41 21 510 Replacing front left door post (front side panel removed)

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

Read contents of BODY, GENERAL .

Use only approved SPOT-WELDING APPARATUS for repairs!

Place vehicle on straightening bench.

NOTE: These repair instructions comprise the procedures for REPAIR STAGE 3 .

Following new body parts are required:

(1) Carrier support, wheel arch, front
(2) A-pillar, outer
(3) Attachment, sill

Following CONSUMABLES are required:

CONSUMABLES MATERIAL REFERENCE CHART

Material	Quantity
Adhesive K5a	1
Blind rivets N1	14
EMC screws	1
Cavity sealing wax remover
Cleaning agent R1	1
Sealant D1

Fig 1: Identifying Front Wheel Arch, Outer A-Pillar And Sill Attachment

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Door post removal

Open welded connections in areas (1).

Fig 2: Identifying Welded Connections Areas

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Open welded connections in areas (1).

Remove support carrier.

Fig 3: Identifying Welded Connections Areas

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Open welded connections in areas (1).

Installation note:

Position sill attachment after painting on body.

Fig 4: Identifying Welded Connections Areas

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

Fig 5: Identifying Welded Connections Areas

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Open MAG welded connection in area (1) and remove door hinge (2).

Fig 6: Identifying MAG Welded Connection Area And Door Hinge

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Open 2 welded connections in area (1) of hinge surface.

Installation note:

Replace welded connections in area (1) with 2 additional plug welds in area (2).

Fig 7: Identifying Welded Connections Area With Plug Welds Area

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Open welded connections in area (1).

Fig 8: Identifying Welded Connections Area

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Open welded connections in area (1).

Fig 9: Identifying Welded Connections Area

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Open welded connections in area (1).

Fig 10: Identifying Welded Connections Area

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Open welded connections in areas (1).

Take off door post.

Fig 11: Identifying Welded Connections Area

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New part preparation

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

Repair stage 2

Adjust new carrier support part to fit and secure.

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

Fig 12: Identifying Holes For Blind Rivets Area

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

Remove new part again and deburr bore holes.

Fig 13: Identifying Holes For Blind Rivets Area

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

Door post installation

Weld in reinforcing panels at all severance cuts.

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

Repair stage 2

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

Apply adhesive K5a to bonding surfaces (1).

Fig 14: Identifying Bonding Surfaces Applying Adhesive K5A

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

Fig 15: Identifying Support Carrier With Blind Rivets

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Rivet support carrier with blind rivets (1).

Fit an EMC SCREW after adhesive has hardened in area (1).

Fig 16: Identifying Support Carrier With Blind Rivets

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