[GTGuy]

I picked up my new X3 M50 on Friday and I guess I didn’t pay too much attention to looking at the car for quality control issues, but this evening I was looking at the car in my garage with different lighting and I noticed a significant gap between the hood and the headlight on the left side versus the right side. Then I started looking and the whole front of the car seems to be a little bit off. I took my caliper and measured the gap and attached the pictures, you can see several millimeters of more gap on the left side of the car versus the right. I plan to contact the dealership tomorrow to see if there’s anything they can do. I’ve had many new BMWs and never had body panel misalignment like this. Has anybody else experienced this? Is this something the dealership in the body shop can repair? Or should I ask for something more drastic because I think this is unsatisfactory.

[MidnightLight]

Silly question probably... but have you already tried opening and re-closing the hood? Could it just be that the hood wasn't closed tightly?

Also: would be helpful if you can post a photo of the entire front so we can gauge the overall extent of the misalignment.

[GTGuy]

I tried the hood several times, definitely latched. Here’s a pic from earlier. A bit harder to see with the lighting but the gap on the left (left image, right/passenger side) is visible if you look closely.

[BokTroy]

Originally Posted by GTGuy

I tried the hood several times, definitely latched. Here’s a pic from earlier. A bit harder to see with the lighting but the gap on the left (left image, right/passenger side) is visible if you look closely.

There is typically a spring on both side that you can adjust it’s travel. Maybe check that as well and see if they have the same height? Otherwise take it to dealer for them to re-adjust the mechanism.

[avi66]

Good old Spartanburg QC at its best.

Take it to the dealer and have it checked and corrected if possible. BMW has a specific set of gap tolerance at certain points on the car and the permissible range can be pretty wide relatively speaking. Hence, you may just get it’s in spec excuse.

[avi66]

Originally Posted by BokTroy

There is typically a spring on both side that you can adjust it’s travel. Maybe check that as well and see if they have the same height? Otherwise take it to dealer for them to re-adjust the mechanism.

Adjusting bonnet/hood sprung catches to counter large gaps at the sides can change the centre alignment/gap across the top of the grille on some models. There are also body mounted adjustable bump stops at each on some models, but again, these can affect other alignments if adjusted too much.

The result is it’s a compromise of gaps, and may not be possible to adjust out without causing an issue elsewhere. Even BMW tolerance spec only applies to fixed points.

[Andre.j]

Hi congrats on the car. Which color is this, brooklyn grey?

[GTGuy]

Originally Posted by Andre.j

Hi congrats on the car. Which color is this, brooklyn grey?

Thanks everyone for the replies. I’ll contact the dealer today and see if I can schedule an appointment. They owe me window tint on by the front windows so I have to take it back soon.

Yes, the color is Brooklyn Grey. Interior is Mocha. Not my favorite combination, but it’s what the dealer had and I didn’t feel like placing an order this time. I really enjoy the way the vehicle drives; however, the interior piano black trim will be getting wrapped in short order.

[GTGuy]

Quick update: went by the dealership to have them look at the issue and two other X3 M50 have the same panel mismatch in the same location. Dealership acknowledged it was abnormal but it’s a manufacturing defect at Spartanburg. They are going to notify Spartanburg. The only way to fix would require disassembly of the front end.

[blackpear]

Originally Posted by GTGuy

Quick update: went by the dealership to have them look at the issue and two other X3 M50 have the same panel mismatch in the same location. Dealership acknowledged it was abnormal but it’s a manufacturing defect at Spartanburg. They are going to notify Spartanburg. The only way to fix would require disassembly of the front end.

That’s terrible. Where on earth is the QC?
I wonder how many others have gone through the assembly line like that.

[Sportstick]

Originally Posted by blackpear

I wonder how many others have gone through the assembly line like that.

Probably several to many to most at that point. The pre-volume cars are subjected to excruciating measurement to confirm body dimensions and assembly, but when volume production starts on an entirely new program, issues frequently arise. The end result you see may be the "tolerance stack" of other welds not properly dimensioned that show themselves at the hood gap. The OP's first step will be to get BMW to agree this constitutes a defect. Once that happens, remedies can be considered, ranging from repair to buy-back. No doubt, the plant (as would any plant with a new program) is collecting an issues list from plant audits and field reports from the initial production of this new model. Rather than collect them for 2026MY implementation after a new validation process, which can happen with the range of more minor issues, this one would seem more immediately susceptible to correction in body assembly for ongoing production. They (simply?) need to get back to the original specification.

[Mavus]

your right fender to hood line is not aligned and it is obvious. this is definitely a defect they need to correct.

[avi66]

Originally Posted by blackpear

That’s terrible. Where on earth is the QC?
I wonder how many others have gone through the assembly line like that.

Spartanburg QC is very hit and miss, or the acceptable “tolerance” has been set at a level that allows this as a pass.

Some posters have mentioned cars showing in QC for three weeks. Wonder if it’s related ?

[GTGuy]

How do I go about contacting BMW to notify of the issue and try and get them to agree it’s a defect? Do I have to go through the dealer? Or can I go to BMW directly? Any advice on how to document and what information I need to include would be helpful. Thanks.

[The Libertine]

Originally Posted by GTGuy

How do I go about contacting BMW to notify of the issue and try and get them to agree it’s a defect? Do I have to go through the dealer? Or can I go to BMW directly? Any advice on how to document and what information I need to include would be helpful. Thanks.

I expect the first line of communication with BMW on your behalf should be the Dealer.

[Sportstick]

Originally Posted by GTGuy

How do I go about contacting BMW to notify of the issue and try and get them to agree it’s a defect? Do I have to go through the dealer? Or can I go to BMW directly? Any advice on how to document and what information I need to include would be helpful. Thanks.

1) Have the Service Advisor write a repair order reflecting your complaint.
2) Ask the Service Advisor to schedule a review with the traveling BMW service rep for your area. Attend that meeting at the dealership.
3) Ask that BMW rep to provide you a copy of his report.

This is sufficient to establish a record to proceed. You need to decide what remedy you want to achieve…repair, replacement? I’m not advocating for either nor their likelihood, but you should tell them your expectation.

[JoeyO]

So the dealership is saying it’s abnormal and is going to notify Spartanburg. What does “notify” even mean? That’s not the same as taking “action”. No doubt, Spartanburg is going to say it’s made within specification.

BMW will never publish its maximum allowable gaps limits. So you will never really know whether they’re telling the truth or pulling your leg.

[hotwasabipeas]

Is the OP measuring the gaps when the engine and engine hood are cold or when he's been driving for awhile and the hood metal is warm/hot?

[avi66]

BMW provides detailed specification information about panel gap tolerance at specific measuring points across the vehicle.

Take note of the "no gap dimension are specified for components which cannot be adjusted" statement. Hence, something that "looks off" outside of these areas, or the tolerance is way off, is unlikely to be easily adjusted, which is probably the reason it wasn't done at plant. It's possibly more cost-effective to deliver the vehicle because the customer may not notice or complain.

Out of curiosity are the G45 hood and fenders steel or aluminium (test with a magnet) ?

Here's an example of the BMW ISTA specification and measurement guidance for the G01 front section (read from bottom up).

On the G01 the maximum deviation tolerance on the bonnet/headlight gap is +/- 1.8mm from target to be within BMW’s maximum panel GAP specification.

[avi66]

Originally Posted by GTGuy

How do I go about contacting BMW to notify of the issue and try and get them to agree it’s a defect? Do I have to go through the dealer? Or can I go to BMW directly? Any advice on how to document and what information I need to include would be helpful. Thanks.

The supplying dealership, as if you contacted BMW direct, it will likely ask you to take to the dealer for assessment.

Photos at the measuring points shown above using your micrometer would a good starting point. Your dealer should have the G45 gap dimension spec on ISTA, so should be easy to compare.

It just demonstrates the lack of attention to detail, or it is noticed, but simply ignored by plant QC and the dealer during PDI.

[ModernAngel]

This kind of crap happens too often for all makes. One of the reasons I went out and inspected all the panel gaps, panels, rubber trim, etc. on my X3 out on the lot while I waited for my SA to work the numbers.

[avi66]

Originally Posted by ModernAngel

This kind of crap happens too often for all makes. One of the reasons I went out and inspected all the panel gaps, panels, rubber trim, etc. on my X3 out on the lot while I waited for my SA to work the numbers.

Are you able to confirm if the hood, fenders and front door are aluminium or steel ?