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41 21 003 Replacing A-Pillar With Reinforcement On Left (Non-Hybrid)

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Procedure OBSERVE  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.

Following new body parts are required (refer to ELECTRONIC PARTS CATALOGUE ):

Following CONSUMABLES  are required:

Material Quantity
Adhesive K1 1
Blind rivets N7 3
Blind rivets N3 2
Cleaning agent R1 1
Sealant D1  
Cavity wax remover  

Removing the A-pillar with reinforcement 

Roughly cut side frame connection along lines (1).

LOOSEN  spot-welded adhesive joints in areas (2).

Open welded connections in areas (3).

Release side frame connection from cavity sealing (4) and remove.

Open remaining welded connections in areas (1).

Fig 2: Releasing Side Frame Connection From Cavity Sealing
G06890392Courtesy of BMW OF NORTH AMERICA, INC.
Fig 3: Identifying A-Pillar With Reinforcement Severance Cutting Dimension
G06890538Courtesy 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 = 200 mm from roof edge.
Dimension b = 100 mm below severance cut a.
Dimension c = approx. 165 mm before center of hole dia. 15 mm.
Dimension d = 140 mm before severance cut c.
Open welded connections in areas (1).
Remove sheet sections (2).
NOTE: Cut-out metal sections (2) are required again for sealing.
IMPORTANT: For following severance cut, do not damage slide/tilt sunroof water drain hose.
Cut outer panel only.

Mark severance cut (1) in accordance with specified dimension and cut.

Dimension a = approx. 250 mm from roof edge.

Fig 4: Identifying A-Pillar With Reinforcement Severance Cutting Dimension
G09850362Courtesy of BMW OF NORTH AMERICA, INC.

Mark severance cut (1) in accordance with specified dimension and cut.

IMPORTANT: Cut outer panel only.

Dimension a = approx. 235 mm before center of 15 mm dia. hole.

Fig 5: Identifying Severance Cutting Dimension
G06890540Courtesy of BMW OF NORTH AMERICA, INC.

View from below.

Open weld joint (1).

Fig 6: Identifying A-Pillar Weld Joints
G06890542Courtesy of BMW OF NORTH AMERICA, INC.
Fig 7: Identifying Spot-Welded Adhesive Joint And Bonded Connection
G09916187Courtesy of BMW OF NORTH AMERICA, INC.

Open weld joint (1).

Open spot-welded adhesive joint (2).

Release bonded connection (3).

Fig 8: Identifying A-Pillar From Cavity Sealings, Spot-Weld Bonded Joints And Welded Connections Areas
G06890541Courtesy of BMW OF NORTH AMERICA, INC.

Open welded connections in areas (1).

Open spot-weld bonded joints in areas (2).

Open bonded connection in area (3).

Release and remove A-pillar from cavity sealings (4).

Installation note:

Replace glued joint in area (3) with MAG weld seam.

New part preparation 

Mark severance cuts on new parts in accordance with severance cuts on vehicle and cut.

Prepare REINFORCEMENT PLATES  at severance cuts.

Adjust new parts to fit with alignment bracket or universal mounting.

Fig 9: Identifying Bore Holes For Blind Rivets N7
G09878719Courtesy of BMW OF NORTH AMERICA, INC.
NOTE: Joining in area (1) is performed using bonding-riveting technology.
Create bore holes (2) to (3) for blind rivets N7 as per specified dimensions:
(2): Dia. 6.8 mm bore hole in accordance with dimension a = 10 mm from component edge.
(3): Dia. 6.8 mm bore hole in accordance with dimension b = 55 mm from bore hole (2).
Fig 10: Identifying Bore Holes For Blind Rivets N7 And N3
G09878720Courtesy of BMW OF NORTH AMERICA, INC.

Create bore holes (1) and (2) for blind rivets N7 and N3 in accordance with schematic diagram:

  1. Bore hole dia. 6.8 mm.
  2. Bore holes dia. 4.2 mm.

In areas (1) and (2) prepare body for plug/spot welding.

Remove new parts and deburr bore holes.

NOTE: In area (3) the new part is adhered to the body. (no riveting)
Fig 11: Identifying Plug/Spot Welding Areas
G09916191Courtesy of BMW OF NORTH AMERICA, INC.
IMPORTANT: Structure bonding! 
OBSERVE  preparation of bonding surfaces.

Installing the A-pillar with reinforcement 

Clean bonding surfaces (1) with cleaning agent R1.

Apply sealant to cavity sealing  . See 41 00... INSTALLING CAVITY SEALING (EXPANDED)  or 41 00... INSTALLING CAVITY SEALING (NOT EXPANDED)  (2).

Apply adhesive to bonding surfaces.

Fig 12: Identifying Cavity Sealing And Bonding Surfaces
G09916192Courtesy of BMW OF NORTH AMERICA, INC.

Install new parts and reinforcement plates with alignment bracket or universal mount.

At the same time, make sure water drain hose of slide/tilt sunroof is correctly fitted.

In areas (1), rivet new part with blind rivets N7.

Weld new part in area (2).

Fig 13: Identifying Blind Rivets N7 And Weld Area
G09878724Courtesy of BMW OF NORTH AMERICA, INC.

Install side frame connection new part and rivet with blind rivets.

Area Blind rivet N7 Blind rivet N3
1 1  
2   2

Weld new parts in the remaining joint areas.

Fig 14: Identifying Blind Rivet Area
G09878725Courtesy of BMW OF NORTH AMERICA, INC.

MAG-weld new part in areas (1).

To do so, apply 10 mm long fillet welds at spacing of 15 mm.

Weld the new parts in the remaining joint areas.

Fig 15: Identifying MAG-Weld Part Areas
G09878542Courtesy of BMW OF NORTH AMERICA, INC.
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