41 32 101 Completely Replace The Top Cowl Panel And A-Pillar

Observe procedure for repair stage 3. See 41 00 REPAIR TECHNIQUES, REPAIR STAGE 3 .

Read contents of 41 00... 0 CONTENTS OF BODY, GENERAL .

Spot-weld bonding is used on this vehicle. Observe specific procedure. See 41 00... SPOT-WELD BONDING STEEL COMPONENTS .

Use only approved spot-welding apparatus for repairs. See 41 00... WORKSHOP EQUIPMENT (BMW AND MINI VEHICLES) .

Place vehicle on straightening bench.

Following new body parts are required (refer to 41 00... OVERVIEW OF CONSUMABLES ):

• (1) Outer side frame
• (2) Reinforcement, A-pillar, inner
• (3) Cowl panel, top
• (4) Shaped part, carrier support, wheel arch, front (not shown)
• (5) Shaped part, carrier support, wheel arch (not shown)

Following consumables are required:

Fig 1: Identifying Outer Side Frame, Reinforcement, A-Pillar, Inner And Top Cowl Panel

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Removing the top cowl panel and A-pillar 

Roughly mark severance cuts (1) and cut.

Open welded connections in areas (2).

Open spot-weld adhesive joints in area (3)

Loosen side frame from cavity sealing (4) and remove.

Remove cavity sealing (4).

Fig 2: Identifying Mark Severance Cuts And Welded Connections Areas

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Roughly cut out crash support (1).

Fig 3: Identifying Crash Support

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Fig 4: Identifying Weld Point Connections And Spot-Welded Adhesive Joints Areas

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Drill 3 weld point connections (1) with drill Ø 6.8 mm.

Remove remaining areas of the 3 weld point connections (1) through grinding.

Create 2 bore holes Ø 6.8 mm as per specified dimensions.

Dimension a = 50 mm from center point of bore hole (1).

Dimension b = 35 mm from center point of bore hole (1).

Loosen spot-welded adhesive joints in areas (2). See 41 00... OPENING BONDED CONNECTIONS .

View of A-pillar in passenger compartment.

Undo metal active gas welded connections in areas (1).

Fig 5: Identifying Metal Active Gas Welded Connections Areas

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Cut (1) according to the schematic diagram.

Remove cowl panel (2).

Fig 6: Identifying Cowl Panel

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Mark severance cut in accordance with dimension and cut.

Dimension a = approx. 265 mm from the edge of the A-pillar component.

Open spot-welded adhesive joints in area (1)

Open welded connections in areas (2).

Fig 7: Identifying Edge Of A-Pillar Component Dimension

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

Open weld joints in area (2) and remove sheet section.

Release bonded connection (3).

Fig 8: Identifying Mark Severance Cut And Weld Joints Area

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

Remove sheet section.

Undo bonded connection (2) and remove A-pillar.

Fig 9: Identifying Mark Severance Cut And Bonded Connection

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Open welded connections in areas (1).

Open spot-weld bonded joints in areas (2).

Remove reinforcement on A-pillar.

Fig 10: Identifying Spot-Weld Bonded Joints Areas

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

Remove section of the cowl panel (2).

Fig 11: Identifying Cowl Panel Section And Welded Connections Areas

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New part preparation 

Mark a severance cut from the lateral frame towards the vehicle and cut it from the new part.

Prepare reinforcement plate at severance cut. See 41 00... WELDING IN REINFORCEMENT PLATE (SHEET STEEL) .

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

Fig 12: Identifying Blind Rivet Bore Hole

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In area (1), drill bore hole Ø 6.8 mm for blind rivet N2.

Set bore hole centrally through hole (2).

For drilling the holes, use twist drill 6.8 x 156 mm. See 41 00... OVERVIEW OF CONSUMABLES  (8.0 Twist Drill).

During removal, transfer created bore holes (1) and (2) to new part.

For this, drill new part through holes (1) and (2) with drill Ø 6.8 mm.

Fig 13: Identifying Transfer Created Bore Holes

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Fig 14: Identifying Blind Rivets Bore Holes Areas

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In areas (1), set bore holes Ø 6.8 mm for blind rivets N1.

Drill bore holes centrally between the welding spots (2).

During removal, transfer created bore holes (1) for blind rivets N1 to new part.

Drill new part through holes (1) with drill Ø 6.8 mm.

Remove new part again and deburr bore holes.

Fig 15: Identifying Blind Rivets Bore Holes

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Fitting cowl panel and A-pillar 

• Install new parts and reinforcement for A-pillar with alignment bracket or universal mount and weld.
• Apply cavity sealing to both cavity sealings. Fit cavity sealings. See 41 00... INSTALLING CAVITY SEALING (NOT EXPANDED) .
• 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.

Coat cavity sealings with sealant.

Install new part for the lateral frame and the reinforcement panel using an alignment bracket or a universal mount and affix.

Fig 16: Applying Adhesive K1 To Bonding Surfaces To Part And Vehicle

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In area (1), rivet new part with blind rivet N2.

Fig 17: Identifying Blind Rivet Area

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Rivet new part in areas (1) with blind rivets N2  .

In area (2), use blind rivet N1  .

Fig 18: Identifying Blind Rivets Areas

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In areas (1), rivet new part with blind rivets N1.

Fig 19: Identifying Blind Rivets Areas

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In areas (1), rivet new part with blind rivets N1.

Fig 20: Identifying Blind Rivets Areas

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Weld new part in remaining joint areas.