.0 Subsequent treatment
    • 7.0 Disposal of adhesive
  • 41 00... Bonding Steel On Steel
    • Notes
    • Overview of topics
    • 1.0 Equipment
    • 2.0 Preparing the surface
    • 3.0 Adhesive application
    • 4.0 Hardening times
    • 5.0 Subsequent treatment of bonding surfaces
  • 41 00... Carrying Over Hole Pattern
  • 41 00... Corrosion Protection
    • Notes
    • 1.0 Removing and applying sealing materials
      • 1.1 Removing sealing materials
      • 1.2 Applying sealing materials
    • 2.0 Cavity preservation of sheet-metal parts
    • 2.1 Cavity preservation of steel parts
    • 2.2 Cavity preservation of aluminium parts
  • 41 00... EMC Screws
    • Notes
    • 1. Purpose
    • 2. Procedure, aluminium front end
    • 3. Procedure, steel body
  • 41..... Filling Bulkhead Cross Member With Foam
  • 99 00... General Instructions On Paintwork
    • Notes
    • Special procedure for matte paintwork
  • 51 14... General Notes For Labelling With Adhesive Films
    • Notes
    • 1. Preparation
    • 2. Procedure for applying labels
  • 41 00... Grinding Aluminium Parts
    • 1.0 Recommended tools and equipment
      • Grinding on the outer shell
      • Grinding work on the structure (except Z8)
      • Z 8 Spaceframe structure
    • 2.0 Grinding outer shell and structure
  • 41 00... Grinding Steel Parts
    • 1.0 Recommended tools and equipment
    • 2.0 Grinding outer shell and structure
  • 41 00... Gun For Cavity Sealing
    • Notes
    • 1.0 Scope of delivery
    • 2.0 Start-up
    • 3.0 Mode of operation
    • 4.0 Application examples
    • 5.0 Safety instructions
  • 41 00... Handling Airbags And Restraint Systems
    • 1.0 Airbags and restraint systems
  • 41 00... Handling Electrical And Electronic Equipment
    • 1.0 Battery
    • 2.0 Control units
    • 3.0 Electrical wires and wiring harnesses
  • 41 00... Information On Hazards
    • 1.0 Aluminium
  • 41 00... Information On Metal Filler
    • Notes
    • Storage
    • Shelf life
    • Surface pre-treatment
    • Processing
    • Applying filler
    • Hardening time
    • Post-processing
    • Paintwork
    • Metal filler disposal
  • 64 00... Information On Using Cleaning Agent/Paints (Personal Protection Equipment)
    • Notes
    • Recycling
  • 41 00... Information On Vehicle Protection
  • 41 00... Information/Warning Labels
  • 41 00... Installation Solution For Straight Shank/Hexagon Rivet Nut
    • Protection measures!
    • Hexagon/straight shank rivet nut (up to thread 8) with hand rivet gun ZS308
    • Hexagon / straight shank rivet nut (up to thread M12) with hand rivet gun MB512
  • 41 00... Installing A Cavity Acoustic Baffle (Expanded)
  • 41 00... Installing A Cavity Acoustic Baffle (Not Expanded)
  • 41 00... Installing A Cavity Sealing With 2-Component PU Cavity Foam
    • Notes
    • Information on dangers/hazards
    • Processing instructions
  • 41 00... Materials Science
    • 1. Aluminum
      • 1.2 Material influences
      • 1.3 Machining properties
      • 1.4 Mounting
  • 41 00... Notes On Adhesive K1
    • Notes
    • Storage
    • Shelf life
    • Surface pre-treatment
    • Required cartridge gun
    • Preparing the glue cartridge
    • Adhesive application
    • Hardening time
    • Disposal of adhesive
  • 41 00... Notes On Adhesive K2
    • Notes
    • Storage
    • Shelf life
    • Surface pre-treatment
    • Required cartridge gun
    • Preparing the glue cartridge
    • Adhesive application
    • Hardening time
    • Disposal of adhesive
  • 41 00... Notes On Adhesive K3
    • Notes
    • Storage
    • Shelf life
    • Surface pre-treatment
    • Required cartridge gun
    • Preparing the glue cartridge
    • 2-component adhesive application
    • Hardening time
    • Adhesive disposal
  • 41 00... Notes On Adhesive K4
    • Notes
    • Storage
    • Shelf life
    • Surface pre-treatment
    • Required cartridge gun
    • Preparing the glue cartridge
    • 2-component adhesive application
    • Hardening time
    • Disposal of adhesive
  • 41 00... Notes On Adhesive K5
    • Notes
    • Storage
    • Shelf life
    • Surface pre-treatment
    • Required cartridge gun
    • Preparing the glue cartridge
    • Adhesive application
    • Hardening time
    • Disposal of adhesive
  • 41 00... Notes On Cleaning Agent R1
  • 61 00... Notes On Handling The High Pressure Cleaner
  • 41 00... Notes On Repairing Threads
  • 41 00... Notes On The Water Drain Hose Of The Slide/Tilt Sunroof
  • 99 00... Notes On Using Temperature-Controlled Infra-Red Radiators
  • 41 00... Opening Adhesive Bonds
    • 1. Opening spot-weld bonds
    • 2. Opening adhesive bonds
    • 3. Opening adhesive bonds on aluminium roofs
    • 4. Opening adhesive bonds on carbon-fibre-reinforced plastic parts
  • 41 00... Opening Brazed Joints
  • 41 00... Opening Riveted Joints
    • Notes
    • 1. Opening blind rivets
      • 1.1 Opening blind rivets (N1 and N2)
      • 1.2 Opening blind rivets (N3 and N6)
    • 2. Opening punch rivets
      • 2.1 Opening punch rivets by extraction
      • 2.2 Opening punch rivets by drilling out
  • 41 00... Opening Welded Connections
    • 1. Opening welding spots (resistance pressure spot welding)
    • 2. Opening MAG weld seams and MIG brazing seams
    • 3. Opening laser weld seams
  • 41 00... Overview Of Adhesive Cartridge Guns
  • 41 00... Overview Of Consumables (Electronic Parts Catalogue)
    • 1.0 Adhesives
    • 1.1 Primer
    • 1.2 Cleaning agent
    • 1.3 Fillers
    • 2.1 Rivets
    • 2.2 Plastic nuts
    • 3.0 Primer
    • 4.0 Sealant
    • 5.0 Cavity preservation
    • 6.0 Cavity foam
    • 7.0 EMC screw (electromagnetic compatibility)
    • 8.0 Twist drill
  • 41 00... Position Of Shaped Parts For Cavity Sealing
  • 41 00... Punch Rivets
    • Notes
    • 1.0 Recommended tools and equipment
    • Setting punch rivets
    • Riveting direction
  • 41 00... Quality Standard
  • 41 00... Reinforcement Plate (Bonded)
    • Notes
    • Installing reinforcement plate
  • 41 00... Reinforcement Plate With Stud Bolt (Bonded)
    • Notes
    • Preparation of new part
    • Procedure for using universal reinforcement plate
    • Installing reinforcement plate
  • 41 05 800 Releasing Bonded Folded Seam Connections
  • 41 05... Removing And Installing Rivet Heads
  • 41 00... Repair Solution For Straight Shank/Hexagon Rivet Nut
    • Protection measures!
    • Hexagon / straight shank rivet nut (up to thread M8) with hand rivet gun ZS308
    • Hexagon / straight shank rivet nut (up to thread M12) with hand rivet gun MB512
  • 41 0 Stage 1 Repair Techniques
  • 41 0 Stage 2 Repair Techniques
  • 41 0 Stage 3 Repair Techniques
  • 41 00... Repairing Clips For Roof Strip
    • Notes
    • 1.0 Information on dangers/hazards
    • 1.0 Equipment
    • 2.0 Preparing the surface
    • 3.0 Applying the adhesive
    • 4.0 Hardening period
  • 41 00... Repairing Plastic Parts
    • 1.0 General information
    • 2.0 Shaping plastic parts
    • 3.0 Bonding plastic parts
  • 41 00... Safety At Work
    • Notes
    • 1.0 Compressed air
    • 2.0 Electrical systems/devices
    • 3.1 Working with aluminium dust
    • 3.2 Removing sealant
    • 3.3 Arc welding and brazing solder
    • 3.4 Working with chemical products (adhesive, cleaning agents, fillers, etc.)
    • First Aid
  • 00 Safety Information For Working On Vehicles With Automatic Engine Start-Stop Function (MSA)
    • Notes
    • MSA function is deactivated by
  • 41 00... Separating Cut Determination With A Template
  • 41 00... Setting Blind Rivet Nuts And Bolts
  • 41 00... Soldering Steel Components
    • Notes
    • 1. General information
    • 2. Work materials
    • 3. Preparation
    • 4. Implementation
    • 5. Subsequent treatment of brazed joints
    • 6. Notes on melting/tinning
  • 41 00... Spot-Weld Bonding Steel Components
  • 41 00... Stamping Vehicle Identification Number (Needle Stamping Unit)
    • Notes
    • Procedure for additional vehicle identification number
    • Stamping second vehicle identification number
  • 41 00... Straightening Aluminium Component On The Outer Skin
    • 1.0 Recommended tools
    • 2.0 Straightening outer skin
  • 41 00... Straightening Aluminium Components In Structure
  • 41 00... Straightening Steel Components In The Structure
    • Notes
    • Heating bearing body components for better reshaping is not permitted!
  • 41 00... Straightening Steel Components On The Outer Skin
    • 1.0 Recommended tools
    • 2.0 Straightening outer skin
    • 2.1 Straightening the wheel arch (rear side panel)
  • 99 00... Touching Up Paintwork Damage
  • 41 00... Use Of Materials In Outer Skin
  • 41 00... General Vehicle Identification Number
    • Notes
    • 1. General notes for stamped vehicle identification numbers
    • 2. General notes for embossed vehicle identification numbers
  • 41 00... Welding In Reinforcement Plate (Sheet Steel)
  • 41 00... Welding Steel Components
    • Notes
    • 1. General information
    • 2. Work materials
    • 3. Preparations for MAG and spot-welding
    • 4. Welding
    • 5. Subsequent treatment of weld joints
  • 41 00... Working With 2-Component PU Cavity Foam
    • Notes
    • Information on dangers/hazards
    • Application instructions
  • 41 00... Workshop Equipment
    • Notes
    • Repair stage 1
    • Repair stage 2
    • Repair stage 3
• Support Members
  • 41... 0 Notes On The Repair Technique Used In The Main Group 41
  • 41 11 150 Cover For Frame Side Member (Part Replacement Between A And B Pillar)
  • 41..... Filling Bulkhead Cross Member With Foam
  • 41 11 565 Replace Sill In Vicinity Of Left C-Pillar (Rear Side Panel Removed)
    • Notes
    • Removing sill section
    • Preparation of new part
    • Installing sill section
  • 41 11 300 Replacing Cover For Longitudinal Member With Left And Right Door Pillar (Partial Replacement B-Pillar)
    • Notes
    • Removing entrance cover with door post
    • New part preparation
    • Installation of B-pillar with reinforcement
  • 41 11 091 Replacing Engine Support In Front Of Bulkhead, Left
    • Notes
    • Removal of engine support
    • New part preparation
    • Installing engine support
  • 41 11 095 Replacing Engine Support In Front Of Wheel Arch, Left
  • 41 11 015 Replacing Engine Support With Wheel Arch, Left
    • Notes
    • Removal of engine support with wheel arch
    • New part preparation
    • Installation of engine support with wheel arch
  • 41 14 531 Replacing Engine Support/Front Left Side Frame Connection (Front Left Wheel Arch Removed)
    • Notes
    • New part preparation
    • To install engine support side frame connection
  • 41 14 021 Replacing Front Left Wheel Arch
    • Notes
    • Removing the wheel arch
    • New part preparation
    • Installing the wheel arch
  • 41 14 500 Replacing Outer Section Of Left Or Right Rear Wheel Housing (Side Panel Removed)
    • Notes
    • Removal of the outside wheel arch
    • New part preparation
  • 41 14 505 Replacing Rear Left Outer Wheel Arch Section Partial Replacement (Side Wall Removed)
    • Notes
    • Removal of outer wheel arch section
    • Preparation of new part
    • Installation of outer wheel arch section
  • 41 14 504 Replacing Rear Right Outer Wheel Arch Section Partial Replacement (Side Wall Removed)
    • Notes
    • Removal of outer wheel arch section
    • Installation of outer wheel arch section
  • 41 11 201 Replacing The Carrier Support Before The Wheel Arch On The Left
    • Notes
    • Removal of carrier support in front of wheel arch
    • Preparation of new part
    • Installation of carrier support in front of wheel arch
  • 41 14 021 Stripping Operations - Replacing Front Left Wheel Arch
• Luggage Compartment Floor
  • 41... 0 Notes On The Repair Technique Used In The Main Group 41
  • 41 12 535 Replace Luggage Compartment Floor And Both Side Members (Tail Panel Trim Removed)
    • Notes
    • Removal of luggage compartment floor and both side members
    • New part preparation
    • Installing side member and luggage compartment floor, left and right
    • Luggage compartment floor and side member reinforcements
  • 41 12 651 Replacing Luggage Compartment Floor, Left Section (Tail Panel Or Side Wall Removed)
    • Notes
    • Removing luggage compartment floor on left
    • Preparation of new part
    • Installation of luggage compartment floor on left
  • 41 12 557 Replacing Luggage Compartment Floor, Middle Section (Tail Panel Removed)
    • Notes
    • Removal of luggage compartment floor
    • Installation of luggage compartment floor
  • 41 12 548 Replacing Rear Cross Member On Luggage Compartment Floor (Tail Panel Removed)
    • Notes
    • Removing cross-member
    • New part preparation
    • Installing cross-member
  • 41 12 535 Stripping Operations - Replacing Complete Luggage Compartment Floor (Tail Panel Removed)
  • 41 12 651 Stripping Operations - Replacing Left Luggage Compartment Floor (Tail Panel Or Side Panel Removed)
  • 41 12 557 Stripping Operations - Replacing Luggage Compartment Floor, Middle (Tail Panel Removed)
  • 41 12 548 Stripping Operations - Replacing Rear Cross-Member On Luggage Compartment Floor (Tail Panel Removed)
• Wheel Wells
  • 41... 0 Notes On The Repair Technique Used In The Main Group 41
  • 41 00... Carrying Over Hole Pattern
  • 41 11 015 Replacing Engine Support With Wheel Arch, Left
    • Notes
    • Removal of engine support with wheel arch
    • New part preparation
    • Installation of engine support with wheel arch
  • 41 14 531 Replacing Engine Support/Front Left Side Frame Connection (Front Left Wheel Arch Removed)
    • Notes
    • To remove engine support side frame connection
    • New part preparation
    • To install engine support side frame connection
  • 41 14 021 Replacing Front Left Wheel Arch
    • Notes
    • Removing the wheel arch
    • New part preparation
    • Installing the wheel arch
  • 41 14 500 Replacing Outer Section Of Left Or Right Rear Wheel Housing (Side Panel Removed)
    • Notes
    • Removal of the outside wheel arch
    • New part preparation
    • Installation outside wheel arch
  • 41 14 505 Replacing Rear Left Outer Wheel Arch Section Partial Replacement (Side Wall Removed)
    • Notes
    • Removal of outer wheel arch section
    • Preparation of new part
    • Installation of outer wheel arch section
  • 41 14 504 Replacing Rear Right Outer Wheel Arch Section Partial Replacement (Side Wall Removed)
    • Notes
    • Removal of outer wheel arch section
    • Preparation of new part
    • Installation of outer wheel arch section
  • 41 00... Stamping Vehicle Identification Number (Needle Stamping Unit)
    • Notes
    • Procedure for additional vehicle identification number
    • Stamping second vehicle identification number
  • 41 14 021 Stripping Operations - Replacing Front Left Wheel Arch
  • 41 14 031 Stripping Operations - Replacing Front Right Wheel Arch
  • 41 00... Vehicle Identification Number, General
    • Notes
    • 1. General notes for stamped vehicle identification numbers
    • 2. General notes for embossed vehicle identification numbers
• Side Frame And Door Pillars
  • 41... 0 Notes On The Repair Technique Used In The Main Group 41
  • 41 11 150 Cover For Frame Side Member (Part Replacement Between A And B Pillar)
  • 41 11 300 Replacing Cover For Longitudinal Member With Left And Right Door Pillar (Partial Replacement B-Pillar)
    • Notes
    • Removing entrance cover with door post
    • New part preparation
    • Installation of B-pillar with reinforcement
  • 41 21 510 Replacing Front Left Door Post (Front Side Panel Removed)
    • Notes
    • Removal of front door post
    • New part preparation
    • Installing door post, front
  • 41 32 000 Replacing Left Or Right Cowl
    • Notes
    • Necessary preliminary tasks
    • Removing the cowl panel
    • New part preparation
    • Installation of cowl panel
• Roof Frame
  • 41... 0 Notes On The Repair Technique Used In The Main Group 41
• Outer Roof Skin
  • 41... 0 Notes On The Repair Technique Used In The Main Group 41
  • 41 00... Repairing Clips For Roof Strip
    • Notes
    • 1.0 Information on dangers/hazards
    • 1.0 Equipment
    • 2.0 Preparing the surface
    • 3.0 Applying the adhesive
    • 4.0 Hardening period
  • 41 31 000 Replacing Roof Outer Skin (Normal Roof)
    • Notes
    • Installing roof outer skin
  • 41 31 001 Replacing Roof Outer Skin (Version With Panorama Glass Roof)
    • Notes
    • Removing roof outer skin
    • Interior, area of C-pillar
    • Installing roof outer skin
  • 41 31 001 Stripping Operations - Replacing Roof Outer Skin (Version With Panorama Glass Roof)
  • 41 31 000 Stripping Operations - Replacing Roof Outer Skin (Version Without Slide/Tilt Sunroof)
• Dash Cowl
  • 41... 0 Notes On The Repair Technique Used In The Main Group 41
  • 41 21 510 Replacing Front Left Door Post (Front Side Panel Removed)
    • Notes
    • Removal of front door post
    • New part preparation
    • Installing door post, front
  • 41 32 000 Replacing Left Or Right Cowl
    • Notes
    • Necessary preliminary tasks
    • Removing the cowl panel
    • New part preparation
    • Installation of cowl panel
• Front Trim Panel
  • 41... 0 Notes On The Repair Technique Used In The Main Group 41
  • 41 33 040 Replacing Front Left Or Right Side Wall Holder
    • Notes
    • General information
    • Removal of side wall holder (variant 1)
    • Preparation of new part
    • Installation of side wall holder
    • Removal of side wall holder (variant 2)
• Rear Trim Panel
  • 41... 0 Notes On The Repair Technique Used In The Main Group 41
  • 41 12 651 Replacing Luggage Compartment Floor, Left Section (Tail Panel Or Side Wall Removed)
    • Notes
    • Removing luggage compartment floor on left
    • Preparation of new part
    • Installation of luggage compartment floor on left
  • 41 34 060 Replacing Outer And Inner Tail Panel Sections
    • Notes
    • Removing rear trim panel
    • New part preparation
  • 41 34 038 Replacing Outer Tail Panel Section
    • Notes
    • Removing rear trim panel
    • New part preparation
    • Installing rear trim panel
  • 41 12 557 Stripping Operations - Replacing Luggage Compartment Floor, Middle (Tail Panel Removed)
  • 41 34 060 Stripping Operations - Replacing Outer And Inner Tail Panel Sections
  • 41 35 101 Stripping Operations - Replacing Rear Side Panel, Left
  • 41 34 038 Stripping-Down Operations - Replacing Tail Panel Outer Section
• Side Panels
  • 41... 0 Notes On The Repair Technique Used In The Main Group 41
  • 41 00... Reinforcement Plate With Stud Bolt (Bonded)
    • Notes
    • Preparation of new part
    • Procedure for using universal reinforcement plate
    • Installing reinforcement plate
  • 41 35 081 Removing And Installing Front Side Panel On Left
  • 41 11 565 Replace Sill In Vicinity Of Left C-Pillar (Rear Side Panel Removed)
    • Notes
    • Removing sill section
    • Preparation of new part
  • 41 14 500 Replacing Outer Section Of Left Or Right Rear Wheel Housing (Side Panel Removed)
    • Notes
    • Removal of the outside wheel arch
    • New part preparation
    • Installation outside wheel arch
  • 41 14 505 Replacing Rear Left Outer Wheel Arch Section Partial Replacement (Side Wall Removed)
    • Notes
    • Removal of outer wheel arch section
    • Preparation of new part
    • Installation of outer wheel arch section
  • 41 35 101 Replacing Rear Left Side Panel
    • Notes
    • Removing side wall
    • Preparation of new part
    • Installing side wall
  • 41 14 504 Replacing Rear Right Outer Wheel Arch Section Partial Replacement (Side Wall Removed)
    • Notes
    • Removal of outer wheel arch section
    • Preparation of new part
    • Installation of outer wheel arch section
  • 41 35 101 Stripping Operations - Replacing Rear Side Panel, Left
• Front Side Doors
  • 41 5.... Adjust Door
    • Notes
    • After setting
  • 41 5.... Removing And Installing Door
  • 41 5.... Replace Door
• Rear Side Doors
  • 41 5.... Removing And Installing Door
  • 41 5.... Replace Door
• Front Lid
  • 41 61 014 Adjusting Engine Compartment Lid
    • Notes
    • Height adjustment at strikers
    • After setting
  • 41 61 000 Removing And Installing Engine Compartment Lid
  • 41 61 050 Removing And Installing/Replacing Left Or Right Hinge For Engine Compartment Lid (Engine Compartment Lid Removed)
  • 41 61 001 Replacing Engine Compartment Lid
• Rear Lid
  • 41 62 033 Adjusting Rear Lid Lower Section
  • 41 62 014 Adjusting Tailgate
  • 41 62 540 Remove / Install / Replace Both Tailgate Hinges (Tailgate Removed)
  • 41 62 007 REMOVING AND INSTALLING REAR LID LOWER SECTIOn
  • 41 62 000 Removing And Installing Tailgate
  • 41 62 541 Removing And Installing/Replacing Both Hinges For Tailgate Lower Section (Tailgate Lower Section Removed)
  • 41 61 050 Removing And Installing/Replacing Left Or Right Hinge For Engine Compartment Lid (Engine Compartment Lid Removed)
• Other Flaps
  • 41 63 000 Removing And Installing Flap For Fuel Filler Neck
  • 41 63 003 Replace Cover Bowl