BMW X3 Service & Repair Manual: Replace sills, left

Procedure OBSERVE repair stage 3! Read contents of BODY, GENERAL.

Use only approved SPOT-WELDING APPARATUS for repairs! Following new body parts are required (see OVERVIEW OF CONSUMABLES):

  • (1) Outer side frame

Body+and+Frame

Removal

Body+and+Frame

Mark severance cut (1) in accordance with dimension and cut.

IMPORTANT: Cut outer panel only.

Measurement a = approx. 40 mm from center point of 8 mm dia. hole.

Open welded connections in areas (2).

Body+and+Frame

Open welded connections in area (1).

Remove sill.

New part preparation

Body+and+Frame

Mark severance cut (1) on the new part according to vehicle + 20 mm extra material and cut.

Body+and+Frame

Adjust new part to fit and secure.

Prepare new part for plug-weld in areas (1).

In area (2) prepare new part for spot-weld.

Remove new part and deburr holes.

Installation

Install new part and weld.

REPLACING ENGINE SUPPORT IN FRONT OF BULKHEAD ON RIGHT

Operation is identical to REPLACING ENGINE SUPPORT IN FRONT OF BULKHEAD ON LEFT.

REPLACING ENGINE SUPPORT IN FRONT OF BULKHEAD, LEFT

Observe procedure of REPAIR STAGE 3.

Read contents of BODY, GENERAL.

Use only approved SPOT-WELDING APPARATUS for repairs.

Place vehicle on straightening bench.

The following body new parts are required (refer to OVERVIEW OF CONSUMABLES)

  • (1) Engine support

Body+and+Frame

Removing the engine support

View of inside engine support.

Mark severance cut in accordance with dimension and cut.

Dimension a = approx. 110 mm from engine support edge.

Open welded connections in areas (1).

Remove partial section (2).

Body+and+Frame

Mark severance cut in accordance with dimension and cut.

Dimension a = 140 mm from cross brace bulkhead.

IMPORTANT: Cut outer metal panel only.

Open welded connections in areas (1) and (2).

Body+and+Frame

Open welded connections in areas (1).

Body+and+Frame

Open welded connections in area (1).

Body+and+Frame

Open welded connections in areas (1) and remove engine support.

Body+and+Frame

New part preparation

Mark severance cut (1) in accordance with vehicle and cut.

Open welded connections in areas (2).

Remove metal section (3).

NOTE: The metal section (3) is needed to close the engine support.

Mark severance cut in accordance with vehicle and cut.

Body+and+Frame

Adjust new parts to fit with alignment bracket or universal mounting.

Prepare REINFORCEMENT PLATES at severance cuts.

Installing engine support

Install new parts and reinforcement plates with alignment bracket or universal mount and weld.

NOTE: The bulkhead cross member (1) is filled with low-flammable cavity foam.

In case of smoke formation, stop the welding procedure and cool the welded area with compressed air if applicable.

  • (2) Bulkhead
  • (3) Engine support

Body+and+Frame

MAG-weld new part in area (1).

Length of weld seam approx. 15 mm.

Body+and+Frame

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