BMW X3 Service & Repair Manual: Replacing front left wheel arch

Follow procedure for REPAIR STAGE 3.

Read contents of BODY, GENERAL.

STRIP DOWN vehicle.

Use only approved SPOT-WELDING APPARATUS for repairs.

Place vehicle on straightening bench.

Following new body parts are required :

• (1) Wheel arch, front
• (2) Outer wheel arch carrier support
• (3) Carrier support end plate
• (4) A-pillar bulkhead
• (5) Shaped part, wheel arch carrier support (not shown)

Following consumables are required:

Removing the wheel arch

Mark severance cut (1) as pictured and cut.

OPEN spot-welded adhesive joints in area (2).

Open welded connections in area (3).

Release metal section from cavity sealing (4) and remove.

NOTE: Separating cut (1) is only required for removal.

Mark severance cut (1) as pictured and cut.

Open welded connections in areas (2).

Remove carrier support end plate metal section (3).

Mark severance cut (1) directly next to bulkhead component edge and cut.

Open welded connections in area (1).

Open welded connections in areas (1).

Open welded connections in area (1).

Open welded connections in areas (1).

Remove the wheel arch.

New part preparation

Release the applicable welded connections and separate the engine support from the wheel arch.

NOTE: Welded connections must be detached from side of engine support!

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

Open welded connections in area (3) and remove wheel arch part section.

NOTE: New part is installed and welded overlapping in area of severance cut.

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

NOTE: New part is joined in area of overlap using adhesive riveting technology.

Adjust new part wheel arch in combination with wheel arch carrier support to fit with alignment bracket or universal mount and secure.

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

In areas (1), create 4 dia. 6.8 mm bore holes for blind rivets N1.

In area (2) set 5 dia. 4.2 mm bore holes for blind rivets N3.

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

In areas (1) and (2), set dia. 6.8 mm bore holes for blind rivets N1.

In area (1) set 5 dia. 4.2 mm bore holes for blind rivets N3.

In area (2) set 5 dia. 6.8 mm bore holes for blind rivets N1.

Remove carrier support new part.

Adjust A-pillar bulkhead new part (1) and secure.

Prepare wheel arch in area of overlap (3) for joining by welding.

NOTE: Bulkhead is welded for installation in area (2).

Adjust carrier support end plate new part (1) and secure.

In areas (1) to (3), set dia. 4.2 mm bore holes for blind rivets N3.

Adjust wheel arch carrier support new part to fit with alignment bracket or universal mount and secure.

In areas (1) and (3), set dia. 4.2 mm bore holes for blind rivets N3 .

In area (2) set bore holes dia. 4.2 mm for blind rivets N6 .

Remove new parts and deburr bore holes.

IMPORTANT: Structure bonding! OBSERVE preparation of bonding surfaces.

Installation of wheel arch with bulkhead

Clean bonding surfaces with cleaning agent R1.

Apply adhesive to bonding surfaces.

Adjust wheel arch to fit with alignment bracket or universal mount and secure.

NOTE: Use wheel arch carrier support to adjust wheel arch.

But do not yet rivet wheel arch carrier support! Rivet wheel arch with blind rivets.

Remove wheel arch carrier support.

Adjust bulkhead new part A-pillar (1) and weld.

Weld wheel arch in area (2).

Set additional 15-mm long metal active gas weld seams at a distance of 20 mm to component edge (3).

Installation of end plate carrier support

Clean bonding surfaces with cleaning agent R1.

Apply adhesive to bonding surfaces.

Adjust end plate carrier support (1) and rivet with blind rivets.

Use N5 punch rivets in areas (2) and (3).

Installation of wheel arch carrier support

Clean bonding surfaces with cleaning agent R1.

Apply adhesive to bonding surfaces.

Apply sealant to new CAVITY SEALING of wheel arch carrier support.

Adjust wheel arch carrier support new part to fit with alignment bracket or universal mount and rivet with blind rivets.

Use N5 punch rivets in areas (1) to (3).

After adhesive has hardened, install one EMC screw in each case in areas (1).

In area (1) install one EMC screw.