BMW X5: Dash Cowl

REPLACING FRONT LEFT DOOR PILLAR (FRONT SIDE PANEL REMOVED)

Read contents of Body, General.

Spot-weld bonding is used on this vehicle. Observe specific procedure.

Remove or cover those vehicle components in the repair area which are susceptible to heat or dust.

Use only approved spot-welding apparatus for repairs! Place vehicle on straightening bench.

Following new body parts are required:

1. A-pillar, outer
2. Support carrier, wheel arch, outer
3. Shaped parts (not pictured)

Fig. 145: Identifying A-Pillar, Outer

Open weld joints in area (1).

Fig. 146: Identifying Open Weld Joints Area

Mark severance cut in accordance with measurement a and cut support carrier.

Measurement a = approx. 50 mm in front of bore dia. 20 mm.

Open weld joints in area (1)

Installation:

Weld in reinforcement plate at severance cut.

Fig. 147: Identifying Open Weld Joints Area

Fig. 148: Identifying Open Weld Joints Area

Mark severance cuts in accordance with specified measurements and cut.

IMPORTANT: Cut outer plate only for following severance cuts.

Measurement a = 160 mm from roof edge.

Measurement b = 80 mm below severance cut a.

Measurement c = approx. 150 mm before hole dia. 25 mm.

Open weld joints in areas (1) and (2).

Installation:

Sheet panel (4) is needed again to seal cowl.

Apply window glass adhesive to cavity acoustic baffles (3).

Bond and rivet new part in area (2).

Use Hemlock 813 blind rivet (sourcing reference: BMW Parts Service picture board - Aluminum and steel/bonding and welding).

Double number of rivets with respect to welding spots in area (2).

IMPORTANT: For following severance cut, do not damage sunroof water drain hose.

Mark severance cut (1) in accordance with measurement and cut.

Measurement a = approx. 200 mm from roof edge.

Fig. 149: Identifying Severance Cut Mark

Open adhesive bonds in areas (1).

Open weld joints in areas (2).

Feed out water drain hose for sliding sunroof (3).

Installation:

Do not weld new part in areas (2).

Make sure water drain hose is correctly seated.

Fig. 150: Identifying Open Weld Joints Area

Preparation of new part:

Mark new part in accordance with severance cuts above and cut.

Installation:

Adjust new part to fit with straightening attachment or universal mount.

Weld in reinforcing panels at all severance cuts.

Apply adhesive in areas (1).

Fig. 151: Identifying Adhesive Applying Area

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