Prepare New Parts

Replace coarse thread studs and threaded welding studs, steel surface  

• Refer to the number and position of the component to be replaced or the attachments.
• Replace coarse thread bolt (1) and threaded welding bolt (2).

  Parts:  Coarse threaded studs (1), threaded weld studs (2)

• Weld the coarse threaded bolt (1) and threaded welding bolt (2) onto the new part.

  Check ground pins and replace if necessary 

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  Check ground pins and replace if necessary 

  NOTE: Schematic diagram is for example purposes. Some parts may differ in certain details.

  Check the ground pins (1) for stability and renew if necessary.

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  Prepare new parts, left side rail 

  Further information is available. 

  NOTE: TECHNICAL INFORMATION 
  Structural adhesive bonding. 
  Observe preparation of bonding surfaces.
  For additional information see: BMW/MINI BONDING INSTRUCTIONS (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) .
• Adjust new parts to fit with alignment bracket or universal mount and secure.
• Prepare areas (1) and (2) for structural adhesive bonding of steel to aluminum.
• Assign the positions of the bores already present in areas (1) and (2) of the vehicle to the new part. Place bores in areas (1) and (2) ø 6.8 mm for blind rivet.

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• Prepare area (1) for structural adhesive bonding of steel to aluminum.
• Assign the positions of the bores already present in area (1) of the vehicle to the new part. Place bores in area (1) ø 6.8 mm for blind rivet.

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• Prepare area (1) for structural adhesive bonding of steel to aluminum.
• Assign the positions of the bores already present in area (1) of the vehicle to the new part. Place bore in area (1) ø 6.8 mm for blind rivet.

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• Prepare areas (1) for joining by welding.

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• Prepare areas (1) for joining by welding.

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  Prepare new parts, left side rail 

  Further information is available. 

  NOTE: TECHNICAL INFORMATION 
  Adhesive technology in the area of the outer skin (not for structural adhesion):
  The bonding surfaces of the new parts may not sharpened or ground.
  For more information see: BMW/MINI BONDING INSTRUCTIONS (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) .
• Adjust new parts to fit and secure.
• Prepare areas (1) for joining by welding. Ensure sufficient distance to the adhesive area in doing so.
• Prepare area (2) for joining using the rivet-and-bonding method. Do not grind bonding surfaces down or off.
• In area (2), assign the two bores present in the side member to the new part.
• Drill out holes to dia. 6.8 mm.
• Prepare areas (1) and (2) for joining with the glue rivet technique. Do not grind bonding surfaces down or off.
• In areas (1) and (2), assign the bores already present to the new part.
• Drill out holes to dia. 6.8 mm.

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• Prepare areas (3) for joining by welding.

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• Replace series of welded connection (1) by MAG-weld seam (2). Prepare in area (2), a MAG-weld seam of length 10 mm. Ensure sufficient distance to the bonded rivet connection (3).
• Remove new parts.
• Deburr bores.

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  Prepare new part, middle luggage compartment floor 

  Further information is available. 

  NOTE: TECHNICAL INFORMATION 
  Structural adhesive bonding. 
  Observe preparation of bonding surfaces.
  For additional information see: BMW/MINI BONDING INSTRUCTIONS (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) .
• Adjust new parts to fit and secure.
• Prepare area (1) for structural adhesive bonding of steel to aluminum.
• Assign the positions of the holes already present in area (2) of the vehicle to the new part. Set holes (2) ø 6.8 mm for blind rivet.
• Mark area (1) for later adhesive application.

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• Prepare area (1) for structural adhesive bonding of steel to steel and aluminum.
• Assign the positions of the holes already present in area (2) of the vehicle to the new part. Set holes (2) ø 6.8 mm for blind rivet.
• Set hole (3) ø 6.8 mm according to dimension b. Dimension b = 30 mm from component edge.
• Prepare area (4) according to dimension a for joining by welding. Dimension a = 40 mm.

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• (2) Mark area (1) for later adhesive application.

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  NOTE: Perform the steps on the left and right side.
• Adjust the new parts in combination with the tail panel to fit and secure.
• Prepare area (1) for structural adhesive bonding of steel to steel and aluminum.
• Transfer the position of the hole (2) that resulted from the removal on the vehicle to the new part. Set hole (2) ø 6.8 mm for blind rivet.
• Set the new hole (3) ø 6.8 mm according to the specified dimensions.

  Dimension a = 40 mm from hole ø 12 mm.

  Dimension b = 24 mm of hole ø 12 mm.

• Prepare area (4) from the reference line (5) for joining by welding.

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• (2) Mark area (1) for later adhesive application.

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• Prepare areas (1) for joining by welding.

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• Prepare areas (1) for joining by welding.

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• Prepare areas (1) for joining by welding.

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• Prepare areas (1) for joining by welding.

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• Prepare areas (1) for joining by welding.
• Remove new part and deburr holes.

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