41 21 685 Replace Side Frame, Left Complete (Rear Side Panel Removed)

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) Water collection box
• (3) Shaped part, carrier support, wheel arch, front (not shown)
• (4) Shaped part, carrier support, wheel arch (not shown)
  Fig 1: Identifying Outer Side Frame And Water Collection Box

  Courtesy of BMW OF NORTH AMERICA, INC.

Following consumables are required:

Removal of side frame, complete 

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 .

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

Courtesy of BMW OF NORTH AMERICA, INC.

Roughly cut out crash support (1).

Fig 3: Identifying Crash Support

Courtesy of BMW OF NORTH AMERICA, INC.

Fig 4: Identifying Spot-Welded Adhesive Joints Areas

Courtesy of BMW OF NORTH AMERICA, INC.

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).

Weld new part in area (4) during installation.

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

Courtesy of BMW OF NORTH AMERICA, INC.

View of B pillar from passenger compartment.

Open welded connections in areas (1).

Fig 6: Identifying Welded Connections Areas

Courtesy of BMW OF NORTH AMERICA, INC.

Open welded connections in area (1).

Fig 7: Identifying Welded Connections Area

Courtesy of BMW OF NORTH AMERICA, INC.

Fig 8: Identifying Spot-Welded Adhesive Joints Areas

Courtesy of BMW OF NORTH AMERICA, INC.

Open brazed connection in area (1).

Open welded connections in areas (2).

Open spot-welded adhesive joints in areas (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 9: Identifying Mark Severance Cut And Weld Joints Area

Courtesy of BMW OF NORTH AMERICA, INC.

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

Remove sheet section.

Undo bonded connection (2) and remove entrance.

Fig 10: Identifying Mark Severance Cut And Bonded Connection

Courtesy of BMW OF NORTH AMERICA, INC.

New part preparation 

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

Fig 11: Identifying Blind Rivet Bore Hole

Courtesy of BMW OF NORTH AMERICA, INC.

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 12: Identifying Transfer Created Bore Holes

Courtesy of BMW OF NORTH AMERICA, INC.

Fig 13: Identifying Blind Rivets Bore Holes

Courtesy of BMW OF NORTH AMERICA, INC.

Set 4 drill holes (1) Ø 6.8 mm for blind rivets N1.

(2) = weld point connections on new part.

Remove new part again and deburr bore holes.

Installation of side frame, complete 

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.

Apply sealant to cavity sealings and install. See 41 00... INSTALLING CAVITY SEALING (NOT EXPANDED) .

Fig 14: Applying Adhesive K1 To Bonding Surfaces To Part And Vehicle

Courtesy of BMW OF NORTH AMERICA, INC.

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

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

Fig 15: Identifying Blind Rivet Area

Courtesy of BMW OF NORTH AMERICA, INC.

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

In area (2), use blind rivet N1  .

Fig 16: Identifying Blind Rivets Areas

Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 17: Identifying Blind Rivets Areas

Courtesy of BMW OF NORTH AMERICA, INC.

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

(1) = bore holes created during removal

Fig 18: Identifying Plug-Weld Part Areas

Courtesy of BMW OF NORTH AMERICA, INC.

Weld new part in remaining joint areas.