318i Tech Procedure -
Door Hinge Replacement

When I purchased the car, the passenger side door would not close properly. It appeared like the bolt going through the hinge required replacement. I didn't think that it would be a big project to replace the door hinge bolt. I brought the car to the dealer to have some small, but critical items to be fixed before I could have the car inspected. I asked them to replace the bolt. They called me back the next day and told me that to fix the hinge they would have to bring it to their body shop. To fix the hinge, they told me that they would need to replace the entire hinge. Hinge replacement requires the old hinge to the unwelded from the body, the hinge to be painted, and the door to be aligned properly. The bill would be about $500. Fortunately the problem can be properly fixed for about $30.

Required tool list:
Small screw driver to remove c-clips
Hammer
Punch
Penetrating Oil
10mm socket and wrench

Requires BMW Parts:
Driver's side bottom - 41-52-1-911-894
Driver's side top - 41-52-1-911-893
Passenger side bottom - 41-52-1-911-966
Passenger side top - 41-52-1-911-965

Double check these numbers for your specific car.

Click on the thumbnails for larger pictures.

	Here is a picture of my lower passenger side hinge. Odd that the passenger side hinge has a problem when the driver's side door gets a lot more use. The circled section refers to the half of the hinge that is a pain to remove. The problem is that the bushing assembly that goes through the hinge is broken. This bushing requires replacement, not the entire hinge. Don't listen to whatever BMW dealers may say.
	Buy a hinge assembly from a dealer. The bushing can not be bought without buying the entire assembly. I purchased mine from Foreign Motors West BMW in Natick, MA for $32 with my BMWCCA discount.
	Take the new hinge apart. Pull the C-clip and washer off the end with the flat screw head. Use a ratchet and remove the hex bolt from the other side. Use a punch and hammer and push the screw head through the hinge. The screw head is useless. Don't bother trying to turn it. Here is a picture of the hinge disassembled.
	I decided to remove the door. Door removal is very easy and it makes the procedure much easier. Pull the rubber cover off the connector. Remove the connector by squeezing the tabs and pulling it straight out of the car.
	Pull the rubber gasket away from the guide hinge. Remove the C-clip from the bottom and use a bunch to push this pin out.
	Remove the hex bolts from both the upper and lower hinge. Remove the door and store it safely.
	I found a stick of eye shadow wedged in my fender. Swell.
	Here is a picture of the broken hinge bushing after I'd been hitting it with a punch and hammer for 10 minutes. Use penetrating lubricant. Mine was broken clean off so I ended up pushing it out of the hinge by hitting it downward. I also tried using a propane torch, but I'm not sure how much it helps. I ended up chipping off some paint, so I stopped using it. Just keep hammering on it. It will come out. Use some muscle.
	Here is a picture of the broken bushing.
	The hinge has a metal screen tape. The old one is probably broken. Remove it from the new hinge and put it in the hinge in the car. Put the new bushing in the car. Reinstall the door. It will line up perfectly. Smile knowing that you only spent $32 rather than $500.

Difficulty:
2/5

Disclaimer: I am not a professional mechanic. Information this page should be used at your own risk and discretion. Different models and model years may be different than my 1991 318i. Read: If you screw your car up following my instructions, sorry. Isn't it sad that in this sue crazy world you have to put a disclaimer on your web page?