41 21 003 Replacing A-Pillar With Reinforcement On Left

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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 (see OVERVIEW OF CONSUMABLES ):

(1) A-pillar with entrance
(2) Middle side frame
(3) Carrier support, outer wheel arch section
Shaped part A-pillar, top, outer
Shaped part A-pillar, bottom, outer

Fig 1: Identifying A-Pillar With Entrance, Middle Side Frame, Carrier Support
Courtesy of BMW OF NORTH AMERICA, INC.

Following CONSUMABLES are required:

Material	Quantity
Adhesive K1	1
Blind rivet N1	5
Cleaning agent R1	1

Removal:

Mark severance cut in accordance with dimension and cut.

IMPORTANT: Cut outer panel only.

Dimension a = approx. 120 mm from hole Ø 6 mm.

LOOSEN spot-welded adhesive joints in area (1).

Open welded connections in area (2).

Remove partial section of carrier support.

Fig 2: Identifying Spot-Welded Adhesive Joints Area

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. 420 mm in front of hole Ø 20 mm.

Dimension b = approx. 450 mm from roof edge.

Fig 3: Identifying Spot-Welded Adhesive Joints Area

Courtesy of BMW OF NORTH AMERICA, INC.

Open welded connections in areas (1).

Open spot-welded adhesive joints in area (2)

Release A-pillar outer skin from cavity sealing (3) and remove.

Mark severance cut (1) as pictured and cut.

IMPORTANT: Cut outer panel only.

Open welded connections in area (2).

Fig 4: Identifying A-Pillar Welded Connections Area

Courtesy of BMW OF NORTH AMERICA, INC.

Open welded connections in area (1).

Remove reinforcement (2).

Fig 5: Identifying Reinforcement Welded Connections Area

Courtesy of BMW OF NORTH AMERICA, INC.

View of passenger compartment.

Open welded connections (1).

Open bonded connection in area (2).

Fig 6: Identifying Passenger Compartment Bonded Connection And Welded Connections Area

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Open weld joint in area (1).

Fig 7: Identifying A-Pillar Open Weld Joint Area

Courtesy of BMW OF NORTH AMERICA, INC.

Roughly mark severance cut (1) as pictured and cut.

Remove metal section (2).

Fig 8: Identifying Metal Section And Severance Cutting Area

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Open welded connections (1).

NOTE: The welded connections are replaced by bonded rivet connections.

Loosen welded connections using BELT SANDER .

Fig 9: Identifying Welded Connections

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Fig 10: Identifying A-Pillar From Cavity Sealing Welded Connections Areas

Courtesy of BMW OF NORTH AMERICA, INC.

Open welded connections in areas (1).

Release A-pillar from cavity sealing (2) and remove.

Release welded connections in areas (1) and (2) and remove reinforcement (3).

NOTE: Welded connections in the area (1) are replaced by bonded rivet connections.

Fig 11: Identifying A-Pillar From Cavity Sealing Area

Courtesy of BMW OF NORTH AMERICA, INC.

Preparation of new part:

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

Prepare REINFORCEMENT PLATES at severance cuts.

Detach welded connections.

Remove reinforcement (1) and side member attachment (2).

NOTE: The reinforcement (1) is used for installation.

Fig 12: Identifying Reinforcement And Side Member Attachment

Courtesy of BMW OF NORTH AMERICA, INC.

Detach welded connections (1) and take off reinforcement (2).

NOTE: The reinforcement must be installed as a separate component for access reasons.

Mark further severance cuts in accordance with vehicle and cut.

Fig 13: Identifying Reinforcement Welded Connections

Courtesy of BMW OF NORTH AMERICA, INC.

Fit reinforcement (3) in combination with A-pillar reinforcement.

Drill three Ø 6.8 mm bore holes for bonded rivet connections in the designated area (1).

Prepare new part in areas (2) for plug/spot welding.

Fig 14: Identifying A-Pillar From Cavity Sealing Area

Courtesy of BMW OF NORTH AMERICA, INC.

Adjust and secure A-pillar and reinforcement with alignment bracket or universal fixture.

In areas (1), introduce 2 holes of Ø 6.8 mm for adhesive rivet connection.

For drilling the holes, use TWIST DRILL 6.8 X 156 mm.

NOTE: When adjusting the new part for the A-pillar reinforcement, the panel thickness of the missing A-pillar outer skin must be taken into consideration depending on straightening system manufacturer.

Fig 15: Identifying Adhesive Rivet Connection Area

Courtesy of BMW OF NORTH AMERICA, INC.

Remove new parts and deburr bore holes.

IMPORTANT: Structure bonding!
OBSERVE preparation of bonding surfaces.

Installation:

Clean bonding surfaces with cleaning agent R1.

Apply adhesive to bonding surfaces.

Install reinforcement (3).

Rivet new part in designated area (1) using N1 blind rivets and plug-weld in designated areas (2).

IMPORTANT: Risk of damage!
Avoid applying too much heat to adjacent adhesive area (1).

Fig 16: Identifying A-Pillar From Cavity Sealing Area

Courtesy of BMW OF NORTH AMERICA, INC.

Fig 17: Identifying A-Pillar Reinforcement From Cavity Sealing Area

Courtesy of BMW OF NORTH AMERICA, INC.

Clean bonding surfaces with cleaning agent R1.

Apply adhesive K1 to bonding surfaces.

Apply sealant to cavity sealing . See 41 00... INSTALLING CAVITY SEALING (EXPANDED) or 41 00... INSTALLING CAVITY SEALING (NOT EXPANDED) (1).

Install and secure new reinforcement part for A-pillar and reinforcement plates with alignment bracket or universal fixture.

Weld new part in the areas (2).

NOTE: When installing the new part for the A-pillar reinforcement, the panel thickness of the missing A-pillar outer skin must be taken into consideration depending on straightening system manufacturer.

Weld new part in the areas (1).

Fig 18: Identifying Passenger Compartment Bonded Connection And Welded Connections Area