BMW X3 Service & Repair Manual: Replacing the carrier support before the wheel arch on the left

Read contents of BODY, GENERAL.

Follow procedure for REPAIR STAGE 2.

STRIP DOWN vehicle.

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

• (1) Outer wheel arch carrier support
• (2) Carrier support, inner wheel arch section
• (3) Holder DSC (right side of vehicle only)

Following CONSUMABLES are required:

Removing carrier support

Open welded connections in area (1).

Right side of vehicle only:

Open weld joint in area (1).

Mark severance cuts in accordance with specified dimensions and cut.

IMPORTANT: Fully sever the carrier support at severance cut (1)!

Only sever outer panel at severance cut (2)!

Dimension a = approx. 40 mm from bore hole Ø 20 mm.
Dimension b = approx. 50 mm from severance cut (1).

Open welded connections in areas (3).

Remove carrier support sections.

New part preparation

Mark new part in accordance with severance cut on vehicle (1) + 20 mm extra material and cut (2).

NOTE: Install new part overlapping in area of severance cut.

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

For the severance cut, create a REINFORCEMENT PLATE (welded) from the trim of the new part.

Adjust new parts with add-on parts to fit and secure.

In areas (1) to (3), introduce Ø 6.8 mm bore holes for blind rivets N1.

In areas (1) and (2) introduce one Ø 6.8 mm bore hole for blind rivets N1.

Prepare area of overlap (1) for plug-welding.

Prepare area of reinforcement plate (1) for plug-welding.

Right side of vehicle only: Fit DSC (1) holder.

In areas (2), introduce three bore holes Ø 4.2 mm for blind rivets N3.

Remove new parts and deburr bore holes.

IMPORTANT: Structure bonding! OBSERVE preparation of bonding surfaces.

Installing carrier support

Clean all bonding surfaces with cleaning agent R1.

Apply adhesive to bonding surfaces.

Install new parts with add-on parts and rivet with blind rivets.

Plug-weld in area of overlap (1).

At severance cut additionally set 4 metal active gas weld seams each with a length of 1 cm.

Install and weld reinforcement plate in area of severance cut.

Clean bonding surfaces with cleaning agent R1.

Apply adhesive to bonding surfaces, and adjust and fix new part.

In areas (1) and (2), rivet each new part with 9 punch rivets N5.

In area of severance cut, weld new part and reinforcement plate.

IMPORTANT: Risk of damage to adhesive area! Avoid applying excessive heat to the neighboring adhesive areas!

NOTE: Do not seal new parts in adhesive rivet areas (1) and (2).

After hardening of adhesive, in areas (2) and (3) install one EMC SCREW in each case.