BMW X3 Service & Repair Manual: Replace tail panel outer section and inner center section

Read contents of BODY, GENERAL.

STRIP DOWN vehicle.

Observe procedure of REPAIR STAGE 3.

Following new body parts are required

• (1) Rear trim, outer skin
• (2) Rear trim, inner

Following CONSUMABLES are required:

Removing the tail panel outer section and inside center section

Operation is partially described on the left side. Right side identical.

IMPORTANT: Cut outer panel only.

Cut severance cuts (1) 15 mm below the component edge of the rear bulb mount and separate.

Open welded connections in areas (2).

Remove rear trim panel outer skin.

NOTE: The new part is installed overlapping in the areas (1).

Open welded connections in areas (1).

Open welded connections in areas (1).

Remove tail panel center section.

New part preparation

Mark new part in accordance with severance cut on rear trim panel outer skin according to vehicle + 15 mm extra material and cut.

NOTE: The outer skin of the rear trim panel is bonded using the bonding riveting process.

The inner panel center section is bonded using the bonding riveting process as well as welded.

IMPORTANT:

Version with automatic tailgate actuation: Risk of damage to spindle drive: only move rear lid slowly by hand.

Mark severance cut (1) on both sides as pictured and cut.

Remove metal section (2).

Open welded connections in area (1).

Remove metal section (2) of center section.

Adjust new parts in combination with tailgate and rear lights to fit and secure.

In area (1), set four Ø 4.2 mm bore holes for blind rivets.

In areas (1) to (4), drill Ø 4.2 mm bore holes for blind rivets.

Remove new part and deburr holes.

IMPORTANT: Do not grind new parts and body in area of bonding surfaces.

Installing tail panel and inner center section

Clean all bonding surfaces on new part and on vehicle with cleaning agent R1.

Apply adhesive to bonding surfaces.

When inserting rear trim panel, make sure there is sufficient adhesive on bonding surfaces.

Install new part and rivet with blind rivets.

In areas (1) weld new part.

Weld new part in area (1).

IMPORTANT: Risk of damage! Avoid applying excessive heat to the neighboring adhesive areas.

Installing the outer skin of the rear trim panel

Clean all bonding surfaces on new part and on vehicle with cleaning agent R1.

Apply adhesive to bonding surfaces.

When inserting rear trim panel, make sure there is sufficient adhesive on bonding surfaces.

Install rear trim panel and rivet with blind rivets.

Use N4 punch rivets in areas (1) to (3).

Press rear trim panel in areas (1) and remove emerging adhesive.

Then install carrier for bumper trim to secure rear trim panel carrier.

IMPORTANT: Prevent emerging adhesive from coming into contact with support.

Do not use any cleaning agents containing solvents.

After hardening of the adhesive install 10 EMC SCREWS in the areas shown (1).