41 21 005 Replacing A-Pillar With Reinforcement And Sill, Inner 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 (refer to 41 00... OVERVIEW OF CONSUMABLES ):

• (1) Outer side frame
• (2) Inner side member
• (2) Shaped part, carrier support, wheel arch, front (not shown)
• (3) Shaped part, carrier support, wheel arch (not shown)
  Fig 1: Identifying Outer Side Frame And Inner Side Member

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Following consumables are required:

Removal of A-pillar with reinforcement and sill 

Roughly mark severance cuts (1) and cut.

Open welded connections in areas (2).

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

Loosen side frame from cavity sealing (4) and remove.

Remove cavity acoustic baffle (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 Weld Point Connection Area

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Drill through weld point connection (1) with 6.8 mm dia. drill.

Open remaining area of weld point connection (1) through grinding.

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

In addition, introduce a bore hole with the specified dimension:

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 And Spot-Welded Adhesive Joints Area

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Mark and cut severance cut (1) through Ø 20 mm hole.

Open brazed connection in area (2).

Open welded connections in areas (3).

Open spot-welded adhesive joints in area (4).

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 A-pillar.

Fig 8: Identifying Mark Severance Cut And Bonded Connection

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Fig 9: Identifying Mark Severance Cut Dimension And Spot-Welded Adhesive Joints Area

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Mark severance cut in accordance with dimension and cut.

Dimension a = approx. 62 mm in front of bulkhead.

Open welded connections in area (1).

Open spot-welded adhesive joints in area (2)

Remove inside side member.

New part preparation 

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

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

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

Fig 10: 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).

Fig 11: Identifying Transfer Created Bore Hole

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During removal, transfer created bore hole (1) Ø 6.8 mm to new part.

In addition, drill two holes (2) Ø 6.8 mm through two new parts as per schematic diagram.

Fig 12: 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) = welded connections on new part.

Remove new part again and deburr bore holes.

Installation of inner side members 

Install new part with alignment bracket or universal mount and weld.

Installation of A-pillar with reinforcement and sill 

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 13: 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 14: 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 15: 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 16: Identifying Blind Rivets Areas

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

(1) = bore holes created during removal

Fig 17: Identifying Plug-Weld Part Areas

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Weld new part in the remaining joint areas.