41 13... Right Bulkhead Partial Replacement (Engine Carrier Front Section Removed)

WARNING: This page is about a different car, the 2010 BMW 535xi, 2009 BMW 535xi, and 2008 BMW 535xi. However, it is still accessible from the selected car via links, so may be relevant.

Read contents of BODY, GENERAL .

The reduced-weight aluminum front end structure (GRAV) is used on this vehicle.

Observe relevant procedures in BODY, GENERAL .

Following new body parts are required:

Bulkhead

Fig 1: Identifying Bulkhead

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Open rivet joints in areas (1) and (2).

Installation:

Use 8 rivets (size 13) in area (1).

Use 1 rivet (size 13) in area (2).

Fig 2: Identifying Rivet Joints Areas

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Mark severance cut (1) in accordance with measurements a and b and cut bulkhead.

Measurement a = 305 mm

Measurement b = 365 mm

NOTE: Severance cut (1) runs next to contact surface (2) for engine carrier front section.
Cut area (2) from engine compartment side.

Fig 3: Identifying Severance Cut Mark In Accordance With Measurements A And B And Cut Bulkhead

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Preparation of new part:

Mark new part in accordance with severance cut on vehicle + 20 mm extra material and cut (1).

Fig 4: Identifying New Part Mark In Accordance With Severance Cut On Vehicle + 20 Mm Extra Material And Cut

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Installation:

Position new component in overlapping area to bulkhead from inside.

Check attachment parts for ease of movement.

Use 11 rivets (size 13) in area (1).

Use 3 rivets (size 13) in area (2).

Area (3) is only riveted together with engine carrier.

Use 4 rivets (size 15) in area (3).

Area (4) is only riveted together with outer bulkhead support carrier.

Drill holes for rivets.

Glue and rivet new component together with engine carrier front section and bulkhead support carrier.

Pay attention to potlife of adhesive.

Fig 5: Identifying Rivets Area

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