BONDING INSTRUCTIONS FOR BMW i REP-ALG-RAI1241-4105402 - V.14

Required Special Tools:

2 357 309

Attention!

Conform with safety regulations!. Refer to SAFETY AT WORK REP-ALG-RAGRP41-4102100 - V.6 .

Brief overview of surface preparation

Material (surface condition) Type of repair	Preparation
Aluminum (used part and new part) Repairs to the Drive module (only I01) All bonded connections with adhesive K1 in combination with blind rivets Example: Replacement side member or wheel arch	Remove coarse dirt from the bonding surfaces using solvent cleaner R2 Do not grind the surface to be bonded (cathodic dip coating) Clean with cleaning agent R1 Bond with adhesive K1
Aluminum (new part) Replacement of aluminum components (BMW I) All bondings with adhesive K2 without blind rivets Example: Bonding Life module and Drive module when replacing front axle module	Remove coarse dirt from the bonding surfaces using solvent cleaner R2 Clean with cleaning agent R1 Grind bonding surfaces to a metallic bright-finish Clean with cleaning agent R1 thin coat with adhesive K1 Bond with adhesive K2
Carbon Fiber Reinforced Plastic (new part) Bonding new parts on the body using K2 adhesive	Remove coarse dirt from the bonding surfaces using solvent cleaner R2 Clean with cleaning agent R1 Sand with non-woven abrasive Clean with cleaning agent R1 Activate with Betawipe 4800 Bond with adhesive K2
Thermoplast (new parts) Bonding new parts on components made of thermoplastic with adhesive K2	Remove coarse dirt from the bonding surfaces using solvent cleaner R2 Clean with cleaning agent R1 Sand with non-woven abrasive Clean with cleaning agent R1 Coat bonding surfaces with bonding base VP 206 (air drying time at least 30 min, maximum 24 h). Bond with adhesive K2
Aluminum/Carbon Fiber Reinforced Plastic/thermoplastic (used part) Bonding new parts on the body using K2 adhesive	Remove coarse dirt from the bonding surfaces using solvent cleaner R2 Clean with cleaning agent R1 Cut back adhesive bead Bond with adhesive K2
Components made of sheet steel Partial replacement of Carbon Fiber Reinforced Plastic components Bonding with adhesive K2	Remove coarse dirt from the bonding surfaces using solvent cleaner R2 Clean with cleaning agent R1 Grind bonding surfaces to a metallic bright-finish Clean with cleaning agent R1 thin coat with adhesive K1 Bond with adhesive K2

The following basic conditions apply to all bonding:
- The working temperature of glue cartridge must be more than 18°C.
- Object temperature, vehicle and new parts, at least 15°C
- Refer to the vehicle-specific REP for the position and thickness of the adhesive bead.
- After applying the adhesive, check whether an adhesive component has emerged at the back of the glue cartridge. If yes, break off the bonding procedure. Clean new part. Use new glue cartridge.
- Join components and secure in position.
- Remove excess adhesive. Do not use solvent cleaning agents.
Prepare surface (aluminum):
- Clean bonding surfaces with cleaning agent R1.
- For better adhesion, remove oxide film and paint from the adhesive areas with a stainless steel wire brush or special emery paper.
- Clean bonding surfaces with cleaning agent R1.
  Allow cleaned surfaces to dry for approx. 5 min.
  
  Bonding surfaces must be completely dry.
Surface preparation (Carbon Fiber Reinforced Plastic new part):
This surface preparation applies to new CFRP parts.

Bonding surfaces on the new part have been pre-treated ex works (mat look).

Clean bonding surfaces with cleaning agent R1.

Sand bonding surfaces with non-woven abrasive.

Clean bonding surfaces with cleaning agent R1.

Let cleaned bonding surfaces dry for at least 2 min.

Bonding surfaces must be completely dry.

Activate bonding surfaces with Betawipe 4800.

Let activated bonding surfaces dry for at least 2 min.

Bonding surfaces must be completely dry.
Surface preparation (thermoplastic new part):
This surface preparation applies to new thermoplastic parts.

Bonding surfaces on spare parts are primed ex works (barely visible).

Clean the bonding surfaces using R1 solvent cleaner.

Sand down the bonding surfaces on the new part using non-woven abrasive.

Attention!

Do not sand through primer coat on new part.

Clean the bonding surfaces using R1 solvent cleaner (minimum air drying time: 2 min).

Coat bonding surfaces with VP 206 bonding primer (air drying time at minimum 30 minutes and at maximum 24 h).

Bonding surfaces must be completely dry.
Surface preparation (aluminum/Carbon Fiber Reinforced Plastic/thermoplastic used part):
This surface preparation also applies to aluminum surfaces on which a CFRP part is adhered with K2 adhesive.

For sufficient adhesion between hardened and new adhesive to be achieved, the adhesive bead has to be cut back.

The surface need not be completely level.

WARNING: Risk of injury from the sharp blade of the scraper!

Cut back the adhesive bead using the scraper 2 357 309 until all processing traces have been removed by grinding.

If adhesive beads came into contact with heat, cut them back into the area that was not heated.

The thickness of the adhesive bead that has been cut back must not be below 0.5 mm.

Clean bonding surfaces with cleaning agent R1.

Let cleaned bonding surfaces dry for at least 2 min.

Bonding surfaces must be completely dry.

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: No spacers are required for the I01 roof outer skin. The spacers are part of the spare part.

Cut back the spacers (1) made of double-sided adhesive tape (size approx. 5x20 mm).

Bond the spacers (1) at a distance of approximately 200 mm along the adhesive flange (2).

NOTE: The adhesive bead (2) must surround the spacers (1) on the outer side (3).

In the case of adhesive beads (2) with a width less than or equal to 20 mm, the spacers are moved toward the vehicle interior (4).

Spacers must not cut through the adhesive bead (2) completely. This reduces the strength of the bonding.
Surface preparation (components made of sheet steel):
Components made of sheet steel are prepared analogous to the surfaces of reinforcement plates.

Reinforcement plates are special shaped parts for joining new parts to the side frame (e.g. partial replacement of door sill).

PREPARE REINFORCEMENT PLATES .