41 21 003 Replacing A-Pillar With Reinforcement On Left

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Follow procedures for REPAIR STAGE 3 .

Read contents of BODY, GENERAL .

Spot-weld bonding is used on this vehicle.

Observe specific PROCEDURE .

Use only approved SPOT-WELDING APPARATUS for repairs.

Place vehicle on straightening bench.

The following new body parts are required:

(1) A-pillar, outer
(2) Middle side frame
(3) Shaped part, A-pillar, top (not shown)
(4) Shaped part, A-pillar, top inside (not shown)

Fig 1: Identifying Outer A-Pillar And Middle Side Frame
Courtesy of BMW OF NORTH AMERICA, INC.

The following consumables are required:

Material	Quantity
Blind rivet N1	1
Blind rivet N2	1

Removing the A-pillar with reinforcement

Fig 2: Identifying Cutting Dimensions, Welded Connections, Spot-Welded Adhesive Joints, And Cavity Sealing

Courtesy of BMW OF NORTH AMERICA, INC.

Mark severance cuts in accordance with specified dimensions and cut.

IMPORTANT: Cut outer panel only for following severance cuts.
Dimension "a" = approx. 200 mm from corner of roof outer skin.
Dimension "b" = approx. 90 mm from center of a 20 mm dia. bore hole.
Open welded connections in areas (1).
OPEN spot-welded adhesive joints in area (2).
Release and remove A-pillar from cavity sealing (3).

Fig 3: Identifying Welded Connections

Courtesy of BMW OF NORTH AMERICA, INC.

Undo welded connections in these areas (1) and remove the A-pillar reinforcement.

New part preparation

Mark severance cuts on new parts according to severance cuts on vehicle and sever.

Prepare REINFORCEMENT PLATES at severance cuts.

Adjust A-pillar to fit with alignment bracket or universal mount and secure.

NOTE: When adjusting, due to the absence of an outer skin, it is necessary to place a panel of equal thickness in the area of the door hinges.

Fig 4: Identifying Welded Connections

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In areas (1), set 2 bore holes Ø 6.8 mm for blind rivets.

Remove new parts and deburr bore holes.

Installing the A-pillar with reinforcement

Apply sealant to cavity sealing. See INSTALLING CAVITY SEALING (EXPANDED) and INSTALLING CAVITY SEALING (NOT EXPANDED) .

Install new A-pillar and reinforcement plates with alignment bracket or universal mount and fix.

For installation, due to the absence of an outer skin, it is necessary to place a panel of equal thickness in the area of the door hinges.

Rivet new part in areas (1) and (2).

Area (1): Blind rivet N1.

Area (2): Blind rivet N2.

Weld new part in further joint areas.

Fig 5: Identifying Areas For Riveting New Part

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Install and weld outer A-pillar and reinforcement plates.

NOTE:

Vehicles with slide/tilt sunroof: Make sure water drain hose (1) is correctly installed (watertightness).
In vehicle with a normal roof , a grommet is installed instead of the water drain hose.
Please ensure correct installation of the grommet.

Fig 6: Identifying Water Drain Hose

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