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

WARNING: This page is about a different car, the 2011 BMW X6 and 2010 BMW X6. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: High-voltage system - danger to life!

WARNING: The following points must be strictly observed prior to starting work :

DE-ENERGIZE THE HIGH-VOLTAGE SYSTEM
Observe SAFETY INFORMATION for handling with hybrid cars

Read contents of BODY .

Spot-weld bonding is used on this vehicle. Observe specific procedure. See SPOT-WELD BONDING STEEL COMPONENTS and OPENING ADHESIVE BONDS .

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.

Place vehicle on straightening bench.

Following new body parts are required (refer to ELECTRONIC PARTS CATALOGUE ):

(1) A-pillar, outer
(2) Carrier support, outer wheel arch section
(3) Shaped parts (not pictured)

Fig 1: Identifying A-Pillar And Carrier Support
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Open welded connections in area (1).

Fig 2: Identifying Welded Connections Area

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Mark severance cut in accordance with measurement a and cut carrier support.

Measurement a = approx. 50 mm in front of bore dia. 20 mm.

Open welded connections in area (1).

Installation note:

Weld in REINFORCEMENT PLATE at severance cut.

Fig 3: Identifying Welded Connections Area

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Fig 4: Identifying Welded Connections In Areas And Sheet Panel

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Mark severance cuts in accordance with specified measurements and cut.

IMPORTANT: Cut outer panel only for following severance cuts.
Measurement a = 160 mm from roof edge.
Measurement b = 80 mm below severance cut a.
Measurement c = approx. 150 mm before hole dia. 25 mm.

Open welded connections in areas (1) and (2).

Installation note:

Sheet panel (4) is needed again to seal cowl panel.

Apply sealant to cavity sealing (3). See INSTALLING A CAVITY ACOUSTIC BAFFLE (EXPANDED) or INSTALLING A CAVITY ACOUSTIC BAFFLE (NOT EXPANDED) .

BOND and rivet new part in area (2).

Use BLIND RIVET N1 (Hemlock 813).

Double number of rivets with respect to welding spots in area (2).

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

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

Measurement a = approx. 200 mm from roof edge.

Fig 5: Identifying Severance Cut

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Open bonded connections in areas (1).

Open welded connections in areas (2).

Feed out water drain hose for slide/tilt sunroof (3).

Installation note:

Do not weld new part in areas (2).

Make sure water drain hose is correctly fitted.

Fig 6: Identifying Bonded Connections Areas, Welded Connections Areas And Slide/Tilt Sunroof

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Preparation of new part:

Mark new part in accordance with severance cuts above and cut.

Installation note:

Adjust new part to fit with alignment bracket or universal mount.

Weld in REINFORCEMENT PLATES at all severance cuts.

Apply ADHESIVEK1 in areas (1).

Fig 7: Identifying AdhesiveK1 Areas

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