Preparation Of New Part

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2010 BMW 535xi, 2010 BMW 535i, 2009 BMW 535xi, 2009 BMW 535i, and 2008 BMW 535xi. However, it is still accessible from the selected car via links, so may be relevant.

Cut new part (1) in accordance with cut on vehicle and if necessary adjust to fit with straightening attachment or universal mount.

Fig 1: Identifying Cutting Position

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Courtesy of BMW OF NORTH AMERICA, INC.

Make reinforcement plate (1) from trim of new part (2).

Length of reinforcement plate is 80 mm.

Fig 2: Identifying Reinforcement Plate And New Part Trim Plate

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Courtesy of BMW OF NORTH AMERICA, INC.

Slide reinforcement plate (1) halfway into component on body and fasten with 2 self-tapping screws (2).

Fig 3: Sliding Reinforcement Plate Half-Way Into Body Component

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Courtesy of BMW OF NORTH AMERICA, INC.

Adjust new part (1) to fit and set 4.3 mm dia. bore holes (2).

Remove new part again.

Release self-tapping screws (3).

Remove reinforcement plate.

Drill out bore holes (3) for screws to 4.3 mm dia.

Deburr all bore holes.

Fig 4: Identifying Bore Drilling Position

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Courtesy of BMW OF NORTH AMERICA, INC.

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