41 21 510 Replacing Front Left Door Pillar (Front Side Panel Removed)
Read contents of BODY, GENERAL .
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.
Spot-weld bonding is used on the E60. Observe specific procedure.
Place vehicle on straightening bench.
Following new body parts are required :
- A-pillar, outer
- Attachment, entrance, outer
- Crashbox
- Connection, side frame, bottom
- Connection, side frame, top
- Attachment, endplate
- Connection, A-pillar/roof frame
- Shaped section, A-pillar, inner
Open brazing solder and weld joints in area (1).
Remove endplate attachment (2).
Open weld joints in areas (3).
Installation:
Replace brazed seams with MAG weld seams in area (1).
Open weld joints in areas (1).
Open weld joints in area (1).
Open weld joints in areas (1) and (2).
Installation:
Weld new part in area (2) from outside with MAG weld seam.
Open weld joints in area (1).
Remove crashbox (2).
Mark severance cut (1) on outer entrance attachment and cut.
Measurement a = approx. 200 mm from edge of hole (2) dia. 20 mm.
Open weld joints in area (3).
Installation:
Weld in reinforcement plate at severance cut.
Mark severance cuts in accordance with specified measurements and cut.
Measurement a = approx. 100 mm before hole dia. 6 mm.
Measurement b = approx. 180 mm below roof edge.
Measurement c = approx. 100 mm below severance cut b.
Open weld joints in areas (1) and (3).
Remove metal section (2).
Installation:
Sheet panel (2) is needed again to seal cowl.
Weld in reinforcing panels at all severance cuts.
Bond and rivet new part in area (3).
Use Hemlock 813 blind rivet .
Double number of rivets with respect to welding spots in area (3).
Mark severance cut (1) at A-pillar/roof frame connection and cut.
Measurement a = approx. 210 mm from roof edge.
Open weld joints in areas (2).
Weld in reinforcement plate at severance cut.
Open weld joints in areas (1).
Open adhesive joints in areas (1) and (2).
Installation:
Replace adhesive in areas (1) with plug welding.
Installation:
Apply window glass adhesive to cavity acoustic baffles (1).
Apply adhesive in area (2).
Preparation of new part:
Open weld joints in areas (2).
Mark A-pillar/roof frame connection (1) in accordance with vehicle and cut.
Preparation of new part:
Open weld joints (1) at outer entrance attachment (2).
Mark severance cut (3) in accordance with vehicle and cut.
Cut off metal section (4) in accordance with measurement a from new part.
A = approx. 100 mm
Preparation of new part:
Apply window glass adhesive to cavity acoustic baffle (1).
Preparation of new part:
Place A-pillar/roof frame (1) in outer A-pillar (2) and adapt.
Weld both parts in areas (3).