Prepare New Parts

Replacing the coarse thread bolt and threaded weld bolts (steel surface) 

• Renew the coarse thread bolt (1)  and the threaded weld bolt (2)  .

  Parts:  Coarse thread bolt, threaded weld bolt

  Take the number and position from the component to be replaced or the add-ons.

• Weld the coarse thread bolt (1)  and threaded weld bolt (2)  onto the new part.

Courtesy of BMW OF NORTH AMERICA, INC.

Check ground pins and replace if necessary 

• Check the ground pins (1)  for stability and renew if necessary.

Courtesy of BMW OF NORTH AMERICA, INC.

Prepare new parts, left side rail 

• Adjust new parts to fit with alignment bracket or universal mount and secure.
• Prepare areas (1)  and (2)  for structural adhesive bonding of steel to aluminum.
• Assign the positions of the bores already present in areas (1)  and (2)  of the vehicle to the new part. Place bores in areas (1)  and (2)  Ø 6.8 mm for blind rivet.

  Courtesy of BMW OF NORTH AMERICA, INC.

• Prepare area (1)  for structural adhesive bonding of steel to aluminum.
• Assign the positions of the bores already present in area (1)  of the vehicle to the new part. Place bores in area (1)  Ø 6.8 mm for blind rivet.

  Courtesy of BMW OF NORTH AMERICA, INC.

• Prepare area (1)  for structural adhesive bonding of steel to aluminum.
• Assign the positions of the bores already present in area (1)  of the vehicle to the new part. Place bore in area (1)  Ø 6.8 mm for blind rivet.

  Courtesy of BMW OF NORTH AMERICA, INC.

• Prepare areas (1)  for joining by welding.

  Courtesy of BMW OF NORTH AMERICA, INC.

• Prepare areas (1)  for joining by welding.

Courtesy of BMW OF NORTH AMERICA, INC.

Prepare new parts, left side rail 

• Adjust new parts to fit and secure.
• Prepare areas (1)  for joining by welding. Ensure sufficient distance to the adhesive area in doing so.
• Prepare area (2)  for joining using the rivet-and-bonding method. Do not grind bonding surfaces down or off.
• In area (2)  , assign the two bores present in the side member to the new part.
• Drill out holes to dia. 6.8 mm.

  Courtesy of BMW OF NORTH AMERICA, INC.

• Prepare areas (1)  and (2)  for joining with the glue rivet technique. Do not grind bonding surfaces down or off.
• In areas (1)  and (2)  , assign the bores already present to the new part.
• Drill out holes to dia. 6.8 mm.
• Prepare areas (3)  for joining by welding.

  Courtesy of BMW OF NORTH AMERICA, INC.

• Replace series of welded connection (1)  by MAG-weld seam (2)  . Prepare in area (2)  , a MAG-weld seam of length 10 mm. Ensure sufficient distance to the bonded rivet connection (3)  .
• Remove new parts.
• Deburr bores.

Courtesy of BMW OF NORTH AMERICA, INC.

Prepare new part, middle luggage compartment floor 

• Adjust new parts to fit and secure.
• Prepare area (1)  for structural adhesive bonding of steel to aluminum.
• Assign the positions of the holes already present in area (2)  of the vehicle to the new part. Set holes (2)  Ø 6.8 mm for blind rivet.
• Mark area (1)  for later adhesive application.

  Courtesy of BMW OF NORTH AMERICA, INC.

• Prepare area (1)  for structural adhesive bonding of steel to steel and aluminum.
• Assign the positions of the holes already present in area (2)  of the vehicle to the new part. Set holes (2)  Ø 6.8 mm for blind rivet.
• Set hole (3)  Ø 6.8 mm according to dimension b. Dimension b = 30 mm from component edge.
• Prepare area (4)  according to dimension a for joining by welding. Dimension a = 40 mm.

  Courtesy of BMW OF NORTH AMERICA, INC.

• (2)  Mark area (1)  for later adhesive application.

  Courtesy of BMW OF NORTH AMERICA, INC.

  NOTE: Perform the steps on the left and right side.
• Adjust the new parts in combination with the tail panel to fit and secure.
• Prepare area (1)  for structural adhesive bonding of steel to steel and aluminum.
• Transfer the position of the hole (2)  that resulted from the removal on the vehicle to the new part. Set hole (2)  Ø 6.8 mm for blind rivet.
• Set the new hole (3)  Ø 6.8 mm according to the specified dimensions.

  Dimension a = 40 mm from hole Ø 12 mm.

  Dimension b = 24 mm of hole Ø 12 mm.

• Prepare area (4)  from the reference line (5)  for joining by welding.

  Courtesy of BMW OF NORTH AMERICA, INC.

• (2)  Mark area (1)  for later adhesive application.

  Courtesy of BMW OF NORTH AMERICA, INC.

• Prepare areas (1)  for joining by welding.

  Courtesy of BMW OF NORTH AMERICA, INC.

• Prepare areas (1)  for joining by welding.

  Courtesy of BMW OF NORTH AMERICA, INC.

• Prepare areas (1)  for joining by welding.

  Courtesy of BMW OF NORTH AMERICA, INC.

• Prepare areas (1)  for joining by welding.

  Courtesy of BMW OF NORTH AMERICA, INC.

• Prepare areas (1)  for joining by welding.
• Remove new part and deburr holes.

Courtesy of BMW OF NORTH AMERICA, INC.