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.
![Body](images/books/4361/index.16(3).png)
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.
![Body](images/books/4361/index.17(3).png)
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.
![Body](images/books/4361/index.18(2).png)
Fig. 68: Identifying Separating Cut On Vehicle
SETTING BLIND RIVET NUTS AND BOLTS
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:
- 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.
READ NEXT:
Read and comply with GENERAL INFORMATION.
The needle stamping system 360 - VRM - BMW is required to stamp the vehicle
identification number.
Order number: 81 43 2 155 736
Sourcing reference:
BMW
Reshaping or heating extruded sections and cast parts is not
permitted!
Failure to comply with this requirement would have the following
results:
In the case of reshaping, weld seams (E52) or
The following illustration is a schematic representation of all the body
variants.
Apply this illustration to the relevant vehicle.
Fig. 76: Identifying Vehicle Components
All components not listed
SEE MORE:
Concept
Blind spot collision warning detects vehicles in
the blind spot or vehicles approaching from behind
in the adjacent lane. A warning is issued in
various gradations in these situations.
General information
Two radar sensors in the rear bumper monitor
the area behind and next to the vehicle
Notes
WARNING: Risk of scalding!
Only perform this repair work after engine has cooled down.
Protective measures/rules of conduct
Wear safety goggles
Wear protective gloves
Observe national/country-specific regulations
IMPORTANT: Risk of skidding due to coolant on the floor.
Danger of injury!