Replacing Top Cowl Panel And A-Pillar, Complete Left (M4 Convertible)

Observe procedure for 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 repair.

For stripping and rigging operations, refer to texts on KSD CD (job number 41 32 101).

Place vehicle on straightening bench.

Following new body parts are required (see applicable BMW Parts Catalog):

• (1) Side frame, outer
• (2) Inner A-pillar
• (3) Cowl panel, top

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Following CONSUMABLES  are required:

Material	Quantity
Adhesive K1	1
Blind rivet N8	1
Blind rivet N9	1
Cleaning agent R1	1
Sealant D1
Cavity wax remover

Removal: 

Cut (1) according to the schematic diagram.

Remove cowl panel (2).

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View of A-pillar vehicle interior.

Loosen metal-active-gas welded connection in area (1).

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Open welded connections in areas (1).

LOOSEN  spot-welded adhesive joints in areas (2).

Release A-pillar from cavity sealing (3) and remove.

View of passenger compartment A-pillar.

Release welded connection in areas (1) and (2).

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Courtesy of BMW OF NORTH AMERICA, INC.

Open welded connections in areas (1).

Open spot-welded adhesive joints in area (2)

Remove A-pillar.

Undo brazing solder and welded connections in these areas (1).

Remove the cowl panel part section.

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Preparation of new part: 

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View inside A-pillar-outer part:

Open welded connections in areas (1) and (2).

Loosen corresponding welded connections on outer side and loosen A-pillar from outer sill.

Adjust new part to fit with alignment bracket or universal mount and secure.

The welded connection in area (2) is replaced by a bonded connection.

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Drill bore holes (2) and (3) of diameter 6.8 mm in areas (1) for blind rivet.

Remove new part and deburr holes.

All further joining areas: Prepare new part for joining by welding.

The series welding point in the range (4) is not used because of bonded rivet connection (3). Replace series welding point (4) by metal active gas weld seam in area (5). Length of weld seam 10 mm.

OBSERVE  preparation of bonding surfaces.

Installation: 

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Install new parts to fit with alignment bracket or universal fixture and secure.

Weld new part in the areas (1) and (2).

Weld new part in the areas (1) and (2).

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Courtesy of BMW OF NORTH AMERICA, INC.

Clean all bonding surfaces on vehicle and on new part with cleaning agent R1.

Apply adhesive K1 to bonding surfaces (1) to new part and vehicle.

Apply sealant to CAVITY SEALING .

Install new part with alignment bracket or universal fixture and secure.

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Install blind rivet N8 in area (1).

Install blind rivet N9 in area (2).

In areas (3) weld new part.

[4] =bonded connection.

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Weld new parts in areas (1) and (2).

(3) = Cavity sealing

Weld new part in area (1).

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Weld new part in the areas (1).

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