Removing and installing/replacing sound insulation in left or right front door (Cooper Convertible)

IMPORTANT: INSTRUCTIONS for sound insulation are an essential part of these repair instructions and must be followed without fail.

Do not detach sound insulation in jerks (risk of damage).

Ensure watertightness of sound insulation after every repair (water ingress).

Preliminary work needed:

Remove DOOR TRIM PANEL .

Removal:

NOTE: Symbolic schematic diagram.
Differences in detail possible.

Position of sealing bead (1).

If necessary, feed out sound insulation (2) at cable (3).

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IMPORTANT: When cutting through sealing bead (1), do not damage sound insulation (2) and if necessary cable.
With a suitable sharp cutting tool (3) cut through sealing bead (1) of sound insulation (2) in the area to be detached.

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When refitting:

Damaged sound insulation must be replaced.

Lay butyl cord with 4 mm dia. (sourcing reference: Applicable BMW Group parts sales/catalog) over original butyl cord.

Replacement :

Remove residual butyl at the door and clean the adhesive area.

Air drying time: 1 minute

IMPORTANT: Bonding surfaces must be dry and free of dust and grease.
Once it has been cleaned, do not touch the adhesive area with bare hands.

Lay butyl cord with 6 mm dia. (sourcing reference: BMW Group parts sales) in specified adhesive area on sound insulation.

NOTE: Position of butyl cord (1) on sound insulation (2).

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NOTE: A mark (2) is provided all round on the sound insulation (1).
Butyl cord (3) rests on or inside the marking (2).
Heat butyl cord (3) (hot air blower) and press sound insulation (1) on firmly all-around.
Contact pressure with hand roller: approx. 20 N/cm
Manual contact pressure: approx. 10 N/cm

NOTE: Firm thumb pressure has approx. 30 N/cm

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Required reworking :

Remove DOOR TRIM PANEL .