41 21 510 Front Left Door Pillar Replacement (Front Side Panel Removed)

Read contents of Body, General  . See 41 0 CONTENTS OF BODY, GENERAL .

Spot-weld bonding is used for the first time on the E65. A specific procedure  must be followed here.

Place vehicle on straightening bench.

Following new body parts are required:

• (1) Support carrier, wheel arch, outer
• (2) Connecting plate, side frame
• (3) A-pillar, outer
• (4) Attachment, entrance, outer
  Fig 1: Identifying Support Carrier, Connecting Plate, A-Pillar And Attachment

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Open weld joints in areas (1).

Remove support carrier (2).

Fig 2: Identifying Weld Joints Areas And Support Carrier

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Open weld joints in area (1).

Fig 3: Identifying Weld Joints Areas

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Mark severance cut (1) on outer entrance attachment and cut.

Measurement a = approx. 50 mm from edge of hole (2) dia. 30 mm.

Open weld joints on section (3) of outer entrance attachment.

Fig 4: Identifying Severance Cut Mark And Weld Joints On Section

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View: wheel arch, front

Open weld joints in areas (1).

Fig 5: Identifying Weld Joints Areas

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Fig 6: Identifying Measurement, Sheet Panel And Weld Joints Areas

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Mark severance cuts in accordance with specified measurements and cut.

Measurement a = approx. 150 mm before rectangular hole 10 mm x 6 mm.

Measurement b = approx. 120 mm below roof edge.

Measurement c = approx. 80 mm below severance cut b.

Open weld joints in areas (1).

Installation: 

Sheet panel (2) is needed again to seal cowl.

Fig 7: Identifying Measurement, A-Pillar Bonded Areas

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Mark severance cut a and cut.

Measurement a = approx. 150 mm below roof edge.

A-pillar is bonded to inner frame in areas (1).

Preparation of new part: 

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

Installation information: 

On all severance cuts, weld in reinforcing plates  approx. 30 mm long. See 41 00... WELDING IN REINFORCEMENT PLATE (STEEL PLATE) .

Apply adhesive  in areas (1). See 41 00... BONDING STEEL PARTS .

Apply window glass adhesive to cavity acoustic baffles  (2). See 41 00... INSTALLING A CAVITY BULKHEAD (EXPANDED)  or 41 00... INSTALLING A CAVITY BULKHEAD (NOT EXPANDED) .

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

Fig 8: Identifying Adhesive Areas And Cavity Acoustic Baffles

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