BMW X3 Service & Repair Manual: Replacing A-pillar with reinforcement on the left (with side member attachment)

BMW X3 Service & Repair Manual / Body and Frame / Side frame and door pillars / Replacing A-pillar with reinforcement on the left (with side member attachment)

Procedure OBSERVE 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:

  • (1) A-pillar with entrance
  • (2) Middle side frame
  • (3) Carrier support, outer wheel arch section
  • Shaped part A-pillar, top, outer
  • Shaped part A-pillar, bottom, outer

Body+and+Frame

Following CONSUMABLES are required:

Body+and+Frame

Removal: Mark severance cut in accordance with dimension and cut.

IMPORTANT: Cut outer panel only.

Dimension a = approx. 120 mm from hole Ø 6 mm.

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

Open welded connections in area (2).

Remove partial section of carrier support.

Body+and+Frame

Mark severance cuts in accordance with specified dimensions and cut.

IMPORTANT: Cut outer panel only for following severance cuts.

Dimension a = approx. 420 mm in front of hole Ø 20 mm.
Dimension b = approx. 450 mm from roof edge.

Body+and+Frame

Open welded connections in areas (1).

Open spot-welded adhesive joints in area (2) Release section of A-pillar outer skin from cavity sealing (3) and remove.

Mark severance cut (1) as pictured and cut.

IMPORTANT: Cut outer panel only.

Open welded connections in area (1).

Body+and+Frame

Open welded connections in area (1).

Remove reinforcement (2).

Body+and+Frame

View of A-pillar interior.

Open welded connections (1).

Open bonded connection in area (2).

Body+and+Frame

Open weld joint in area (1).

Body+and+Frame

Roughly mark severance cut (1) as pictured and cut.

Remove metal section (2).

Body+and+Frame

Open welded connections (1).

NOTE: The welded connections (1) are replaced by adhesive rivet connections.

Body+and+Frame

Body+and+Frame

Open welded connections in areas (1).

Release A-pillar from cavity sealing (2) and remove.

Mark severance cut in accordance with dimension and cut.

IMPORTANT: Cut outer panel only.

Dimension a = approx. 120 mm from bulkhead.

Release welded connections in areas (1) and (2) and remove side member attachment with reinforcement.

Body+and+Frame

NOTE: The welded connections in areas (1) are replaced by adhesive rivet connections.

Preparation of new part: Open welded connections (1) and remove reinforcement.

Mark severance cut (2) in accordance with severance cut on vehicle and cut.

NOTE: The reinforcement (1) is used for installation.

Body+and+Frame

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

Prepare REINFORCEMENT PLATES at severance cuts.

Adjust A-pillar to fit with alignment bracket or universal mount and secure.

In areas (1), introduce 9 holes of Ø 6.8 mm for adhesive rivet connection.

For drilling the holes, use TWIST DRILL 6.8 X 156 mm.

Body+and+Frame

In areas (1), introduce 2 holes of Ø 6.8 mm for adhesive rivet connection.

Remove new parts and deburr bore holes.

Body+and+Frame

IMPORTANT: Structure bonding! OBSERVE preparation of bonding surfaces.

Installation: Clean bonding surfaces with cleaning agent R1.

Apply adhesive to bonding surfaces.

Apply sealant to cavity sealing .

Install new A-pillar and reinforcement plates with alignment bracket or universal mount and fix.

Rivet new part in the areas (1).

Body+and+Frame

Rivet new component in area (1).

If possible move rivets from vehicle interior to the outside.

Weld A-pillar.

Body+and+Frame

Install further new parts and reinforcement plates and weld in place.

REPLACING A-PILLAR WITH REINFORCEMENT, RIGHT

The work is identical to replacing the A-PILLAR WITH LEFT REINFORCEMENT.

REPLACING OUTER RIGHT A-PILLAR

Operation is identical to replacing OUTER LEFT A-PILLAR.

    Replacing A-pillar with reinforcement on left
    Procedure OBSERVE repair stage 3! Read contents of BODY, GENERAL. Spot-weld bonding is used on this vehicle. Observe specific PROCEDURE. Use on ...

    Roof outer skin
    ...

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