BMW X5: Installation Of A Cavity Seal With Cavity Foam

Sourcing reference for cavity foam.

IMPORTANT: The cavity foam may only be use for cavity sealing at the points at which cavity sealing is present as standard!

The following repair represents the replacement of a shaped part for the cavity seal by the use of cavity foam.

This type of cavity sealing is used at points at which shaped parts cannot be used for repairs.

This is the case when large amounts of heat occur (e.g. due to welding, soldering or tin-plating) in the direct vicinity or at the point of the standard cavity sealing.

It is not possible here to install shaped parts for the cavity seal because of the fire risk!

To replace shaped parts with cavity foam at further locations, adopt the procedure shown here and adapt it to the relevant conditions.

It must be ensured that the cavity is completely sealed off.

NOTE: Check the accessibility for the spraying pipe of the cavity foam to the affected cavity after removing the damaged part.

Properties of cavity foam:

• 2K-PUR foam, solvent-free.
• Excellent flow capacity, enabling complete sealing of cavities.
• Good strength, preventing slipping in cavities.
• Low water absorption, preventing corrosion.

IMPORTANT: Observe processing instructions and safety precautions on the spray can!

• Use by date on can.

  Do not use the spray can after the use-by date has expired as the properties of the cavity foam would no longer meet the requirements of the BMW Group.

• Before applying to the vehicle, fill a clearly visible cavity of corresponding size with foam on a used part.

  This enables an optimal dosage (i.e. spraying time) to be specified for filling the cavity on the vehicle with foam.

• Backing surface must be clean and free from dust, grease, oil and stripping agent.
• Tape off open passages to visible areas with adhesive tape to prevent foam from escaping.
• Application time after mixing: within 8 minutes.
• Do not eat, drink or smoke during this operation.
• Completely empty open can after use.
• Cavity sealing of repair area possible after an air drying time of 1 hour.

Installing A Cavity Bulkhead (expanded)

NOTE: Carry over schematic representation to the relevant vehicle type.

The following repair represents the procedure for an already expanded cavity bulkhead.

The cavity bulkhead remains on the body in this instance.

Before these work steps, prepare the new part so that it is ready to install (adapting, cutting to size, applying welding primer etc.).

Clean contact surface (1) with spirit.

Apply an approx. 15 mm high bead (2) of original BMW window adhesive to contact surface (1).

Fit, secure and weld up new part.

Fig. 13: Identifying Contact Surface

WARNING: Ensure adequate ventilation over entire processing period.

Installing A Cavity Bulkhead (not Expanded)

NOTE: Carry over schematic representation to the relevant vehicle type.

The following repair represents replacement of a cavity bulkhead.

Before these work steps, prepare the new part so that it is ready to install (adapting, cutting to size, applying welding primer etc.).

Sand contact surface of cavity bulkhead (1) with coarse-grained abrasive paper (grain 50 - 100).

Clean contact surface (1) with spirit.

Apply an approx. 15 mm high bead of original BMW window adhesive to contact surface (1).

Attach cavity bulkhead in specified position (see old part).

Fit, secure and weld up new part.

Fig. 14: Identifying Contact Surface

WARNING: Ensure adequate ventilation over entire processing period.

Materials Science

Aluminum

1.1 Chassis and suspension components

Read and observe the Notes on chassis and suspension components before handling aluminum.

1.2 Material influences

MATERIAL INFLUENCES CHART

1.3 Machining properties

MACHINING PROPERTIES

1.4 Mounting

MOUNTING REFERENCE

Notes On Repairing Threads

IMPORTANT: Install Heli-coil thread inserts so that they are flush with the original thread.

NOTE: Damaged threads may be repaired with Heli-coil thread inserts. Comply with the procedure described in the example.

SCREW/BOLT SPECIFICATION

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