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Contents

Wiring diagrams Section: Body Panel System - Repair (E82)

41 00...AFGS (active Pedestrian Protection) Procedure After Accident

41 00...Blind Rivets

41 0 Contents Of Body, General

41 00... Bonding Steel On Steel

Equipment

Expiry Date Of Adhesive

Grinding And Cleaning

Hardening Times

After Treatment Of Bonding Surfaces

Disposing Of Adhesive

41 00... Carrying Over Hole Pattern

41 00... Corrosion Protection

Removing Sealing Materials

Corrosion Protection Of Sheet-Metal Parts

Cavity Protection Of Steel Parts

Cavity Protection Of Aluminum Parts

41 00...EMC screws

41 00... Gap Dimensions, Body

41 00... General Cementing Instructions

Recommended Tools And Equipment

Grinding Outer Shell And Structure

Scope Of Delivery

Start-Up

Safety Instructions

1.0 Airbags And Restraint Systems

Battery

Control Units

Optical Fibers

41 00... Information/Warning Labels

Aluminum

41 00... Information On Vehicle Protection

Protection Measures!

Straight Shank Rivet Nut

Hexagon Rivet Nut (Up To M8 Thread)

Hexagon Rivet Nut (From M10 Thread)

41 00... Installing A Cavity Acoustic Baffle (Expanded)

41 00... Installing A Cavity Acoustic Baffle (Not Expanded)

41 00... Installing A Cavity Acoustic Baffle With 2-Component PU Cavity Foam

Information On Dangers/Hazards

41 00... Materials Science

41 00... Notes on adhesive K1

Storage

Shelf life

Surface pre-treatment

Required cartridge gun

Preparing the glue cartridge

Hardening time

Disposal of adhesive

41 00... Notes on adhesive K2

41 00... Notes on adhesive K3

Adhesive disposal

41 00... Notes on adhesive K4

41 00... Notes on adhesive K5

Do not move the vehicle before the adhesive has hardened

41 00... Notes on cleaning agent R1

41 00... Notes On Repairing Threads

41 00... Opening Adhesive Bonds

41 00... Opening brazed joints

41 00... Opening riveted joints

1.1 Opening blind rivets (N1 and N2)

1.2 Opening blind rivets (N3 and N6)

2.1 Opening punch rivets by extraction

2.2 Opening punch rivets by drilling out

41 00... Opening Weld Joints

Adhesives

Rivets

Primer

Sealing Compounds

Cavity Sealing

1.0 Adhesives

1.1 Primer

1.2 Cleaning agent

1.3 Fillers

2.1 Rivets

2.2 Plastic nuts

3.0 Primer

4.0 Sealant

5.0 Cavity preservation

6.0 Cavity foam

7.0 EMC screw (electromagnetic compatibility)

8.0 Twist drill

41 00... Position Of Shaped Parts For Cavity Acoustic Baffle

41 00... Punch rivets

1.0 Recommended tools and equipment

Setting punch rivets

41 00... Quality Standard

41 00... Repair Solution For Straight Shank/Hexagon Rivet Nut

Extracting Punch Rivets

Drilling Out Punch Rivets

Drilling Out Blind Rivets

Blind Riveting In Conjunction With Bonding

Setting Blind Rivets

Setting Blind Rivet Nuts And Blind Rivet Studs

Setting Blind Rivet Nuts And Blind Rivet Bolts

Working With Aluminium Dust

Arc Welding And Brazing

Working With Adhesive Products (Adhesives, Cleaning Agents, Primers Etc.)

41 00... Spot-Weld Bonding Steel Parts

Reshaping or heating extruded sections and cast parts is not permitted!

1.0 Recommended tools

2.0 Straightening outer shell

41 00... Straightening steel components in the structure

Heating bearing body components for better reshaping is not permitted!

The body must be anchored as follows for reshaping

Recommended Tools

Straightening Outer Shell

Straightening Structure

41 00... Use Of Materials In Outer Shell

41 00... Welding And Soldering Steel Parts

41 00... Welding In Reinforcement Plate (Steel Plate)

41 00... Working With 2-Component PU Cavity Foam

41 00... Workshop Equipment

41 11 023 Replacing Front Section Of Engine Support To Left Wheel Arch

41 11 043 Replacing Front Section Of Left Engine Support

41 12 535 Replacing Complete Rear Luggage Compartment Floor (Tail Panel Removed)

41 12 560 Replacing Luggage Compartment Floor (Complete With Both Inner Wheel Arch Sections, Tail Panel Removed)

41 12 590 Replacing Luggage Compartment Floor (Complete With Left Or Right Inner Wheel Arch Section, Tail Panel Removed)

4112651 Replacing luggage compartment floor, left section (Tail panel or side wall removed)

New part preparation

41 14 021 Replacing Front Left Wheel Arch

41 14 502 Replacing Rear Left Outer Wheel Arch Section (Rear Left Side Panel Removed)

41 14 511 Replacing complete rear left wheel arch (rear left side panel removed)

41 21 510 Replacing Front Left Door Pillar (Front Side Panel Removed)

41 21 930 Replacing Inside Left Side Frame (B-Pillar Reinforcement)

41 31 010 Replacing Roof Outer Skin (Version With Slide/Tilt Sunroof)

41 33 040 Replacing Front Wall

41 34 041 Replacing Complete Tail Panel

41 35 010 Removing And Installing/Replacing Side Panel, Front Left Or Right

41 35 101 Replacing Rear Left Side Panel

41 51.... Adjusting Door

41 5.... Removing And Installing Door

41 61 000 Removing And Installing Hood/Bonnet

41 61 014 Adjusting Engine Bonnet/Hood

41 61 014 Adjusting engine compartment lid (for vehicles with active pedestrian protection AFGS)

41 61... Checking hinge for engine compartment lid (for vehicles with active pedestrian protection system)

41 61 010 Removing and installing engine compartment lid (active pedestrian protection AFGS)

41 61 571 Removing and installing/replacing left hinge for engine compartment lid, (for vehicles with active pedestrian protection AFGS)

51 23 400 Removing and installing/replacing left or right actuator (active pedestrian protection)

41 62 000 Removing And Installing Rear Lid

41 62 014 Adjusting Rear Lid

41 62 520 Removing And Installing/Replacing Left Or Right Hinge For Rear Lid (Rear Lid Removed)

41 63 000 Removing And Installing Flap For Fuel Filler Neck

All sections

Start-Up BMW 1 series F20/F21

Body Panel System - Repair (E82)

Start-Up

Open pressure vessel and introduce cavity sealant in form of a 1-liter can. Close pressure vessel.
Connect spray hose to quick-connect coupling.
Connect apparatus to compressed air supply. Working pressure 2-6 bar, max. 8 bar!