41 03 09 (537)

Min/max tolerance sample catalogue for paintwork and corrosion damage

All
Situation: Min/max tolerance samples are available to enable improved pinpointing of paint and
corrosion damage. They are a supplement to the BMW Paintwork publication announced
in Service Information 41 01 08 (452) and published in October 2008.
Vehicles that are older than three years after the first registration date may only be repaired by replacing
components if the damage exceeds a defined extent (see min/max tolerance samples). With immediate effect,
certain paint damage patterns attributed to incipient corrosion may only be repaired by means of spot repairs
as small as possible.
There are currently five max/min tolerance samples:
Paintwork damage with min/max tolerance sample A (critical damage pattern)
Paintwork damage with min/max tolerance sample B (minor damage pattern)
Paintwork damage with min/max tolerance sample C (scrape marks)
Paint damage with tolerance sample D (rubber grommets)
Paint damage with min/max tolerance sample E (vehicle underbody)
All customer complaints are to be classified based on these additional min/max tolerance samples.
1. Min/max tolerance sample A (critical paintwork damage)

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General appearance: Rust is visible without scratching the surface.

Sample A1:
Visible rusting on fold and its seal (1).

Sample A2:
Bubbling on outside (1) of fold seal.
Note:
Bubbling between fold seal and outer edge. The fold seal
covers an approx. 5 mm wide strip at the edge of the
component.

Sample A3:
Bubbling on the inside of the fold seal (1) is more extensive than the width.
2. Min/max tolerance sample B (minor paintwork damage)
General appearance: Rust is NOT visible without scratching the surface.

Sample B1:
Bubbling on the inside of the fold seal (1) is less extensive
than the width. Lengthwise distribution is less than the width of
the fold seal (1).

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Sample B2:
Bubbling on the inside of the fold seal (1) is less extensive
than the width. Lengthwise distribution is greater than the width
of the fold seal (1).

3. Min/max tolerance sample C (scrape marks)

Sample C1:
Scrape marks on paint surface of the tailgate (2) by plastic
trim (1) (only Touring).

Sample C2:
Chafe marks on paint surface caused by tailgate handle strip (1) on tailgate (2).
3. Tolerance sample D (rubber grommets)

Formation of blisters is not visible without lifting the rubber

grommet (1).

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3. Min/max tolerance sample E (vehicle underbody)

Visible red rust formation originating from an edge or a spot-

weld.

Procedure: The damage patterns are now differentiated based on min/max tolerance samples. The
following extended warranty applies:

Not for damage Period in years Selection of the repair

caused by method
customer First registration after
1.1.2004

Min/max tolerance 12 Component

sample A replacement if feasible
in terms of time
Min/max tolerance 3 Component
sample B replacement
Min/max tolerance from 3 NO part exchange
sample B permitted. The
approval regulations of
the local market must
be observed at all
times.
Min/max tolerance 12 Paint
sample C
 Tolerance sample 12 Paint
D
Min/max tolerance 12 Seal and preserve.
sample E

The paint structure must be built up as specified in the ColorSystem painting handbook.
Attention!
The repair is only carried out in justified case of customer complaint.
In the case of rust damage and paint damage, all mounted parts must be retained wherever
possible and remounted as part of the repair procedure.
In contentious cases, e.g. repeated repairs, the advise of the respective Warranty department
should be sought in order to clarify the procedure.

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41 01 98 (374)
Dent repairs without damaging paintwork
All
Situation: Light dents have previously only been repaired through conventional means such as
Multispot and filling followed by repainting.
However, methods of rectifying parking and hailstone damage that do not damage the
paintwork are becoming increasingly common.Vehicle insurers are fully supportive and endorse this approach.
This procedure involves pressing out damage from the inside of sheet metal panels using levers followed by
polishing. The total outlay is much lower than for conventional dent repairs with subsequent repair painting. It is
to be noted here that some areas of damage cannot be reached on account of reinforced or bonded body
components. For safety reasons, no additional holes may be drilled to improve accessibility.
The size of the dent should not exceed a diameter of 80 mm.
This procedure can also be used during general workshop repair processes, such as:
- Preparing for painting (reduction in filling work)
- Rectifying any damage following repair painting.
Based on this background as well as environmental aspects and the positive effect on insurance coverage
classification, this method of repairing dents without paintwork damage is approved for BMW vehicles. This
approval only applies to dents that do not have visible paintwork cracks.

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Procedure: Repairing dents without damaging the paintwork requires continuous practice and a high
degree of skill. In order to cater for the relevant situation at all contractual partners, two
application methods for optimum use are offered.
1. In the same way as professional body and paintwork shops are already used, it is also possible in this
case to commission qualified contractors for the purpose of conducting dent repairs without paintwork
damage.
2. Purchase of a BMW pressing-out tool set for dent repairs.
The form and materials of this set have been carefully selected for BMW vehicles. It consists of a
standard set (for approx. 80 % of the outer body skin that can be reached) and an extension set (for the
remaining 20 %).
Training is recommended so that the tool set can be used effectively. This training is offered by external
companies and can be conducted locally (e.g. for Germany the company Ur-Form).
See Service Information 5 04 98 (328).
Note:
Make sure that the training provider does not conduct training under the prerequisite of
purchasing his particular set of pressing-out tools.
41 01 08 (452)
New BMW paint brochure
All
Presentation of BMW paint brochure:
The existing BMW paint brochure has been thoroughly revised and in its new form provides good reference for
assessing all kinds of paint and corrosion damage.
The examples and detailed descriptions contained in the brochure are intended to find a standard language for
identifying paint and corrosion damage. Unambiguous descriptions of damage mean that misinterpretations
can be largely ruled out when assessing a possible warranty claim. Communication between the customer and
the authorised BMW dealer during assessment on the vehicle is also made greatly easier.
If for example the following damage is unambiguously identified on the paint surface, this will always be
considered to be the responsibility of the customer, and warranty will be ruled out:
Mechanical influences on the paint surface (e.g. scratches)
Damage to the paint surface caused by chemical or biological influences (e.g. animal droppings)
The new BMW paint brochure complements the BMW paint handbook when eliminating paint and corrosion
damage. This means that the repair procedures described in the BMW paint handbook are adapted
unambiguously and purposefully to the fault pattern.
Subsequent orders for BMW paint brochure:

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The BMW paint brochure can be ordered via the usual parts-related channel under the BMW parts number 01
29 2 148 332.
41 02 09 (521)
New repair methods ”Gluing / Riveting” on steel bodies
BMW/MINI
Situation: Advance technical developments in the field of adhesives and equipment technology
have made modified repair methods possible. This procedure has been tested and
approved following exhaustive endurance runs and corrosion tests in the Development
division.
Similar to the procedure for the tail panel on the F01/F02, the repair methods "welding/soldering" will change to
"gluing/riveting" on various outer skin and structural components of steel bodies from the launch of the E89
and R57. This procedure has already been introduced for repair work on the reduced-weight aluminium front
end (GRAV) of the E60.
The repairs can be performed by all workshops that have participated in a GRAV or the current bonding and
riveting training, in combination with the training video.
Another positive point of this method is the significantly improved corrosion protection resulting from the wide-
area bonding of the spare part coating (KTL).
Procedure: Essentially, the following components are affected:
Rear side wall
Tail panel
Boot floor

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Roof outer skin
engine carrier
support carrier
Model series affected:
MINI (R55, R56, R57)
BMW 1 Series (as of E8x)
3 Series (as of E9x)
5 Series (as of E60)
X1 (E84)
X5 (E70)
X6 (E71)
Z4 (E89)
7 Series (as of F01)
And all future series.
Necessary workshop equipment:
Punch riveting tool
Blind riveting tongs
Cartridge gun for body glue
Universal collet (for roof ducts)
Infrared lamp
For more information on the required tools, see Service Information.
Parts required:
The new parts and consumables required for the respective scope of repair work are listed in the Electronic
Parts Catalogue (EPC).
In addition, vehicle-specific service repair packages are also offered. Here, the vehicle identification number is
to be entered in KSD2, the corresponding "Packages" button selected and the required job item selected in
main group 41.
Repair instructions:
The repair instructions have been revised to take account of the new repair method:
To differentiate the individual repair methods, the repair stage is inserted in the repair instructions.
 Repair stage 1: All repairs that only provide for replacement of screwed/bolted components and
planishing operations.
Repair stage 2: Repairs that are carried out by bonding and riveting without the use of a straightening
bench.
Repair stage 3: Repairs that are carried out by bonding and riveting with the use of a straightening bench
or welding.
Training video for bonding and riveting:
The new methods, for example "punch riveting", have been described on a training video that will be distributed
to National Sales Companies.
Please make sure the training video is made available to the staff who will be performing this work and, if you
do not perform body repair in your own workshop, to the staff of your specialist body workshop.
The BMW paint brochure can be ordered via the usual parts-related channel under the BMW parts number
01 69 0 037 577.
Time allowances:
Time allowances (flat rates) have been revised to take account of the new repair methods and shall apply
retrospectively.

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41 02 07 (377)
Repair of corrosion damage
All
Situation: A paint brochure is available for the evaluation and repair of body components relating to
corrosion damage.
It contains examples for the definition of paint and corrosion damage and provides
information on remedies and repairs. Details on contents and distribution were published in the Service
Information (bulletin) 41 01 08 (452).
The procedure for chafe marks (e. g. tailgate repair) is described in detail in the vehicle-specific Service
Information (bulletin).
Chafe mark on a painted surface generally are not considered to justify a part replacement.
Procedure: Important!
Repair of corrosion damage only if there is a specific customer complaint!
To the extent that the design allows, all add-on parts must be retained and converted.
Always adhere to the following procedure when dealing with corrosion damage:
1. Establish the fault pattern of the damaged area with the aid of the new paint brochure and use this as a
basis to determine the repair measures.
2. Remove the partial area of the body as specified in the repair instructions.

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3. Repair the partial area affected by corrosion in accordance with the repair instructions and the BMW paint
manual.
4. Reassemble the vehicle using the removed add-on parts.
Note:
Only the following repairs of the body components may be invoiced.
Replacement of the corroded body component (only in case of rust damage without partial
repair)
Paint
Conversion of add-on parts
Cavity preservation
31 01 12 (833)
Visible corrosion on vehicle add-on parts

Situation: Since the market introduction of the E65/66 the engine compartment and underbody
preservation has successively been dropped from all series for environmental protection
reasons. This may result in visible corrosion of machined surfaces such as, for example,
on chassis/suspension components, machined screwing/bolting points, screw connections, or on surfaces
such as, for example, the joints and drive shafts!
To prevent or re-treat this surface corrosion, the dealer organisation should use the corrosion protection with
BMW part number 83 19 2 317 997.

Vehicles concerned:All BMW, MINI series

Procedure: Apply a thin coating of corrosion inhibitor (using only a brush) to the affected areas.
Warning!
Risk of fire!
Do not apply any corrosion inhibitor to the engine or the exhaust system!

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