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

WARNING: This page does not describe the selected car, but rather 31 other vehicles, including the 2015 BMW Alpina B7L, 2015 BMW Alpina B7, 2015 BMW 750i, 2015 BMW 750Li, and 2015 BMW 740i. However, it is still accessible from the selected car via links, so may be relevant.

Procedure OBSERVE repair stage 3.

Read contents of BODY, GENERAL .

Spot-weld bonding is used on this vehicle. Observe SPECIFIC PROCEDURE .

Place vehicle on straightening bench.

The following new body parts are required:

(1) A-pillar, outer
(2) Connection, side frame
(3) Shaped part, carrier support, wheel arch, front (not shown)
(4) Shaped part, carrier support, wheel arch (not shown)

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

Open spot-welded adhesive joint in area (1).

Open welded connections in areas (2).

Roughly cut side frame connection along lines (4).

Remove side frame connection (3).

Installation note:

MAG-weld new part in areas (4).

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

Fig 2: Identifying Spot-Welded Adhesive Joints Area And Side Frame Connection

Courtesy of BMW OF NORTH AMERICA, INC.

Fig 3: Identifying Welded Connections Areas And Sheet Sections

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 = 200 mm from roof edge.
Dimension b = 100 mm below severance cut a.
Dimension c = approx. 165 mm before center of hole diameter 15 mm.
Dimension d = 140 mm before severance cut c.
Open welded connections in areas (1).
Remove sheet sections (2).

Installation note:

Cut-out metal sections (2) are required again for sealing.

Weld in REINFORCEMENT PLATES at all severance cuts.

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 Roof Edge Cutting Dimension

Courtesy 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 Outer Panel Cutting Dimension

Courtesy of BMW OF NORTH AMERICA, INC.

Fig 6: Identifying Bonded Connection Area, Cavity Sealing And Welded Connections Areas

Courtesy of BMW OF NORTH AMERICA, INC.

Open welded connections in areas (1).

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

Open bonded connection in area (3).

Installation note:

Replace bonded connection in area (3) with MAG weld seam.

Apply sealant to cavity sealing (4). See INSTALLING A CAVITY ACOUSTIC BAFFLE (EXPANDED) or INSTALLING A CAVITY ACOUSTIC BAFFLE (NOT EXPANDED) .

View from below.

Open welded connection (1).

Fig 7: Identifying Welded Connection

Courtesy of BMW OF NORTH AMERICA, INC.

View from inside.

Open spot-welded adhesive joint (1 welding spot in each case) in areas (1).

Open welded connection (2).

Feed out sliding sunroof water drain hose (3) and door post.

Installation note:

Prepare body in areas (1) for plug welding.

Fig 8: Identifying Sunroof Water Drain Hose, Spot-Welded Adhesive Joint Areas And Welded Connection

Courtesy of BMW OF NORTH AMERICA, INC.

Installation note:

Apply repair welding spots in area (1) to existing welding spots on new part/vehicle. This is necessary because the adhesive between the spot flanges acts as an insulator.

Fig 9: Identifying Welding Spots Area

Courtesy of BMW OF NORTH AMERICA, INC.

Installation note:

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

Adjust new part to fit with alignment bracket or universal mount.

Make sure water drain hose is correctly fitted.