Preparing New Part

Further information is available.

NOTE: TECHNICAL INFORMATION
For additional information see: SPOT-WELD BONDING 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) .

Remove adhesive residue on the joining surfaces on the vehicle.
Release the welded connections and remove the rocker panel boost (1).

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Detach the welded connections (1).
Crash reinforcement (2) is reused.

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Make separating cut (1) as shown and remove crash reinforcement (2).
NOTE: TECHNICAL INFORMATION
For additional information see: 41 00... Welding in reinforcement plates (sheet steel)
Make a reinforcement plate for separating cut (1).
Mark the separating cut (1) on the new part according to the separating cut on the vehicle and cut.

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Adjust the new part using an alignment bracket or a universal fixture and secure it.
NOTE: TECHNICAL INFORMATION
For additional information see: WELDING IN REINFORCEMENT PLATE (SHEET STEEL) - (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) .

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Make a reinforcement plate for separating cut (1).
Prepare area (2) for joining by welding.
Prepare areas from (1) to (3) for joining by welding.
NOTE: TECHNICAL INFORMATION
For additional information see: SPOT-WELD BONDING 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) .
In areas (3), follow the procedure for the replacement of the spot-welded adhesive joints for the series.

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Prepare areas (1) and (2) for joining by welding.
To do this, remove the cavity foam in the cowl cross-member on the inside.
Prepare area (1) for spot-welding.
Prepare area (2) for plug-welding (MAG weld) from the inside.

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Prepare area (1) for joining by welding.

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In the area (1), prepare a 15 mm long MAG weld seam.

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NOTE: To provide a better overview: Schematic diagram with partially hidden components.
Prepare areas from (1) to (3) for joining by welding.
For better clarity, the joint plate (4) is not shown.
Prepare the joining area (1) so that the repair spot-weld (spot-welding) can be placed on the production spot-weld on the vehicle.
Prepare joining areas (2) for spot-welding.
Prepare joining area (3) for plug-welding (inside).
Prepare area (1) for joining by welding.
In areas (1), prepare spot-welding 6 times as shown.

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Prepare areas (1) and (2) for joining using spot-welding.
Prepare joining areas (2) so that the 4 repair spot-welds (spot-welding) can be set on the production spot-welds on the vehicle.

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Prepare areas (1) and (2) for joining by welding.
Prepare the joining area (1) so that the repair spot-weld (spot-welding) can be placed on the production spot-weld on the vehicle.
In the area (2), prepare a 15 mm long MAG weld seam.

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Prepare 4 spot-welds in area (1).

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Prepare joining area (1) for spot-welding.
The repair spot-weld must be set to the production spot-weld.
In areas (2), prepare a 15 mm-long MAG weld seam twice.
In areas (3), prepare the plug-welds.

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NOTE: To provide a better overview: Schematic diagram with partially hidden components.
In areas (1), prepare the plug-welds.
Reinforcement plate (4) not shown for better reference.
In the area (2), prepare a 10 mm long MAG weld seam.
Prepare joining area (3) for spot-welding.
The repair spot-weld must be set to the production spot-weld.
Adjust the new part of crash reinforcement (1) and, in areas (2) and (3), prepare for joining by welding.
In area (3), follow the procedure for the replacement of the spot-welded adhesive joints for the series.

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NOTE: To provide a better overview: Schematic diagram with partially hidden components.
In areas from (1) to (3), prepare for joining by welding.
For better clarity, the bulkhead (5) is not shown.
Prepare the joining area (2) so that the repair spot-weld (spot-welding) can be placed on the production spot-weld on the vehicle.
In the area (3), prepare a 10 mm long MAG weld seam. For this purpose, slightly adjust the new part in the area (3).
Adjust reinforcement plate (4) for the separating cut.
Mark the separating cuts (1) and (2) on the new part according to the separating cuts on the vehicle and cut.

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NOTE: TECHNICAL INFORMATION
For additional information see: WELDING IN REINFORCEMENT PLATE (SHEET STEEL) - (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) .

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Prepare reinforcement plates for separating cuts (1) and (2).
Fit in new part.
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) .

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Prepare area (1) for the structural adhesive bonding of steel on steel.
In area (1), make 3 bores of Ø 6.8 mm for the blind rivets.
Prepare areas (2) and (3) for joining by welding.
In areas (3), follow the procedure for the replacement of the spot-welded adhesive joints for the series.
Prepare areas (1) and (2) for joining by welding.
In area (2), follow the procedure for the replacement of the spot-welded adhesive joints for the series.

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Renew T-bolt

NOTE: Schematic diagram is for example purposes. Some parts may differ in certain details.
Take the quantity and position from the component to be renewed.
Renew T-bolts (1).
Parts: T-bolt
Weld the T-bolt (1) onto the new part.

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