BMW X3 Service & Repair Manual: Replacing engine support with left wheel arch in front of bulkhead

Observe procedure of REPAIR STAGE 3.

Read contents of BODY, GENERAL.

Spot-weld bonding is used on this vehicle. Observe specific procedure .

Use only approved SPOT-WELDING APPARATUS for repairs.

Place vehicle on straightening bench.

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

• (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)

Removal of engine support with wheel arch

Mark severance cut (1) roughly 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.

IMPORTANT: Cut outer metal panel only.

Open welded connections in areas (2).

Remove carrier support end plate metal section (3).

Mark severance cut (1) as pictured and cut.

Open welded connections in area (1).

Open weld joint in area (1).

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

Dimension a = 110 mm from engine support edge.

Open welded connections in area (1).

Remove partial section (2).

Mark and cut severance cut (1) at a distance of approx. 25 mm to bulkhead cross member (2).

Open welded connections in areas (3).

Remove engine support with wheel arch.

NOTE: New part is installed with overlap in area of severance cut (1).

New part preparation

Release the applicable welded connections and remove metal sections that are not needed from the new wheel arch.

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.

Perform severance cut (1) according to illustration.

Carry out severance cut (2) in accordance with severance cut on vehicle + 15 mm extra material.

Mark further severance cuts in accordance with vehicle and cut.

Prepare REINFORCEMENT PLATES at severance cuts.

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

Adjust the new A-pillar bulkhead (1) in the area of the reinforcement plate (2).

(The new A-pillar bulkhead is set onto the reinforcement plate)

Installation of engine support with wheel arch

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

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

Weld the new part to the body in the areas (1) and (2)!

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

Weld new components in area (1) additionally.

REPLACING ENTRANCE FOR FRONT RIGHT DOOR

Operation is identical to replacing FRONT LEFT DOOR ENTRANCE.

REPLACING RIGHT SIDE SILL

Operation is identical to replacing LEFT SIDE SILL.