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

Read 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: Outer Wheel Arch Support Carrier, Side Frame Connecting Plate, Outer A-Pillar And Outer Entrance Attachment

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Open weld joints in areas (1).

Remove support carrier (2).

Fig 2: Open Weld Joint Areas And Support Carrier

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Open weld joints in area (1).

Fig 3: Open 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: Open Weld Joints, Severance Cut And Hole

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View: wheel arch, front

Open weld joints in areas (1).

Fig 5: Open 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 6: Open Weld Joints Areas, Sheet Panel And Measurement 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).

Fig 7: A-Pillar/Inner Frame Bonded Areas And Measurement

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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.

Apply adhesive   in areas (1).

Apply window glass adhesive to cavity acoustic baffles   (2).

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

Fig 8: Adhesive Application Areas And Cavity Acoustic Baffles

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