41 21 510 Replacing Front Left Door Post (Front Side Panel Removed)

Observe procedure for REPAIR STAGE 3 .

Read contents of BODY, GENERAL .

Spot-weld bonding is used on this vehicle. Observe specific PROCEDURE .

Use only approved SPOT-WELDING APPARATUS  for repairs.

Place vehicle on straightening bench.

Following new body parts are required (refer to BMW ELECTRONIC PARTS CATALOGUE ):

• (1) A-pillar, outer
• (2) Connection, side frame, rear
• (3) Shaped part, carrier support, wheel arch, front (not shown)
• (4) Shaped part, carrier support, wheel arch (not shown)

Following CONSUMABLES  are required:

Fig 1: Identifying A-Pillar And Carrier Support

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Removal of front door post 

Open welded connections in areas (1).

LOOSEN  spot-welded adhesive joints in areas (2).

Roughly cut side frame connection along lines (3).

Remove side frame connection.

Open remaining welded connections in areas (3).

Fig 2: Identifying Welded Connections And Spot-Welded Adhesive Joints Areas

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Fig 3: Identifying Severance Cuts Dimensions

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Mark severance cuts in accordance with specified dimensions and cut.

Mark severance cut (1) in accordance with specified dimension and cut.

Dimension a = approx. 260 mm from roof edge.

Fig 4: Identifying Roof Edge Dimension

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Mark severance cut (1) in accordance with specified dimension and cut.

Measurement a = approx. 235 mm before centerpoint of 20 mm dia. hole.

Fig 5: Identifying Severance Cut Dimension

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Fig 6: Identifying Cavity Sealing, Welded Connections And Spot-Weld Bonded Joints Areas

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Open welded connections in areas (1).

Open spot-weld bonded joints in areas (2).

Open bonded connection in area (3).

Remove cavity sealing (4).

Installation note:

Replace glued joint in area (3) with MAG weld seam.

View from below.

Open weld joint (1).

Fig 7: Identifying Weld Joint

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View from inside.

Open weld joint (1).

Feed out water drain hose (2) for slide/tilt sunroof.

Fig 8: Identifying Weld Joint And Water Drain Hose

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Remove holder (1) for side wall.

Mark severance cuts (2) in accordance with schematic diagram and cut.

Cut out A-pillar metal section and A-pillar reinforcement underneath.

Remove cavity acoustic baffle (3).

Fig 9: Identifying Holder, Acoustic Baffle And Severance Cuts

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Fig 10: Identifying Welded Connections Areas

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Drill through 2 welded connections in areas (1) with 6.8 mm dia. drill.

Installation note:

In areas (1), joining is performed using bonding-riveting technology.

Fig 11: Identifying Rivet Positions Installation Areas

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Additional rivet positions are required for installation in areas (1) for strengthening reasons.

• Additional rivet positions (black, number 2)
• Welded connections ex works (grey, number 2)

Drill additional rivet positions with 6.8 mm dia. drill in accordance with schematic drawing.

Open remaining areas of welded connections (grey, number 2) through grinding.

Release bonded connections in areas (1) and remove A-pillar.

New part preparation 

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

Prepare REINFORCEMENT PLATES  at severance cuts.

Adjust new part A-pillar to fit with alignment bracket or universal mount.

Fig 12: Identifying Blind Rivets Dimensions

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Create bore holes (2) to (3) for blind rivets N7 as per specified dimensions:

(2): Dia. 6.8 mm bore hole in accordance with dimension a = 10 mm from component edge.

(3): Dia. 6.8 mm bore hole in accordance with dimension b = 55 mm from bore hole (2).

Fig 13: Identifying Bore Holes For Blind Rivets

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Create bore holes (1) and (2) for blind rivets N1 and N3 in accordance with schematic diagram:

(1): Bore hole dia. 6.8 mm.

(2): Bore holes dia. 4.2 mm.

Transfer bore holes (1) created during removal to new part.

Also drill new part through holes (1) with drill Ø 6.8 mm.

Remove new parts and deburr bore holes.

Fig 14: Identifying Bore Holes

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Installing door post, front 

Clean bonding surfaces (1) with cleaning agent R1.

Apply sealant to cavity sealing (2). See INSTALLING CAVITY SEALING (EXPANDED)  and INSTALLING CAVITY SEALING (NOT EXPANDED) .

Apply adhesive to bonding surfaces.

Fig 15: Identifying Bonding Surfaces And Cavity Sealing

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Clean bonding surfaces with cleaning agent R1.

Install new parts and reinforcement plates with alignment bracket or universal mount.

At the same time, make sure water drain hose of slide/tilt sunroof is correctly fitted.

In areas (1), rivet new part with blind rivets N7.

Fig 16: Identifying Blind Rivets Area

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In areas (1), rivet new part with blind rivets N7.

Weld new part in area (2).

Fig 17: Identifying Blind Rivets And Weld Part Area

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Install side frame connection new part and rivet with blind rivets.

Weld new parts in the remaining joint areas.

Fig 18: Identifying Blind Rivet N3/N7 Area

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MAG-weld new part in areas (1).

To do so, apply 10 mm long fillet welds at spacing of 15 mm.

Weld new part in the remaining joint areas.

Fig 19: Identifying MAG-Weld Part Areas

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