41 11 300 Longitudinal Member Cover With Left Or Right Door Pillar Replacement (Partial Replacement B-Pillar, Rear 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 .

Spot-weld bonding is used on this vehicle.

Observe relevant procedures in BODY, GENERAL .

Use only approved spot-welding apparatus for repairs!

Place vehicle on straightening bench.

Following new body parts are required :

B-pillar with entrance
Attachment, entrance, outer
Shaped part, B-pillar, inner

Fig 1: Attachment, Entrance, Outer And Shaped Part, B-Pillar, Inner

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Fig 2: Severance Cuts Mark In Accordance With Specified Measurements And Cut

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Mark severance cuts in accordance with specified measurements and cut.

IMPORTANT: Cut outer plate only for following severance cuts.

Measurement a = approx. 40 mm in front of bore dia. 6 mm.

Measurement b = approx. 90 mm behind bore dia. 6 mm.

Measurement c = approx. 460 mm above upper door hinge mounting.

Measurement d = approx. 80 mm above cut c.

Open weld joints on outer entrance attachment (1) before and after severance cuts and remove components.

Fig 3: Weld Joints Areas

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

Remove metal section (2).

Installation:

Apply repair welding spots in area (3) to existing welding spots on new component/car. This is necessary because the adhesive between the spot flanges acts as an insulator.

Mark severance cut in accordance with specified measurement and cut.

Measurement a = 500 mm above upper door hinge mounting.

Fig 4: Severance Cut Mark In Accordance With Specified Measurement And Cut

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NOTE: View from inside
Open weld joints and bonded joints in areas (1).

Fig 5: Weld Joints And Bonded Joints Areas

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Release cavity acoustic baffle in area (1).

Open adhesive bonds in areas (2).

Fig 6: Cavity Acoustic Baffle Area

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Fig 7: Severance Cuts Mark On New Part In Accordance With Previous Severance Cuts And Cut

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Preparation of new part:

Mark severance cuts (1) on new part in accordance with previous severance cuts and cut.

IMPORTANT: Cut only outer plate at severance cut (2).

Measurement a = 80 mm below severance cut (2).

Open weld joints on sheet panel (3) and remove component.

Installation:

Cut-out sheet panel (3) is needed again to seal B-pillar.

Open weld joints on outer entrance attachment (4) between severance cuts and remove component.

Fig 8: Severance Cut Mark In Accordance With Vehicle And Cut

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Mark severance cut (1) in accordance with vehicle and cut.

IMPORTANT: Cut only outer plate at severance cut (1).

Installation:

Weld in reinforcing panels at all severance cuts.

Fig 9: Cavity Acoustic Baffle

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Apply adhesive in areas (1).

Apply window glass adhesive to cavity acoustic baffle (2).

Installation information:

Adjust new part to fit with straightening attachment or universal mount.

Adjust outer entrance attachment to fit after pressing down on paintwork on body and new part.

Prepare flange area of entrance attachment for plug welding.

Hole diameter approx. 5 to 6 mm

Fig 10: Preparing Flange Area Of Entrance Attachment For Plug Welding

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Installation:

Apply repair welding spots in areas (1) next to existing welding spots on new component/car.

Fig 11: Repair Welding Spots Areas

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Installation:

Bond and rivet new part in area (1).

Use Hemlock 813 blind rivet .

Double number of rivets with respect to welding spots in area (1).

Fig 12: Welding Spots Area

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Installation:

Observe the following procedure when setting the rivets:

First rivet adjacent areas (1).
Then smooth and rivet areas (2).

IMPORTANT: Risk of damage!

Rivet head must rest flat in relation to sheet metal flange.
To do so, bend sheet metal flange slightly.

Reshape sheet metal flange after setting rivets.

Rivet heads that do not rest flat will cause damage to the riveting tongs!
Do not damage the floor panel behind when drilling the rivet holes.

Fig 13: First Rivet Adjacent Areas

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