41 21 510 Replacing Front Left Door Pillar (Front Side Panel Removed)

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Read contents of BODY, GENERAL .

Spot-weld bonding is used on this vehicle. Observe specific procedure , see 41 00... Opening bonded connections and 41 00... Spot-weld bonding steel parts .

Remove or cover those vehicle components in the repair area which are susceptible to heat or dust.

Use only approved spot-welding apparatus for repairs WORKSHOP EQUIPMENT !

Place vehicle on straightening bench.

Following new body parts are required:

(1) A-pillar, outer
(2) Support carrier, wheel arch, outer
(3) Shaped parts (not pictured)

Fig 1: Identifying A-Pillar And Support Carrier

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Open weld joints in area (1).

Fig 2: Identifying Weld Joints Area

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Mark severance cut in accordance with measurement a and cut support carrier.

Measurement a = approx. 50 mm in front of bore dia. 20 mm.

Open weld joints in area (1).

Installation:

Weld in reinforcement plate at severance cut, see 41 00... Welding in reinforcement plate (steel plate) .

Fig 3: Identifying Weld Joints Area

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Fig 4: Identifying Cut Mark Area And Weld Joints Area

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Mark severance cuts in accordance with specified measurements and cut.

IMPORTANT: Cut outer plate only for following severance cuts.

Measurement a = 160 mm from roof edge.

Measurement b = 80 mm below severance cut a.

Measurement c = approx. 150 mm before hole dia. 25 mm.

Open weld joints in areas (1) and (2).

Installation:

Sheet panel (4) is needed again to seal cowl.

Apply window glass adhesive to cavity acoustic baffles (3), see 41 00... Installing a cavity acoustic baffle (expanded) and 41 00... Installing a cavity acoustic baffle (not expanded) .

Bond and rivet new part in area (2), see 41 00... Bonding steel on steel .

Use Hemlock 813 blind rivet (sourcing reference: BMW Parts Service picture board - Aluminum and steel/bonding and welding).

Double number of rivets with respect to welding spots in area (2).

IMPORTANT: For following severance cut, do not damage sunroof water drain hose.

Mark severance cut (1) in accordance with measurement and cut.

Measurement a = approx. 200 mm from roof edge.

Fig 5: Identifying Cut Mark Area

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Open adhesive bonds in areas (1).

Open weld joints in areas (2).

Feed out water drain hose for sliding sunroof (3).

Installation:

Do not weld new part in areas (2).

Make sure water drain hose is correctly seated.

Fig 6: Identifying Weld Joints Area And Adhesive Bonds Areas

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Preparation of new part:

Mark new part in accordance with severance cuts above and cut.

Installation:

Adjust new part to fit with straightening attachment or universal mount.

Weld in reinforcing panels at all severance cuts, see 41 00... Welding in reinforcement plate (steel plate) .

Apply ADHESIVE in areas (1).

Fig 7: Identifying Adhesive Areas

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