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

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Observe procedures for 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.

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)

Following CONSUMABLES are required:

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

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Material	Quantity
Adhesive K1	1
Blind rivets N7	7
Blind rivets N3	2
Cleaning agent R1	1
Sealant D1
Cavity wax remover

Removal of front door post

Roughly cut side frame connection along lines (1).

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

Open welded connections in areas (3).

Release side frame connection from cavity sealing (4) and remove.

Open remaining welded connections in areas (1).

Fig 2: Identifying Cavity Sealing, Welded Connection And Spot-Welded Adhesive Joints Areas

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Fig 3: Identifying Welded Connections Areas, Metal Section And Sheet Sections

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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 dia. 15 mm.

Dimension d = 140 mm before severance cut c.

Open welded connections in areas (1).

Remove sheet sections (2).

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

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

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Mark severance cut (1) in accordance with specified dimension and cut.

IMPORTANT: Cut outer panel only.

Measurement a = approx. 235 mm before centerpoint of 20 mm dia. hole.

Fig 5: Identifying Outer Panel Cutting Dimension

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

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Open welded connections in areas (1).

Open spot-weld bonded joints in areas (2).

Open bonded connection in area (3).

Remove cavity sealing (4).

Installation note:

Replace glued joint in area (3) with MAG weld seam.

View from below.

Open weld joint (1).

Fig 7: Identifying Weld Joint

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View from inside.

Open weld joint (1).

Feed out water drain hose (2) for slide/tilt sunroof.

Fig 8: Identifying Weld Joint And Water Drain Hose

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Roughly mark severance cut (1).

Cut out A-pillar metal section (2) and A-pillar reinforcement underneath.

Fig 9: Identifying A-Pillar Metal Section And Severance Cut Mark

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Release bonded connection (1).

Fig 10: Identifying Bonded Connection

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Remove holder (1) for side wall.

Roughly mark severance cut (2).

Cut out A-pillar metal section and A-pillar reinforcement underneath.

Remove cavity acoustic baffle (3).

Fig 11: Identifying Holder, Severance Cut And Cavity Acoustic Baffle

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Fig 12: Identifying Welded Connection Areas

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Drill through 2 welded connections in areas (1) with 6.8 mm dia. drill.

NOTE: New part is joined in areas (1) by bonding-riveting technology.

Fig 13: Identifying Rivet Positions

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Additional rivet positions are required for installation in areas (1) for strengthening reasons.

Additional rivet positions (black, number 2)
Welded connections ex works (grey, number 2)

Drill additional rivet positions with 6.8 mm dia. drill in accordance with schematic drawing.

Open remaining areas of welded connections (grey, number 2) through grinding.

Release bonded connections in areas (1) and remove A-pillar.

New part preparation

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

Prepare REINFORCEMENT PLATES at severance cuts.

Adjust new parts to fit with alignment bracket or universal mounting.

Fig 14: Identifying Blind Rivets Bore Holes Dimension And Joint Area

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NOTE: Joining in area (1) is performed using bonding-riveting technology.

Create bore holes (2) to (3) for blind rivets N7 as per specified dimensions:

(2): Dia. 6.8 mm bore hole in accordance with dimension a = 10 mm from component edge.

(3): Dia. 6.8 mm bore hole in accordance with dimension b = 55 mm from bore hole (2).

Fig 15: Identifying Blind Rivets Bore Holes

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Create bore holes (1) and (2) for blind rivets N1 and N3 in accordance with schematic diagram:

(1): Bore hole dia. 6.8 mm.

(2): Bore holes dia. 4.2 mm.

Transfer bore holes (1) created during removal to new part.

Also drill new part through holes (1) with drill Ø 6.8 mm.

Remove new parts and deburr bore holes.

NOTE: In all further joint areas, prepare new parts and body for joining by welding.

Fig 16: Identifying Bore Holes Area

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IMPORTANT: Structure bonding!
OBSERVE preparation of bonding surfaces.

Installing door post, front

Clean bonding surfaces (1) with cleaning agent R1.

Apply sealant to cavity sealing (2). See INSTALLING A CAVITY ACOUSTIC BAFFLE (EXPANDED) and INSTALLING A CAVITY ACOUSTIC BAFFLE (NOT EXPANDED) .

Apply adhesive to bonding surfaces.

Fig 17: Identifying Adhesive Applying Areas On Bonding Surfaces

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Install new parts and reinforcement plates with alignment bracket or universal mount.

At the same time, make sure water drain hose of slide/tilt sunroof is correctly fitted.

In areas (1), rivet new part with blind rivets N7.

Fig 18: Identifying Bore Holes Area

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In areas (1), rivet new part with blind rivets N7.

Weld new part in area (2).

Fig 19: Identifying Blind Rivets And Welded Areas

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Install side frame connection new part and rivet with blind rivets.

Area	Blind rivet N7	Blind rivet N3
1	1
2		2

Weld new parts in the remaining joint areas.

Fig 20: Identifying Blind Rivet Joint Areas

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MAG-weld new part in areas (1).

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

Weld new part in the remaining joint areas.

Fig 21: Identifying Wheel Arch Component MAG Welding Area

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