BMW 7 Series: Replacing Engine Support In Front Of Bulkhead, Left

Observe procedure of REPAIR STAGE 3.

Read CONTENTS OF BODY, GENERAL.

Steel-aluminium composite construction is used on the vehicle.

Observe specific procedures for OPENING ADHESIVE BONDS, BONDING ALUMINIUM ON STEEL, and OPENING RIVETED JOINTS.

Use only approved spot-welding apparatus for repairs. Place vehicle on straightening bench.

The following new body parts are required (see BMW Electronic Parts Catalogue):

1. Engine support
2. Engine support, rear

The following consumables are required:

Removal of engine support

Open welded connections in area (1).

Drill out rivet connections in areas (1) and (2).

Important!

Do not damage aluminium spring strut dome! Drill diameter max. 6.8 mm.

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

Dimension a=140 mm

Roughly mark severance cuts (1) and cut.

Important!

Do not damage aluminium spring strut dome (2)! Heat ADHESIVE AREAS with hot air blower and release sheet sections (1) from spring strut dome.

Important!

Do not damage aluminium spring strut dome (2)! Open welded connections in area (1) and remove engine support section (2).

New part preparation

Mark severance cuts on new parts in accordance with severance cuts on vehicle and cut.

Prepare REINFORCEMENT PLATES at severance cuts.

NOTE: The following graphics serve as general illustrations of reinforcement plate repair work. They are applicable to all sectional repairs.

Mark component in accordance with dimension A and cut.

Fig. 92: Marking Component

Cut new part (1) in accordance with cut and if necessary adjust to fit with alignment bracket or universal mount.

Installation note: Maintain a distance of approximately one to no more than two material thicknesses at the severance cut to ensure welding with the reinforcement metal and enable more tolerant adjustment.

Fig. 93: Cutting New Part

Clean inner and outer sides of connection faces (1) on new part and (2) on body.

Coat insides with welding primer.

Fig. 94: Identifying Cleaning Areas

Drill bore holes (1) and (2) at distance of 25 mm to each other.

Hole diameter approx. 8 mm.

Fig. 95: Identifying Areas For Drilling Bore Holes

Make reinforcement plate (1) from trim of new part.

If applicable, produce more reinforcement plates.

Length of reinforcement plates is min. 40 mm.

Coat reinforcement plates on both sides with welding primer.

Fig. 96: Identifying Reinforcement Plate

Push reinforcement plate (1) into component on body up to half way and plug-weld (3).

Fig. 97: Positioning Reinforcement Plate

If applicable, adjust the new part (1) with the alignment bracket or universal tool and plug-weld (2).

MAG weld the joint (3).

Grind and clean weld seam and plug weld spots.

Only visible areas of the outer skin and on the carrier support must be tinned.

All areas which have covers on the vehicle are not to be tinned.

NOTE: Only applicable within the European Union: European used-vehicle regulations prohibit the use of tin containing lead in motor vehicles introduced after 01.07.2003!

Fig. 98: MAG Welding Joint

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