BMW X3 Service & Repair Manual: 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

Following CONSUMABLES are required:

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.

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.

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).

Open welded connections in area (1).

Remove reinforcement (2).

View of A-pillar interior.

Open welded connections (1).

Open bonded connection in area (2).

Open weld joint in area (1).

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

Remove metal section (2).

Open welded connections (1).

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

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.

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.

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.

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

Remove new parts and deburr bore holes.

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).

Rivet new component in area (1).

If possible move rivets from vehicle interior to the outside.

Weld A-pillar.

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.