LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Mini >> 2014 >> Cooper Base, 2D Convertible, Automatic Trans >> Repair and Diagnosis >> External Pages >> Different car >> Section 2132 (COLLISION - BODY PANEL REPAIR (E60) 535i, 535xi) >> Body Panel Repair General Information >> 41 00... Overview Of Front End Repair Elements
April 5, 2026: LEMON Manuals is launched! Read the announcement.

41 00... Overview Of Front End Repair Elements

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2010 BMW 535xi, 2010 BMW 535i, 2009 BMW 535xi, 2009 BMW 535i, and 2008 BMW 535xi. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Overview Of Front End Repair Elements
G05503156Courtesy of BMW OF NORTH AMERICA, INC.
FRONT END REPAIR ELEMENTS COMPONENTS REFERENCE

Component Repair element(1) Part number Matching
(1) Engine carrier Repair kit, lug, radiator bracket 41 11 7 165 339 Mounting, carrier, bumper
  Threaded bolt, short Mounting, carrier, bumper 07 14 6 951 379
  Threaded bolt, long 07 14 6 951 380  
  Screw, self-tapping 51 16 8 220 001 Bracket, washer fluid reservoir
Bracket, secondary air pump
  Helicoil thread insert 07 14 6 958 589 Bushing, front axle, front/middle
(2) Support carrier Blind rivet nut 41 12 8 223 082 Support carrier, wheel arch, front right
  Blind rivet nut, countersunk head 41 32 8 257 508 Support carrier, wheel arch, front left
  Flange nut 07 14 6 949 832 Support carrier, wheel arch, outer
  Shim 41 35 7 001 794  
(3) Spring support M8 Helicoil thread insert 07 14 6 958 587 V-strut on spring support
  Blind rivet bolt with coarse thread 41 12 8 244 333 Spring support, right
  Blind rivet nut 32 41 1 094 185  
(4) Bulkhead M8 Helicoil thread insert 07 14 6 958 587 Cross-member, bulkhead
  Flange nut 07 14 6 949 832 Mounting, wiper system
  Shim 41 35 7 001 794  
Repair solution, threaded bolt Expander rivet 51 11 1 908 077  
  Cable strap 32 41 1 112 282  
Various repairs M8 hexagon nut 07 11 9 904 024  
  M6 hexagon nut 07 12 9 904 859  
  M5 hexagon nut with shim 07 12 9 904 381  
  M5 Helicoil thread insert 07 14 6 958 585  
  M6 Helicoil thread insert 07 14 6 958 586  
  M10 Helicoil thread insert 07 14 6 958 587  
(1) The required tools are featured on the Workshop Equipment Planning CD (WEP)

For a detailed depiction for using the repair elements, see below.

All the repair elements for the weight-reduced aluminium front end are depicted in the following.

Read contents of Body, General.

Mark severance cut (1) in accordance with measurement a and cut.

Measurement a = 63 mm from top edge, lug, radiator bracket.

Carry over holes from new part, drill and screw new part into place.

Fig 2: Identifying Severance Cut Mark
G05503157Courtesy of BMW OF NORTH AMERICA, INC.

Drive through damaged threaded bolts (1) towards rear.

Insert new threaded bolts (1) and (2) in same position, turn if necessary.

Peen threaded bolts (1) and (2) from front end with 2 mm punch.

NOTE: Cut off threaded bolt (2) before driving through.

Installation: 

Grind off 3.5 mm of threaded bolt (2) at head on one side and apply primer coating.

Fig 3: Identifying Threaded Bolts
G05503158Courtesy of BMW OF NORTH AMERICA, INC.

Grind off torn threaded bolts (1) until flush and apply primer coating.

IMPORTANT: Do not damage aluminium surface.

Drill 5.5 mm dia. holes (2) at distance of approx. 8 mm in a level plane.

Insert self-tapping screw.

Tightening torque 8 Nm.

Fig 4: Identifying Threaded Bolts And Holes
G05503159Courtesy of BMW OF NORTH AMERICA, INC.

Thread repair with Helicoil thread insert can be used on the spring support (1).

Read and comply with tool manufacturer's instructions.

Fig 5: Identifying Spring Support
G05503160Courtesy of BMW OF NORTH AMERICA, INC.

Thread repair with Helicoil thread insert can be used on the bulkhead (1).

Read and comply with tool manufacturer's instructions.

Fig 6: Identifying Bulkhead
G05503161Courtesy of BMW OF NORTH AMERICA, INC.

Thread repair with Helicoil thread insert can be used on the front engine carrier bushings (1) and middle engine carrier bushings (2).

Read and comply with tool manufacturer's instructions.

Fig 7: Identifying Front Engine Carrier Bushings And Middle Engine Carrier Bushings
G05503162Courtesy of BMW OF NORTH AMERICA, INC.

Remove damaged press-in nuts in areas (1).

Fig 8: Identifying Damaged Press-In Nuts In Areas
G05503163Courtesy of BMW OF NORTH AMERICA, INC.

Drill out hole (1) to 18 mm.

Fit Limbach nut (2) from below; if necessary, secure with sealing compound.

Insert shim (3) in bore.

Install screw (4).

Fig 9: Identifying Limbach Nut, Screw And Shim
G05503164Courtesy of BMW OF NORTH AMERICA, INC.
scientia non olet · About LEMON Manuals