BMW 7 Series: Replacing Engine Support With Wheel Arch, Left

Procedure OBSERVE repair stage 3!

Read contents of BODY, GENERAL.

Steel-aluminium composite construction is used on the vehicle. Observe specific procedure Spot-weld bonding is used on this vehicle. Observe specific PROCEDURE.

Place vehicle on straightening bench.

Following new body parts are required:

1. Engine support
2. Engine support, rear
3. Wheel arch, front
4. Connection, wheel arch/entrance
5. Connection, side frame, rear
6. Shaped parts, carrier support, wheel arch, front (not shown)

Fig. 198: Identifying Engine Support, Rear Side Frame Connection And Wheel Arch/Entrance Connection

Open welded connections in area (1).

Fig. 199: Identifying Welded Connections Area

Open welded connections in area (1).

Fig. 200: Identifying Welded Connections Area

LOOSEN spot-welded adhesive joints in area (1).

Open welded connections in area (2).

Roughly cut side frame connection (3) along lines (4).

Remove side frame connection (3).

Installation note: MAG weld new part in areas (4).

To do so, apply 10 mm long fillet welds at spacing of 15 mm.

Fig. 201: Identifying Spot-Welded Adhesive Joints Area And Side Frame Connection

Open welded connections in area (1).

Installation note: Replace CAVITY SEALING (2).

Fig. 202: Identifying Welded Connections Area And Cavity Sealing

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

Dimension a = 140 mm

Installation note: Weld in REINFORCEMENT PLATE at severance cut.

Fig. 203: Identifying Reinforcement Plate Severance Cut

Drill out rivet connections in area (1).

Open BONDED CONNECTIONS in area (1).

Remove wheel arch (2) with engine support.

Installation note: Use 6 N2 RIVETS in area (1).

Glue new part with ADHESIVE K1.

Fig. 204: Identifying Bonded Connections Area And Wheel Arch

Open welded connections in area (1).

Remove metal section (2).

Fig. 205: Identifying Welded Connections Area And Metal Section

Mark severance cut (1) and cut.

IMPORTANT: Cut outer panel only.

Open welded connections in area (2).

Fig. 206: Identifying Outer Panel Severance Cut And Welded Connections Area

View of engine support from front.

Open welded connections in area (1).

Fig. 207: Identifying Front Engine Support Welded Connections Area

Open welded connections in area (1).

Remove metal section (2).

Fig. 208: Identifying Welded Connections Area And Metal Section

Preparation of new part

Open welded connections in areas (1). Remove metal section (2).

Fig. 209: Identifying Welded Connections Areas And Metal Section

Preparation of new part

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

Dimension a = 20 mm

Fig. 210: Identifying Part Cutting Dimension

Preparation of new part

Mark rear engine support in accordance with severance cut on vehicle and cut (1).

Fig. 211: Identifying Rear Engine Support Cutting Mark

Installation note:

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

Dimension a = 15 mm

Remove metal section (2).

Fig. 212: Identifying Metal Section Cutting Dimension

IMPORTANT: To avoid contact corrosion, do not grind the new wheel arch part in the area of the BONDING SURFACES.

Grind bonding surfaces on body blank.

Clean bonding surfaces with cleaning agent R1.

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

Drill new rivet holes in areas (1) and (2).

Deburr bore holes.

Use 19 N2 rivets.

Glue new part with adhesive K1.

Fig. 213: Identifying Rivet Holes Drill Areas

View from below.

Installation note: Weld new components in area (1) additionally.

Fig. 214: Identifying New Components Welding Area

Installation note:

Weld new components in area (1) additionally.

Fig. 215: Identifying New Components Welding Area

Installation note: Weld new component in area (1) additionally.

Fig. 216: Identifying New Components Welding Area

Installation note:

MAG-weld new component in area (1) additionally.

To do so, apply 2 fillet welds at distance of approx. 20 mm. Length of fillet welds approx. 10 mm.

Fig. 217: Identifying New Component MAG-Welding Area

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