WELDING STEEL COMPONENTS - (530i 2017-2022, 530i xDrive 2017-2022, 530e PHEV 2018-2022, 530e xDrive PHEV 2018-2022, 540i 2017-2022, 540i xDrive 2017-2022, M550i xDrive 2018-2022)

Attention!

Comply with the following topics from Body, General:

Safety regulations. Refer to INFORMATION ON HAZARDS (530I, 2017-2022) or SAFETY AT WORK - (530I, 2017-2022) .

Handling electrical system, electronics, airbags and restraint systems. Refer to HANDLING AIRBAGS AND RESTRAINT SYSTEMS (530I, 2017-2022) or HANDLING ELECTRICAL SYSTEM AND ELECTRONICS (530I, 2017-2022) .

General Information
- The following procedures are used for repairs:
  - MAG welding (MAG welding)
  - Resistance pressure spot welding (referred to in the following and in the repair instructions as spot-welding).
- Take the number and position of spot-welds and MAG weld seams from the separated part. Replace areas inaccessible to spot-welding tongs with MAG plug welds at the same distance. The bore hole diameter for MAG plug welds is 8 mm.
- In the case of emissions extraction, observe a minimum distance of 30 cm for MAG welding during the welding process. Otherwise the inert gas would be sucked away.
- Follow the equipment manufacturer's instructions for use.
Equipment
- MAG welding:
  - Steel welder (see WORKSHOP EQUIPMENT ).
  - Steel welding wire - G3SI1 (SG2) or alternatively G4SI1 (SG3)
  - Welding mask
  - Gas bottle containing inert gas (82 % argon, 18 % C0₂ )
- Resistance pressure spot welding:
  - Spot welder (see WORKSHOP EQUIPMENT ).
  - Safety goggles
Preparations for MAG and spot-welding
- Remove the paint coat in a range of approx. 30 mm around the weld seam or point.
  - For the MAG welding method, the zinc layer beneath this must be removed.
  - It is not necessary to remove the zinc layer underneath during spot-welding.
- Remove the paint coat on the rear of the weld seam or point.
  - Otherwise contaminants will get into the weld pool through the root of the weld seam.
  - An insufficient electron flow prevents an optimum spot-weld joint.
- Coat all metal overlaps and weld spot flanges with welding primer.
- To keep a short path for the flow of electrons during MAG welding on the body, the ground terminal must, if possible, be fastened directly to the component to be welded.
Welding
- During MAG welding, the weld gap must be kept as small as possible. The bigger the weld gap, the lower the strength of the connection.
- For spot-welding, the sheet metal flanges to be joined must be placed together with as few gaps as possible.
  The bigger the gap, the lower the strength of the connection.
  
  Minimum distance between welding spots 25 mm.
Subsequent treatment of welded connections:
- When grinding a weld seam, do not grind thin the base material next to the seam.
- After joining, clean all weld seams and spots with a stainless steel wire brush.
- Remove burnt paint with a stainless steel wire brush.
- All welded connections sealed off with body sealing compound in original condition must be primed and sealed off again thoroughly after repairing. Replace damaged or removed anti-droning layers.