41 21 XXX Replacing A-Pillar With Reinforcement On The Left (With Side Member Attachment)

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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	11
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 section of 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 (1).

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

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View of A-pillar interior.

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

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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 (1) are replaced by adhesive rivet connections.

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.

Mark severance cut in accordance with dimension and cut.

IMPORTANT: Cut outer panel only.

Dimension a = approx. 120 mm from bulkhead.

Release welded connections in areas (1) and (2) and remove side member attachment with reinforcement.

Fig 11: Identifying Bulkhead Welded Connections Areas

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: The welded connections in areas (1) are replaced by adhesive rivet connections.

Preparation of new part:

Open welded connections (1) and remove reinforcement.

Mark severance cut (2) in accordance with severance cut on vehicle and cut.

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

Fig 12: Identifying Reinforcement Plate Welded Connections Area

Courtesy of BMW OF NORTH AMERICA, INC.

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

Prepare REINFORCEMENT PLATES at severance cuts.

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

In areas (1), introduce 9 holes of Ø 6.8 mm for adhesive rivet connection.

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

Fig 13: Identifying Adhesive Rivet Connection Area

Courtesy of BMW OF NORTH AMERICA, INC.

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

Remove new parts and deburr bore holes.

Fig 14: Identifying Adhesive Rivet Connection Area

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT: Structure bonding!
OBSERVE preparation of bonding surfaces.

Installation:

Clean bonding surfaces with cleaning agent R1.

Apply adhesive to bonding surfaces.

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

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

Rivet new part in the areas (1).

Fig 15: Identifying Adhesive Rivet Connection Area

Courtesy of BMW OF NORTH AMERICA, INC.

Rivet new component in area (1).

If possible move rivets from vehicle interior to the outside.

Weld A-pillar.

Fig 16: Identifying Adhesive Rivet Connection Area

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Install further new parts and reinforcement plates and weld in place.