41 00... BONDING INSTRUCTIONS FOR BMW i

Special tools required:

2 357 309

IMPORTANT: Observe all applicable SAFETY INFORMATION .

Brief overview of surface preparation

Material (surface condition) Type of repair	Preparation
Aluminium (used part and new part) Repairs to the Drive module (only I01) All bondings with adhesive K1 in conjunction with blind rivets Example: Replacement side member or wheel arch	Do not grind the surface to be bonded (cathodic dip coating) Clean with cleaning agent R1 Bond with adhesive K1
Aluminium (new part) Replacement of aluminium components (BMW I) All bondings with adhesive K2 without blind rivets Example: Bonding Life module and Drive module when replacing front axle module	Grind bonding surfaces to a metallic bright-finish Clean with cleaning agent R1 Flame-coating thin coat with adhesive K1 Bond with adhesive K2
Carbon (new part) Bonding new parts to the body with adhesive K2	Sand with non-woven abrasive S1 Clean with cleaning agent R1 Activate with Betawipe 4800 Bond with adhesive K2
Thermoplast (new parts) Bonding new parts on components made of thermoplastic with adhesive K2	Sand with non-woven abrasive S1 Clean with cleaning agent R1 Coat bonding surfaces with bonding base VP 206 (air drying time at least 30 min, maximum 24 h). Bond with adhesive K2
Aluminium/carbon/thermoplastic (used part) Bonding new parts to the body with adhesive K2	Cut back adhesive bead Clean with cleaning agent R1 Bond with adhesive K2
Components made of sheet steel Partial replacement of carbon components Bonding with adhesive K2	Grind bonding surfaces to a metallic bright-finish Clean with cleaning agent R1 thin coat with adhesive K1 Bond with adhesive K2

2.1 The following general conditions are applicable to all bondings:
- The working temperature of glue cartridge must be more than 18°C.
- Object temperature, vehicle and new parts, at least 15°C.
- Refer to the individual repair instructions for the position and thickness of the adhesive bead.
- After applying the adhesive, check whether an adhesive component has emerged at the back of the glue cartridge. If yes, break off the bonding procedure. Clean new part. Use new glue cartridge.
- Join components and secure in position.
- Remove excess adhesive. Do not use solvent cleaning agents.
2.2 Flame-coating (aluminium):
- For better adhesion, remove oxide film and paint from the adhesive areas with a stainless steel wire brush or special emery paper.
- Clean bonding surfaces with cleaning agent R1.
  Allow cleaned surfaces to dry for approx. 5 min.
  
  Bonding surfaces must be completely dry.
- Flame spray the surface:
  Slowly move over bonding surfaces with the flame.
  
  Avoid flaming with the blue part of the flame.
  
  Condensation water appears on the area that is still uncoated. The condensation water in the line of the flame must evaporate completely.
  
  Directly after flaming, coat the still hot bonding surfaces (approx. 50 °C) with primer.
  
  Apply primer with a brush, cotton or similar item.
  
  Allow the coated surfaces to dry for approx. 5 minutes.
2.3 Surface preparation (carbon new part):
This surface preparation is applicable to new carbon parts.

Bonding surfaces on the new part have been pre-treated ex works (mat look).

Sand bonding surfaces with non-woven abrasive S1.

Clean bonding surfaces with cleaning agent R1.

Let cleaned bonding surfaces dry for at least 2 min.

Bonding surfaces must be completely dry.

Activate bonding surfaces with Betawipe 4800.

Let activated bonding surfaces dry for at least 2 min.

Bonding surfaces must be completely dry.
2.4 Surface preparation (thermoplastic new part):
This surface preparation is applicable to new thermoplastic parts.

Bonding surfaces on replacement parts are primed ex works (barely visible).

Sand adhesive flange on new part with non-woven abrasive S1.

Attention!

Do not sand through primer coat on new part.

Clean the adhesive flange using R1 solvent cleaner (air drying time at minimum 2 minutes).

Coat bonding surfaces with VP 206 bonding primer (air drying time at minimum 30 minutes and at maximum 24 h).

Bonding surfaces must be completely dry.

2.5 Surface preparation (aluminium/carbon/thermoplastic used part):

This surface preparation is also applicable to aluminium surfaces, on which a carbon part is bonded with adhesive K2.

Cut back the adhesive bead to guarantee adequate adhesion between the hardening and the new adhesive.

The surface need not be completely level.

WARNING: Danger of injury caused by sharp scraper blade!

Cut back the adhesive bead using the scraper 2 357 309 until all processing traces have been removed by grinding.

Cut back adhesive beads that came into contact with heat up to the areas unaffected by heat.

The thickness of the adhesive bead that has been cut back must not be below 0.5 mm.

Clean bonding surfaces with cleaning agent R1.

Let cleaned bonding surfaces dry for at least 2 min.

Bonding surfaces must be completely dry.

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: No spacers are required for the I01 roof outer skin. The spacers are an element of the replacement part.

Cut back the spacers (1) made of double-sided adhesive tape (size approx. 5x20 mm).

Bond the spacers (1) at a distance of approximately 200 mm along the adhesive flange (2).

NOTE: The adhesive bead (2) must surround the spacers (1) on the outer side (3).

Offset the spacers towards the vehicle interior (4) on adhesive beads (2) with a width of 20 mm or below.

The spacers must not fully cut through the adhesive bead (2). This reduces the firmness of the bonding.

2.6 Surface preparation (components made of sheet steel):
Components made of sheet steel are prepared analogous to the surfaces of reinforcement plates.

Reinforcement plates are special shaped parts for joining new parts to the side frame (e.g. partial replacement of side sill).

PREPARE REINFORCEMENT PLATES .