41 21 510

Work instructions: Refer to 41 00 … Notes on body repairs.

Replacing front left door column (partial replacement) (front side panel removed) BMW 3 E46

This replacement operation involves the following components:

Door pillar (A-pillar)

Replacing front left door column (partial replacement) (front side panel removed) BMW 3 E46

Connecting plate, side frame

Replacing front left door column (partial replacement) (front side panel removed) BMW 3 E46

Sealing, connection, side frame

 

Caution!

Remove or cover up other vehicle components in the repair zone which are at risk from heat, flying sparks and dust.

Determine and mark upper cowl panel cutting line.

Measurement (A) = 140 mm from roof edge.

Measurement (B) = 90 mm from center of bore for trim strip.

  1. = Roof edge
  2. = Bore for trim strip

Expose and drill out welding spots in windshield frame.

Assembly, cowl panel:

  1. = Water drainage pipe, slide/tilt sunroof
  2. = Reinforcement, cowl panel
  3. = Cowl panel

Caution!

Carefully cut cowl panel.

Do not damage sunroof water drainage pipe.

Note:

Possibility of repair for water drainage pipe, slide/tilt sunroof, through hose, refer to BMW Parts Service.

Define separating point in cover for side member and mark out.

Measurement (A) = 25 mm from 2nd bore for finishing strip, entrance.

  1. = 1st bore for finishing strip, entrance
  2. = 2nd bore for finishing strip, entrance

Drill out welding spots in door opening.

Drill out welding spots on door pillar (A-pillar), inside, in upper area of door retaining strap.

Drill out welding spots on door pillar (A-pillar), inside, in lower area of door retaining strap.

Clean connection face at cover for side member from interior.

Open weld seams on cover for side member for door pillar (A-pillar) from interior.

Expose and open welding spots on floor plate.

Open weld seam on connection point, windshield frame/door pillar.

Drill out welding spots on connecting plate, side frame, and acoustic baffle, connection, side frame.

Remove acoustic baffle, connection, side frame.

Drill out welding spots on connecting plate, side frame.

Remove connecting plate, side frame.

Drill out connection points, door pillar (A-pillar) on body, inside, in area of door opening of door retaining strap.

At door hinge, top, cut open door pillar and open welding spot.

Caution!

Do not use a naked flame for heating!

Fire hazard!

Extract vapors and provide good ventilation.

Note:

The sunroof water drainage pipe is secured in position by a foam jacket in the body.

To facilitate removal, the area around the foam surface can be heated gently.

Foam jacket, sunroof water drainage pipe, in body.

Remove door pillar (A-pillar) Remove scrap metal.

Remove adhesive residue.

Straighten and grind connection points.

In vehicles before 6/2002 drill out reinforcement (1).

Reinforcement has been modified and is now located in the spare part.

Mark out and cut partition area for door pillar spare part for cowl panel, top.

1..4 = Bores for trim strip

Measurement (A) = 80 mm from 4th bore for trim strip.

Mark out and cut partition area for door pillar spare part for cover for side member.

Measurement (A) = 140 mm.

  1. = 1st bore for finishing strip, entrance
  2. = 2nd bore for finishing strip, entrance

Make reinforcement plate from remaining metal sheet for cowl panel connection, top.

Width approx. 40 mm.

Make reinforcement plate from remaining metal sheet for cover connection for side member.

Width approx. 60 mm.

Coat connection faces on reinforcement plate and body with zinc dust paint.

At door pillar spare part (A-pillar), clean connection faces and coat with zinc dust paint.

Drill holes for plug welding at reinforcement plates, connection point, cowl panel, top, and cover for side member.

At door pillar spare part (A-pillar), clean connection faces and coat with zinc dust paint.

Fit reinforcement plates, cowl panel, top and cover for side member with 1/2 width each in connection points of body, locate in position and weld up.

Grind down welded surfaces.

Install shaped part for cavity acoustic baffle, cowl panel, top: Procedure and materials, refer to 41 00 … Installing shaped parts for cavity acoustic baffle, except cover for frame member.

Short summary:

Gently bend open retaining lug (1) for securing shaped part so that shaped part can be attached.

Clean bearing surface (2) of shaped part for cavity acoustic baffle on body and on door pillar (A-pillar) spare part.

Clean shaped part for cavity acoustic baffle (1).

Coat shaped part for cavity baffle (1) with recommended window adhesive and attach with lug (2) to retaining lug (3).

Bend back retaining lug with shaped part for cavity acoustic baffle up to bearing surface on door pillar (A-pillar) spare part.

Shaped part for cavity acoustic baffle must be positioned 90° to plate of door pillar (A-

pillar).

Check sealing with window adhesive; if necessary, reseal with window adhesive.

Then place window adhesive on shaped part for cavity acoustic baffle.

Installing shaped part for cavity sealing, sunroof water drainage pipe: Procedure and materials, refer to 41 00 … Installing shaped parts for cavity acoustic baffle, except cover for frame member.

Short summary:

Cut off lug.

Protect polished areas against rust.

Clean bearing surface of shaped part for cavity acoustic baffle on body and on door pillar

(A-pillar) spare part.

Clean shaped part for cavity sealing.

Coat shaped part for cavity acoustic baffle with recommended window adhesive.

Install shaped part for cavity acoustic baffle in door pillar (A-pillar) spare part.

Check sealing with window adhesive; if necessary, reseal with window adhesive.

Then apply window adhesive to shaped part for cavity sealing and opening for sunroof water drainage pipe.

Coat contact surface of shaped part for cavity sealing on sunroof water drainage pipe with recommended window adhesive so as to guarantee a complete seal.

Remove door pillar (A-pillar), locate in position and weld up.

Weld up reinforcement plates.

At connection point

Cowl panel, side, top Cover for side member arrange individual welding spots so tightly together that a sealed seam is created.

Locate welding spots in a way which prevents distortion caused by heat elongation.

Ensure that welded areas have cooled down sufficiently.

Grind down welding surfaces on connection points of door pillar (A-pillar).

Coat connection point, cowl panel, top, and cover for side member with tin and grind down.

Note:

Carefully seal sunroof water drainage pipe so as to prevent water from leaking into passenger compartment!

Seal sunroof water drainage pipe with window adhesive.

Fit side frame connecting plate and mark out holes for plug welding.

Remove connecting plate, side frame.

Drill holes for plug welding connecting plate, side frame.

Clean connection faces on connecting plate, side frame, and on body and coat with zinc dust paint.

Fit side frame connecting plate, locate in position and weld up.

Replacing front left door column (partial replacement) (front side panel removed) BMW 3 E46

Fit acoustic baffle, connection, side frame, and mark out holes for plug welding.

Replacing front left door column (partial replacement) (front side panel removed) BMW 3 E46

Remove acoustic baffle, connection, side frame, and drill holes for plug welding.

Clean connection faces on acoustic baffle, connection, side frame, and on body and coat with zinc dust paint.

Replacing front left door column (partial replacement) (front side panel removed) BMW 3 E46

Fit acoustic baffle, connection, side frame, locate in position and weld up.

Grind down welded surfaces.