BMW 7 Series: Separating Cut Determination With A Template

In the case of a partial replacement piece, a body component is cut at a point described in the repair instructions.

A template may be used for the exact position determination for the separating cut.

The template is made from the reinforcement plate and can be reused.

Carry over schematic diagram at the separation cut C-pillar to the relevant vehicle type.

Remove stud bolts (1).

Set bore holes Ø 4 mm at the positions of the removed stud bolts.

If applicable, place additional bore holes in the area of the edges.

Fig. 66: Identifying Stud Bolts

Insert the template (1) into the new part (in direction of arrow) until it is flush (without gap).

Carry over the positions of the holes (2) to the new part.

Remove reinforcement plate again.

Fig. 67: Inserting Template Into New Part

Connect marks (positions of holes) to the separating cut line (1).

Carry out the separating cut.

Tear and separate the separating cut on the vehicle according to the new part.

Fig. 68: Identifying Separating Cut On Vehicle

SETTING BLIND RIVET NUTS AND BOLTS

• Studs welded as standard are always replaced by blind rivet bolts.
• Drill holes (0.2 mm larger than the outside diameter of the blind rivet nuts or blind rivet bolts).
• Blind rivet nuts and studs must have a special coating for anti-corrosion purposes (sourcing reference: BMW Parts Department).

  Use the blind rivet nuts and bolts supplied in the case of the manual riveting tool for steel only!

• It will no longer be possible to set a blind rivet nut if the drilled hole is too big. In this event, set a clip nut (sourcing reference: BMW Parts Department). This nut tightens itself automatically when screwed to the component.
• Insert blind rivet nuts or bolts and TIGHTEN DOWN WITH RIVET TOOL.
• Seal blind rivet nuts and blind rivet bolts with SEALANT D1 (risk of corrosion).

Soldering Steel Components

IMPORTANT: Comply with the following topics from "Body, General": Safety regulations.

Handling electrical/electronic equipment, airbags and restraint systems.

1. General information

• For repair cases the following method will implemented:
  • Gas brazing
• The MIG soldering procedure is not used in repairs for strength reasons. MIG soldered/brazed seams used in series production are replaced in repairs by MAG weld seams.
• Brazed areas from vehicle production are bonded with the same method.

2. Work materials

• Tube pack and torch (gas torch)
• Brazing solder
• Gas bottles (oxygen and acetylene)
• Welding goggles

3. Preparation

• Remove the paint and zinc coating in an area of approx. 30 mm around the seam to be soldered.

4. Implementation

• Execute brazed seam without overheating the solder and with low heat dissipation. If necessary, use heat protecting paste.

5. Subsequent treatment of brazed joints

• Remove burnt residual zinc completely. Align and grind visible connection faces.
• Remove burnt paint with a stainless steel wire brush.

6. Notes on melting/tinning

Only applicable within the European Union! European used-car regulations prohibit the use of tin containing lead in motor vehicles introduced after 01.07.2003! Even out unevenness smaller than 2 mm with filler according to painting handbook If an exceptional unevenness is larger than 2 mm, use METAL FILLER.

Only perform in visible areas of the outer skin and on the carrier support.

All areas which have covers on the vehicle are not to be processed.

SPOT-WELD BONDING STEEL PARTS

IMPORTANT: Comply with the following topics from "Body, General": Safety regulations.

Handling electrical/electronic equipment, airbags and restraint systems.

Welding steel parts

• The spot-weld bonding process is used starting from the E65 to increase vehicle rigidity. In partial bodywork areas, a 1-component adhesive is applied to the spot flanges and this is followed by resistance pressure spot welding. The adhesive is hardened only after the paint drying process (at approx. 180ºC).
• In the case of repairs, adhesive is not applied to the spot flanges. The number of welding spots is doubled as a substitute for the omitted adhesive.
  • The following processes are used as a substitute for spot-weld bonding:
  • MAG welding (M etal A ctive G as welding)
• Resistance pressure spot welding (referred to in the following and in the repair instructions as spot welding).
• Adhesive is not applied between the spot flanges on new parts in the case of 2- or multi-sheet joints.

  Areas which cannot be reached by the spot-welding tongs can be joined by MAG spot welding. The number of welding spots is doubled as a substitute for the omitted adhesive.

  Exceptions (e.g. E65) are described in the relevant repair instructions. Apply welding spots to existing welding spots on new part. This is necessary because the adhesive between the spot flanges of the new part acts as an insulator.

CAUTION: Extract smoke and fumes during welding work.

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