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.

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 1: Adjusting Reinforcement Plate On Components Of Vehicle

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.

Fig 2: Fitting New Part

Courtesy of BMW OF NORTH AMERICA, INC.

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)!

Round off cutting edges

On joint by grinding.
Component on vehicle
New part

Fig 3: Identifying Cutting Edges, Vehicle Component And New Part
Courtesy of BMW OF NORTH AMERICA, INC.

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