BMW X5: Welding In Reinforcement Plate (Steel Plate)

In the case of a partial replacement piece, a body component is cut at a point described in the repair instructions.

A reinforcement plate is welded in to ensure sufficient strength.

Follow notes for welding steel parts.

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

Mark component in accordance with distance A and cut.

Fig. 21: Identifying Distance A And Cut

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

Installation:

Adhere to a gap at severance cut of approx. one to max. two material thicknesses in order to ensure welding with the reinforcement plate and to facilitate a more tolerant fit.

Fig. 22: Identifying Cutting Part

Clean inner and outer sides of connecting areas (1) on new part and (2) on body.

Coat inner sides with welding primer.

Fig. 23: Identifying Inner And Outer Sides Of Connecting Areas On Body

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

Hole diameter approx. 8 mm.

Fig. 24: Identifying Hole

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

If necessary, make further reinforcement plates.

Length of reinforcement plates is min. 40 mm.

Coat reinforcement plates (1) and (2) on both sides with welding primer.

Fig. 25: Identifying Reinforcement Plate

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

Fig. 26: Identifying Reinforcement Plate

If necessary, adjust new part (1) to fit with straightening attachment or universal mount and plug-weld (2).

MAG weld joint (3).

Grind and clean weld seam and plug weld spots.

Only visible areas of the outer skin and worn areas on the support carrier 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-car regulations prohibit the use of tin containing lead in motor vehicles introduced after 01.07.2003!

Fig. 27: Identifying Plug Weld Spots And MAG Joint

WORKSHOP EQUIPMENT

Minimum workshop equipment requirements in order to ensure the correct and expert performance of body repairs: The tools listed below must be used.

SPECIAL TOOL SPECIFICATION

IMPORTANT: In vehicles from model year 2001, higher-tensile and high-tensile steels are used in certain areas.

It is essential to check whether the spot-welding apparatus used conforms to the technical requirements of the currently recommended welding sets. Should you have any questions, please contact the country - specific Hotline.

The use of technically obsolete equipment may have serious consequences for the structure of the vehicle (e.g. in the event of a crash). In the end, this can result in safety and product liability risks which cannot be calculated.

Use and restrictions: Definition of Recommendation: All currently recommended spot welding sets comply with the requirements relating to reliable welding of today's and future BMW Group vehicles. A spot welding unit will loose its recommendation as soon as tests with materials and material combinations designated for future use in BMW Group vehicles return negative results.

All previous application before the withdrawal of the recommendation shall remain unaffected.

DEVICE DESIGNATION CHART

Application options and restrictions of above devices.

VEHICLE AND GROUP REFERENCE

NOTE: (March 2007) All models not listed can be repaired using the Group 1 and Group 2 devices.

GENERAL INSTRUCTIONS ON PAINTING

General instructions and classification of paint stages are described on the KSD-CD (notes-general information on flat rate unit data, passenger car explanation for FR specifications for painting).

The marked area serves as the starting point for painting. This area may differ from the illustration for technical painting reasons.

Touching-up areas are taken into account.

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