41 21 510 Front Left Door Pillar Replacement (Front Side Panel Removed)

WARNING: This page is about a different car, the 2010 BMW 535xi, 2009 BMW 535xi, and 2008 BMW 535xi. However, it is still accessible from the selected car via links, so may be relevant.

Read contents of BODY, GENERAL .

Remove or cover those vehicle components in the repair area which are susceptible to heat or dust.

Use only approved spot-welding apparatus for repairs.

Spot-weld bonding is used on the E60.

Observe relevant procedures in BODY, GENERAL .

Place vehicle on straightening bench.

Following new body parts are required:

A-pillar, outer
Attachment, entrance, outer
Crash box
Connection, side frame, bottom
Connection, side frame, top
Attachment, endplate
Connection, A-pillar/roof frame
Shaped section, A-pillar, inner

Fig 1: Identifying A-Pillar, Outer And Connection, Side Frame, Bottom

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Open brazing solder and weld joints in area (1).

Remove endplate attachment (2).

Open weld joints in areas (3).

Installation:

Replace brazed seams with MAG weld seams in area (1).

Fig 2: Identifying Weld Joints Areas

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Open weld joints in areas (1).

Fig 3: Identifying Weld Joints Areas

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Open weld joints in area (1).

Fig 4: Identifying Weld Joints Area

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Open weld joints in areas (1) and (2).

Installation:

Weld new part in area (2) from outside with MAG weld seam.

Fig 5: Identifying Weld Joints Areas

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Open weld joints in area (1)

Remove crash box (2).

Fig 6: Identifying Crashbox

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Mark severance cut (1) on outer entrance attachment and cut.

Measurement a = approx. 200 mm from edge of hole (2) dia.

20 mm.

Open weld joints in area (3).

Installation:

Weld in reinforcement plate at severance cut.

Fig 7: Identifying Weld Joints Area

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Fig 8: Identifying Severance Cuts Mark In Accordance With Specified Measurements And Cut

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Mark severance cuts in accordance with specified measurements and cut.

Measurement a = approx. 100 mm before hole dia. 6 mm.

IMPORTANT: Only cut outer metal plate on both severance cuts.

Measurement b = approx. 180 mm below roof edge.

Measurement c = approx. 100 mm below severance cut b.

Open weld joints in areas (1) and (3).

Remove metal section (2).

Installation:

Sheet panel (2) is needed again to seal cowl.

Weld in reinforcing panels at all severance cuts.

Bond and rivet new part in area (3).

Use Hemlock 813 blind rivet (sourcing reference: BMW Parts Service picture board - Aluminum and steel/bonding and welding).

Double number of rivets with respect to welding spots in area (3).

IMPORTANT: For following severance cut, do not damage sunroof water drain hose.

Mark severance cut (1) at A-pillar/roof frame connection and cut.

Measurement a = approx. 210 mm from roof edge.

Open weld joints in areas (2).

Weld in reinforcement plate at severance cut.

Fig 9: Identifying Severance Cut Mark At A-Pillar/Roof Frame Connection And Cut

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Open weld joints in areas (1).

Open adhesive joints in areas (1) and (2).

Installation:

Replace adhesive in areas (1) with plug welding.

Fig 10: Identifying Adhesive Joints Areas

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Installation:

Apply window glass adhesive to cavity acoustic baffles (1).

Apply adhesive in area (2).

Fig 11: Identifying Cavity Acoustic Baffles

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Preparation of new part:

Open weld joints in areas (2).

Mark A-pillar/roof frame connection (1) in accordance with vehicle and cut.

Fig 12: Identifying Weld Joints Areas

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Preparation of new part:

Open weld joints (1) at outer entrance attachment (2).

Mark severance cut (3) in accordance with vehicle and cut.

Cut off metal section (4) in accordance with measurement a from new part.

A = approx. 100 mm

Fig 13: Identifying Severance Cut Mark In Accordance With Vehicle And Cut

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Preparation of new part:

Apply window glass adhesive to cavity acoustic baffle (1).

Fig 14: Identifying Cavity Acoustic Baffle

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Preparation of new part:

Place A-pillar/roof frame (1) in outer A-pillar (2) and adapt. Weld both parts in areas (3).

Fig 15: Identifying A-Pillar/Roof Frame And Outer A-Pillar

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