BMW X3 Service & Repair Manual: Replace tail panel outer section and inner 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
• (3) Luggage compartment floor, left and right

Following CONSUMABLES are required:

Remove tail panel outer section and inner section

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

Open welded connections in area (1).

Completely drill through welded connections in these areas (2).

Roughly cut out tail panel outer section and inner section.

Open welded connections in areas (1).

Open welded connections in areas (1).

View from vehicle interior.

Open welded connections in areas (1).

Remove exterior and interior tail part.

New part preparation

NOTE: The outer skin of the rear trim panel is bonded using the bonding riveting process. All other components are welded.

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

Undo welded connections and disconnect the rear trim panel support (1) from the luggage compartment floor.

Mark severance cut (1) as pictured and cut.

Remove metal section (2).

Shown on left side. Right side as mirror image.

Adjust new parts to fit and secure.

In areas (1) to (3), set 4.2 mm diameter 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 inner rear trim panel and support of rear trim panel

Install and weld new parts.

NOTE: The inner rear trim panel is welded to the outer skin of the rear trim panel in this area (1).

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).

Weld the outer skin of the rear trim panel and the inner rear trim panel to the side wall in these areas (4).

IMPORTANT: Risk of damage! Avoid exposing neighboring adhesive areas to excessive heat!

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.