Body - Structural Aluminum Repair Precautions
SI B 41 04 05Body
May 2005
Technical Service
SUBJECT
Structural Aluminum Repair Precautions
MODEL
E60, E61, E63, E64
SITUATION
The new weight reduction aluminum front section (GRAV) on the new 5 and 6 Series is unique since the front structure consists of a mixture of aluminum alloys and steel parts. Due to aluminums specific handling characteristics, special precautions and procedures must be observed when making repairs to the front structure.
PROCEDURE
Reshaping or heating of extruded and cast parts is not permitted!
Failure to comply with this requirement would have the following results:
^ In the case of reshaping, glued connections may tear in the surrounding areas as as the material losing up to 40% of its original strength.
^ In the case of heating, the material may lose up to 40% of its original strength as as damaging adhesive in the surrounding area with temperatures above 120°C (250°F).
Extruded and cast parts which show visible or measurable signs of deformation must be replaced!
Be sure to check for deformation with the aid of an approved straightening system. (Refer to bulletin 41 01 04 for more information on approved straightening systems)
EXCEPTIONS
The support carrier and bulkhead (cowl) may be straightened only if they do not have any cracks, sharp edged damage or holes. After repair work is completed be sure to check again for any cracks.
Any repairs to the bulkhead (cowl) if cracked are only permitted after consultation with and approval by BMW. Should you have questions, please contact your country-specific Hotline.