41 21 511 Replacing Front Left Door Pillar (Front Side Panel Removed)

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.

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

The following new body parts are required:

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

Fig 1: Identifying Support Carrier, Side Frame, Front With Side Frame, Outer
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Open weld joints in areas (1).

Fig 2: Identifying Weld Joints In Areas

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Open weld joints in areas (1).

Remove support carrier.

Fig 3: Identifying Weld Joints In Areas

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CAUTION: Cut through outer plate only for following severance cuts. The water drain pipe of the panorama sunroof is located behind the door pillar.

Roughly cut door pillar above water drain (2) along line (1).

Fig 4: Identifying Water Drain Hole

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Open weld joint in area (1).

Open weld joints in area (3) from car interior.

Installation:

For reasons of accessibility, the repair joining sequence differs from the standard joining sequence.

Weld sheet metal flange of water drain pipe (2) in area (1) on inner A-pillar. Adjustment to fit with new part necessary!

Fig 5: Identifying Weld Joints In Area From Car Interior

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Mark severance cuts in accordance with dimensions a and cut.

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

Dimension (b) = 35 mm before elongated hole dia. 12 x 18 mm.

Open weld joints in areas (1).

Open weld joints in area (2).

Fig 6: Identifying Weld Joints In Areas With Hole Dimension

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Preparation of new part:

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

Door post installation:

Apply window glass adhesive to cavity acoustic baffles in areas (1). See INSTALLING A CAVITY ACOUSTIC BAFFLE (EXPANDED) / INSTALLING A CAVITY SEALING (NOT EXPANDED) .

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

Weld in REINFORCEMENT PLATES at all severance cuts.

Fig 7: 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 8: Identifying Bonding Surfaces

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

Fig 9: Identifying Support Carrier And Rivet With Blind Rivets

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Rivet support carrier with blind rivets (1).

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

Fig 10: Identifying Rivet Support Carrier With Blind Rivets

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