Table of Contents E93 Introduction Subject Page The 3 Series Convertible .3 Dimensions and Weight.3 Bodyshell.4 Strut Concept.8 Diagonal Strut, Engine Compartment.9 Spring Tower Strut .9 Underbody Struts.10 Aerodynamics.12 J oint Reduction .12 Side Panel.13 Doors .13 Important Body Equipment.14 Partition Module .14 Seats .15 Ski Bag .15 Rear Bag.16 Accident Repairs .16 Accident Damage: Replacing boot lid .16 Accident Damage: Replacing rear apron .16 Accident Damage: Replacing rear left or rightframe side member.16 Initial Print Date: 04/07 Revision Date: Introduction Model: E93 Production: From Start of Production ■MICTIWIS After completion of this module you will be able to • Understand dimensional changes of the E93 • Understand basic body construction of the E93 • Understand changes to seating on the E93 2 E93 Introduction The 3 Series Convertible With the 3 Series Convertible, customers have always enjoyed the exhilarating feeling of driving with the top down. The E93 consistently continues this line while adopting the sporty characteristics of the E92. This sport-orientated performance is reflected in the deep-drawn front and the wide, flat rear. New engines, an even more rigid body with 19 Hz torsion frequency (torsional rigidity) and a sophisticated strut, chassis and suspension concept support the sports character. Dimensions and Weight In terms of dimensions, the E93 is larger compared to the E46/C. The E93 is 4580 mm long, 1782 mm wide and 1384 mm high.The weight has also increased from 1565 kg (E46)to 1655 kg (E93). E93 Introduction Bodyshell By using high-strength materials, the philosophy of lightweight body construction has been consistently realized in the E93. E93 Use of Body Materials 4 E93 Introduction E93 Use of Body Materials Index Explanation Index Explanation 1 DC 03/04 6 HC 600 c/HD 680 C/HC 680 C 2 HC 180 BD/HC 220 BD 7 22 M n B5, Docol 1000 DP 3 HC260 BD/HC 300 BD 8 Plastics 4 HC 400TD/HC 380 LAD 9 Other 5 HC 420 LAD 5 E93 Introduction E93 Use of Body Materials Index Explanation Index Explanation 1 DC 03/04 6 HC 600 c/HD 680 C/HC 680 C 2 HC 180 BD/HC 220 BD 7 22 Mn B5, Docol 1000 DP 3 HC260 BD/HC 300 BD 8 Plastics 4 HC 400TD/HC 380 LAD 9 Other 5 HC 420 LAD 6 E93 Introduction Higher dynamic forces are introduced into the body structure while driving due to the runflat tires and harder suspension setup in the E93 compared to the E46/C. Consequently, the rigidity targets have been raised even further compared to the E46/C. Torsional Rigidity E46/C E93 Dynamic 17.5 Hz 19 Hz Static 11500 Nm/° 14500 Nm/° The sill represents the decisive load path from the front end to the rear end. A horizontal flange is used between the inner and outer sill shell in orderto optimally utilize the available package space for bending and torsional rigidity. The sill is reinforced with trans¬ verse bulkheads. To effectively absorb stress and strain, the outer skin panel of the sill is designed as a flexibly rolled sheet metal component with wall thickness varying between 2.00 mm and 3.00 mm. The greatest wall thickness is at the nodes forthe A and B-pillars. With minimum weight, the partition is an assembled module that provides a large, customer-friendly load space. Also in this area, the main load paths run via struts. 7 E93 Introduction Strut Concept A strut concept is employed with the aim of increasing the body rigidity, consisting of: • Front end struts • Spring strut tower - bulkhead - struts • Front axle subframe - struts • Tension struts at rear • Strut in rollover protection system The cross section ofthe sill has been additionally increased compared to the E92. Index Explanation Index Explanation 1 Diagonal strut, engine compartment 5 Underbody strut 2 Front axle subframe struts 6 Strut in rollover protection system 3 Spring tower strut 7 Tension strut 4 Sill 8 E93 Introduction Diagonal Strut, Engine Compartment Index Explanation 1 Mounting points of diagonal strut S pring Tower Strut Index Explanation Index Explanation 1 Bulkhead mounting 2 Wheel arch mounting 9 E93 Introduction Underbody Struts Index Explanation 1 M ounting points of underbody strut, front 10 E93 Introduction joa. 11 E93 Introduction Aerodynamics The outstanding aerodynamic qualities ofthe 3 Series Coupe have been transferred to the 3 Series Convertible. Ultimately, a drag coefficient cx = 0.29 was realized on the 325i. J oint Reduction The size ofthe joint gaps has been reduced on the E93. 1 ) 12 9 8 7 6 5 4 3 Index Explanation Index Explanation 1 5.0 +/- 0.1 mm 6 2.5 +/- 0.6 mm 2 4.0 +/- 1.0 mm (previously 6.0 +/- 1.2 mm) 7 3.8 +/- 0.9 mm (previously 5.0 +/- 1.9 mm) 3 4.2 +/- 0.7 mm (previously 5.2 +/- 0.7 mm) 8 4.0 +/- 1.2 mm (previously 6.0 +/- 1.2 mm) 4 3.8 +/- 1.0 mm (previously 3.8 +/- 2.8 mm) 9 Trim strip offset 5 4.2 +/- 1.2 mm (previously 5.0 +/- 1.2 mm) 12 E93 Introduction Side Panel The side panel of the E93 is made from thermoplastic material. It is common part from the E92. The advantage of a plastic side panel is the weight reduction of approximately 3 kg compared to a side panel made from steel. Minor bumps are absorbed. Doors From a workshop point of view, the doors of the E93 are the same as the doors of the E92. All assembly and installation work corresponds to that of the E92. The doors of the E93 are also based on a lightweight steel construction. The anti-corro¬ sion concept with a 2C PVC seal is the same as on the E92. 13 E93 Introduction Important Body Equipment • Retractable three-piece hardtop (see reference material "Retractable hardtop E93") • Folding rear seat backrest with storage compartment • Concealed antennas • Easy-load luggage compartment • Wind deflector with new functionality • Multifunctional ski bag with largerthrough-load width (380 mm instead of 250 mm) Partition Module The partition module consists ofthe aluminum cross member section with nodes and corresponding struts as well as the rollover protection system. The partition module additionally contains the control units forthe Convertible top module (CTM), park distance control (PDC), Passive Go and rollover control (ROC). 14 E93 Introduction Seats A special feature of the front seats in the E93 is the seat-integrated seat belt system. This system is known from the E46 and E64. A new feature of the leathertrim finish is so-called cool leather, i.e. sun reflective technology. This technology involves a change in physical properties by introducing modified color pigments in the leather, thus achieving a clearly noticeable temperature difference of up to 20°C (on black leather). The folding rear seat backrest is a new development in the E93. Ski Bag The considerably larger ski bag provides the option of storing skis, snowboards as well as a golf bag. The volume of the luggage compartment is 350 liters and 210 liters with the top down. The front cover of the ski bag is hinged such that it can be opened even when the backrest is in the upright position. In this position, a restricted through-load opening can be used while simultaneously carrying four persons. The full cross section of the through-load area can be used when the backrest is folded down. The front cover can be detached by means of an adapter system so as to increase the loading cross section even further. Item Dimension Loading width 405 mm Loading height 263 mm Ski bag length 1300 mm Ski bag volume approximately 0.13 15 E93 Introduction Rear Bag The rear bag has been specially developed forthe E93 forthe purpose of transporting items of luggage, clothing and other items in a clean and dry condition and to protect them from nosy-parkers when the top is down. The bag is fixed to the vehicle so that it and the contents remain secure even during sudden braking. It fits conveniently under the wind deflector. Accident Repairs The following procedures must be complied with in the event of accident damage in the vicinity of the retractable hardtop: Accident Damage: Replacing boot lid Procedure - Check kinematic rear end module, support tube and coupling locks and main mount of roof module, including Convertible top compartment lid for damage and replace as required. Accident Damage: Replacing rear apron Procedure - Remove and install rear end module for retractable hardtop to perform weld¬ ing jobs (accessibility of welding tong at weld). Check both main mounts, support tube and coupling locks when removed fordamage and replace as required. Accident Damage: Replacing rear left or right frame side member Procedure - Remove and install rear end module for retractable hardtop to perform weld¬ ing jobs (accessibility of welding tong at weld). Check both main mounts, support tube and coupling locks when removed fordamage and replace as required. 16 E93 Introduction