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

Read contents of Body, General . See 41 0 CONTENTS OF BODY, GENERAL .

Spot-weld bonding is used for the first time on the E65. A specific procedure must be followed here.

Place vehicle on straightening bench.

Following new body parts are required:

(1) Support carrier, wheel arch, outer
(2) Connecting plate, side frame
(3) A-pillar, outer
(4) Attachment, entrance, outer

Fig 1: Identifying Support Carrier, Connecting Plate, A-Pillar And Attachment
Courtesy of BMW OF NORTH AMERICA, INC.

Open weld joints in areas (1).

Remove support carrier (2).

Fig 2: Identifying Weld Joints Areas And Support Carrier

Courtesy of BMW OF NORTH AMERICA, INC.

Open weld joints in area (1).

Fig 3: Identifying Weld Joints Areas

Courtesy of BMW OF NORTH AMERICA, INC.

Mark severance cut (1) on outer entrance attachment and cut.

Measurement a = approx. 50 mm from edge of hole (2) dia. 30 mm.

Open weld joints on section (3) of outer entrance attachment.

Fig 4: Identifying Severance Cut Mark And Weld Joints On Section

Courtesy of BMW OF NORTH AMERICA, INC.

View: wheel arch, front

Open weld joints in areas (1).

Fig 5: Identifying Weld Joints Areas

Courtesy of BMW OF NORTH AMERICA, INC.

Fig 6: Identifying Measurement, Sheet Panel And Weld Joints Areas

Courtesy of BMW OF NORTH AMERICA, INC.

Mark severance cuts in accordance with specified measurements and cut.

Measurement a = approx. 150 mm before rectangular hole 10 mm x 6 mm.

CAUTION: Cut outer plate only for following severance cuts.

Measurement b = approx. 120 mm below roof edge.

Measurement c = approx. 80 mm below severance cut b.

Open weld joints in areas (1).

Installation:

Sheet panel (2) is needed again to seal cowl.

Fig 7: Identifying Measurement, A-Pillar Bonded Areas

Courtesy of BMW OF NORTH AMERICA, INC.

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

Mark severance cut a and cut.

Measurement a = approx. 150 mm below roof edge.

A-pillar is bonded to inner frame in areas (1).

Preparation of new part:

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

Installation information:

On all severance cuts, weld in reinforcing plates approx. 30 mm long. See 41 00... WELDING IN REINFORCEMENT PLATE (STEEL PLATE) .

Apply adhesive in areas (1). See 41 00... BONDING STEEL PARTS .

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

Fig 8: Identifying Adhesive Areas And Cavity Acoustic Baffles

Courtesy of BMW OF NORTH AMERICA, INC.