Correction
CORRECTIONOn a customer complaint basis, the following steps should be taken:
1. Match balance the rear wheel and tire assemblies.
2. Increase the rigidity of the convertible top cover.
3. Modify the way in which the rear axle carrier is mounted to the body of the vehicle (does not apply to all models).
PROCEDURE
Balancing Wheels
1. Match balance the rear wheel and tire assemblies, using approved tire balancing equipment.
NOTE:
Optimizing the tire-wheel assembly will minimize any vibrations, and contribute to the overall effectiveness of the repair.
Convertible Top Cover Rigidity
1. Park the vehicle in a location where this work can be performed, and the vehicle can be parked for at least 24 hours. After the structural foam is applied, the vehicle must not be moved during the 24 hour curing time.
2. Perform the following procedure for the left side of the storage lid. It will later be performed for the right side.
3. Follow all applicable safety precautions when performing the following repair.
4. Use a marker to make a mark on the tube at a distance of approximately A=6cm from the top of the cartridges.
5. Remove the fastening nut and sealing plug from the cartridge. Next, install the mixing nozzle (1) onto the cartridge and secure it with the fastening nut (2).
6. Install the included extension tube (1) over the end of the mixing tube (2). Use a permanent marker to mark a line (3) at a distance of B=10cm from the end of the extension tube.
7. Due to the high viscosity of the 2-part structural foam, it must be warmed in order to flow out of the cartridge properly, and into the void it is intended to fill. Place the cartridge to be used under hot running water, or in a large pail of hot water to heat the cartridge thoroughly. This should take 15-20 minutes.
8. Cut a rectangular piece of covering film to 40mm x 60mm.
9. Open the RHT until the roof panels are in the stacked position, and the convertible top cover is fully open. Install the rear module supports (Cartool number 54 0 240) to hold the storage compartment lid in the open position.
10. Structural foam will be installed in the area (1) shown in the illustration. The left side is shown and is a mirror image of the right side.
11. Mask off the inside of the luggage compartment, as well as the sides of the rear quarter panels, to protect them from being damaged during the repair.
12. Remove the cartridge assembly from the hot water, and immediately install it into the applicator.
13. Connect the recommended pneumatic applicator to a shop air supply. A pneumatic applicator is recommended, as a manual applicator can make it difficult to fully fill the necessary cavity.
14. Pull the trigger and apply a small amount to a piece of scrap material to see the rate at which the foam will come out of the applicator, and then immediately wipe off any excess material on the end of the flexible tube.
15. If necessary, adjust the regulator on the applicator so that it dispenses at a fairly slow and consistent rate.
16. Feed the flexible tube into the lower outer-most hole in the cover (1), up to the line drawn previously at 10cm.
17. Fill the cavity with approximately 60% of the cartridge. When the plungers in the cartridge have reached the line drawn previously on the outside of the cartridge in Step 4, 60% has been applied. The red indicator on the side of the applicator displays the position of the plungers.
18. Remove the flexible tube from the panel and wipe off any foam that is on the outside of the tube.
NOTE:
If any foam spills onto the outside of the cover, clean it off immediately with a clean cloth. Do not use any solvents or cleaning products to remove it.
19. If the foam was flowing very slowly prior to removing the tube from the panel, it may need to be warmed again before the remainder is applied.
20. Insert the tube into the larger hole (1) toward the inside of the panel, as shown in the illustration. The tube should be inserted until it reaches the outside edge of the hole used previously (2).
21. Peel the backing from the pre-cut square of covering film and install it over the previously used hole (1). The paper on the front of the film may also be removed.
22. Pull the trigger until the cartridge is empty.
23. Remove the tube from the storage compartment cover and wipe away any foam which may have spilled onto the outside of the cover.
24. Repeat steps 4-22 for the opposite side of the storage lid, using the 2nd foam cartridge as well as a new mixing nozzle and extension tube.
25. Allow the foam to cure for 24 hours.
Rear Axle Carrier Mounting (does NOT apply to the 335i equipped with a manual transmission)
1. Replace the rear 2 rear-axle carrier bushings per Repair Instruction RA 33 33 101.
2. While the rear axle carrier is lowered, install a damping disk to the top of each of the 4 sub-frame bushings. Ensure that the damping disk is rotated until it's fully seated on top of the respective bushing.
3. After raising the rear axle carrier, install the new stop plates to the bottom of the rear two subframe bushings.