SECTION 18: BODY
DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
55
FIGURE 49: ZONE 7
18630
15.7.1 X3 SMOOTH SIDE PANEL REPLACEMENT PROCEDURE
Material:
Anti-silicone (682989)
Scotchbrite gray (680226)
Sika 221 gray
CHIX cloth (682384)
Sika 205 1liter (683097)
Sika 252 black
Blue cloth (682383)
Equipment:
Glue gun
Pencil
SECTION 1 SMOOTH SIDE PANEL REMOVAL
1.00
REMOVAL
A) Remove finishing molding. Insert a screwdriver into
snap-on finishing molding joint. Bend finishing
molding enough to be able to fix a pair of locking
pliers. Using the pair of locking pliers, pull the
stainless steel molding and at the same time
gradually cut Sika bead with a sharp knife.
Be careful not to damage the adjacent
surfaces.
B) Using a hammer and punch, drive out rivet shanks
from top and bottom and from front and rear finishing
molding supports. Use a #11 titanium drill bit to
remove rivet heads.
C)
Grind tig weld spots at each end of side panel.
D)
Safely support or temporary fix side panel.
Warning: Panel weights over 200 pounds
E)
Insert a flat screwdriver between the side panel and
the vehicle chassis, in the top left and right corners.
Make sure to separate side panel from structure.
Be careful not to damage the adjacent
surfaces.
F)
Use the c-clamp to separate the side panel from the
back structural panel and at the same time gradually
cut Sika bead with a sharp knife.
Ideally, the hoist or chain block must be
fastened to the floor while pulling from a 45
o
angle so as not to damage the vehicle
structure
G) Remove as much glue as possible from the structure
using a putty knife or pneumatic knife without
damaging 206 G+P primer.
Never heat SikaFlex adhesive to remove.
H) Check panel horizontal supports for straightness
using a straight edge. Take measurements with a
ruler.
Tolerance : 1mm towards the outside and
1.5mm towards the inside.
