41 21 511 Replacing front left door post (front side panel removed)

WARNING: This page is about a different variant/trim than selected.

Refer to relevant service information in BODY, GENERAL .

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.

These repair instructions comprise the procedures for REPAIR STAGE 3 .

The following new body parts are required:

Support carrier, side frame, front (1)
Side frame, outer (2)

Fig 1: Identifying Support Carrier And Side Frame

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Door post removal:

Open weld joints in areas (1).

Fig 2: Identifying Open Weld Joint Area

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Open weld joints in areas (1).

Remove support carrier.

Fig 3: Identifying Open Weld Joint Area

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Open weld joints in area (1).

Fig 4: Identifying Open Weld Joint Area

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Separate MAG-welded joints in area (1) and remove door hinge (2).

Fig 5: Identifying MAG Welded Connection Area And Door Hinge

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Separate 2 welded joints in area (1) of the hinge mounting surface.

Installation note:

Replace welded joints in area (1) by 2 additional plug welds in area (2).

Fig 6: Identifying Welded Connections Areas Of Hinge Surface

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Mark severance cut in accordance with dimension and cut.

Dimension (a) = 60 mm below bore dia. 8 mm.

Dimension (b) = 35 mm before elongated hole dia. 12x18 mm.

Open weld joints in areas (1).

Open weld joints in area (2).

Take off door pillar.

Fig 7: Identifying Open Weld Joint Areas (1 & 2)

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Preparation of new part:

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

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

Repair stage 2:

Adjust new support beam to fit and secure.

Set eleven 6.7 mm dia. holes for blind rivets in area (1).

Fig 8: Identifying Hole For Rivet Area

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In areas (1) set three 6.7 mm dia. holes for blind rivets.

Remove all new parts again. Deburr bore holes.

IMPORTANT: Do not grind/sand new part in area of bonding surfaces.

Fig 9: Identifying Hole For Rivet Area

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Door post installation:

Apply sealant to cavity acoustic baffles in areas (1). See INSTALLING A CAVITY ACOUSTIC BAFFLE (EXPANDED) and INSTALLING CAVITY SEALING (NOT EXPANDED) .

Adjust new part to fit with straightening attachment or universal mount and weld.

Weld in REINFORCEMENT PLATES at all severance cuts.

Fig 10: Identifying Cavity Acoustic Baffles In Areas

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Repair stage 2:

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

Apply adhesive K5a to bonding surfaces (1).

Fig 11: Identifying Bonding Surfaces

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Mount support carrier and rivet with blind rivets N1 (1).

Fig 12: Identifying Support Carrier And Rivet With Blind Rivets

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Rivet support carrier with blind rivets N1 (1).

After adhesive has hardened in area (1), fit an EMC SCREW .

Fig 13: Identifying Rivet Support Carrier With Blind Rivets

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