41 21 003 A-Pillar With Reinforcement On Left

Observe procedure for repair stage 3. See 41 00 REPAIR TECHNIQUES, REPAIR STAGE 3 .

Read contents of 41 00... 0 CONTENTS OF BODY, GENERAL .

Spot-weld bonding is used on this vehicle. Observe specific procedure. See 41 00... SPOT-WELD BONDING STEEL COMPONENTS .

Use only approved spot-welding apparatus for repairs. See 41 00... WORKSHOP EQUIPMENT (BMW AND MINI VEHICLES) .

Place vehicle on straightening bench.

Following new body parts are required:

• (1) Outer side frame
• (2) Shaped part, carrier support, wheel arch, front (not shown)
• (3) Shaped part, carrier support, wheel arch (not shown)

Following consumables are required:

Fig 1: Identifying Outer Side Frame

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Removing the A-pillar with reinforcement 

Roughly mark severance cuts (1) and cut.

Open welded connections in areas (2).

Loosen spot-welded adhesive joints in area (3). See 41 00... OPENING BONDED CONNECTIONS .

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

Remove cavity sealing (4).

Fig 2: Identifying Mark Severance Cuts And Welded Connections Areas

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Roughly cut out crash support (1).

Fig 3: Identifying Crash Support

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Fig 4: Identifying Spot-Welded Adhesive Joints Areas

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Drill 2 weld point connections (1) with drill Ø 6.8 mm.

Remove remaining areas of the 2 weld point connections (1) through grinding.

Drill through weld point connection (2). (installation preparation for plug-welding)

Introduce another 2 bore holes with the specified dimensions:

Bore hole at dimension a = 50 mm from center point of bore hole (1). Diameter 6.8 mm.

Bore hole at dimension a = 35 mm from center point of bore hole (2). (installation preparation for plug-welding)

Release spot-welded adhesive joints in areas (3) and (4).

During installation, the new part is welded in area (4).

View of A-pillar in passenger compartment.

Undo metal active gas welded connections in areas (1).

Fig 5: Identifying Metal Active Gas Welded Connections Areas

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Fig 6: Identifying Mark Severance Cut Dimension And Welded Connections Areas

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Mark severance cut in accordance with dimension and cut.

Dimension a = approx. 95 mm from 20 mm diameter hole.

Open brazed connection in area (1).

Open welded connections in areas (2).

Open spot-weld adhesive joints in area (3)

Roughly mark severance cut (1) as pictured and cut.

Open weld joints in area (2) and remove sheet section.

Release bonded connection (3).

Fig 7: Identifying Mark Severance Cut And Weld Joints Area

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Roughly mark severance cut (1) as pictured and cut.

Remove sheet section.

Undo bonded connection (2) and remove entrance.

Fig 8: Identifying Mark Severance Cut And Bonded Connection

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New part preparation 

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

Prepare reinforcement plate at severance cut. See 41 00... WELDING IN REINFORCEMENT PLATE (SHEET STEEL) .

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

Fig 9: Identifying Blind Rivet Bore Hole

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In area (1), drill bore hole Ø 6.8 mm for blind rivet N2.

Set bore hole centrally through hole (2).

For drilling the holes, use twist drill 6.8 x 156 mm. See 41 00... OVERVIEW OF CONSUMABLES  (8.0 Twist Drill).

During removal, transfer created bore holes (1) and (2) to new part.

For this, drill new part through holes (1) and (2) with drill Ø 6.8 mm.

Fig 10: Identifying Transfer Created Bore Holes

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Fig 11: Identifying Blind Rivets Bore Holes

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In areas (1), create 4 dia. 6.8 mm bore holes for blind rivets N1.

(2) = weld point connections on new part.

Remove new part again and deburr bore holes.

Installing the A-pillar with reinforcement 

Clean all bonding surfaces on vehicle and on new part with cleaning agent R1.

Apply adhesive K1 to bonding surfaces (1) to new part and vehicle.

Coat cavity sealings with sealant. See 41 00... INSTALLING CAVITY SEALING (NOT EXPANDED) .

Install new part and reinforcement plate with alignment bracket or universal mount and secure.

Fig 12: Applying Adhesive K1 To Bonding Surfaces To Part And Vehicle

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In area (1), rivet new part with blind rivet N2  .

Fig 13: Identifying Blind Rivet Area

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Rivet new part in areas (1) with blind rivets N2  .

In area (2), use blind rivet N1  .

Fig 14: Identifying Blind Rivets Areas

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In areas (1) rivet new part with blind rivets N1  .

(2) = weld point connections on new part.

Fig 15: Identifying Blind Rivets Areas

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In areas (1), plug-weld new part.

(1) = bore holes created during removal

Fig 16: Identifying Plug-Weld Part Areas

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Weld new part in the remaining joint areas.