41 21 511 Replacing front left door post (front side panel removed)

Read contents of BODY, GENERAL .

Use only approved SPOT-WELDING APPARATUS for repairs.

Remove or cover those vehicle components in the repair area which are susceptible to heat or dust.

Place vehicle on straightening bench.

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

The following new body parts are required:

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

The following CONSUMABLES are required:

Fig 1: Identifying Front Side Frame Support Carrier And Outer Side Frame

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MATERIAL QUANTITY SPECIFICATION

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

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 weld joints in area (1).

Fig 4: Identifying Weld Joints Area

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Separate MAG-welded joints in area (1) and remove door hinge (2).

Fig 5: Identifying MAG Welded Connection Area And Door Hinge

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Separate 2 welded joints in area (1) of the hinge mounting surface.

Installation note:

Replace welded joints in area (1) by 2 additional plug welds in area (2).

Fig 6: Identifying Areas Of Welded Connections And Plug Welds

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Mark severance cut in accordance with dimension and cut.

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

Dimension (b) = 35 mm before elongated hole dia. 12x18 mm.

Open welded connections in areas (1).

Open welded connections in area (2).

Take off door post.

Fig 7: Identifying Severance Cut Area And Welded Connections Areas

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New part preparation

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

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

Repair stage 2:

Adjust new support beam to fit and secure.

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

Fig 8: Identifying Area For Blind Rivet Bore Holes

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In areas (1) set three 6.7 mm dia. holes for blind rivets.

Remove all new parts again. Deburr bore holes.

Fig 9: Identifying Areas For Blind Rivet Bore Holes

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

Door post installation

Apply sealant to cavity acoustic baffles in areas (1). Refer to INSTALLING CAVITY SEALING (EXPANDED) and INSTALLING CAVITY SEALING (NOT EXPANDED) .

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

Weld in REINFORCEMENT PLATES at all severance cuts.

Fig 10: Identifying Sealant Application Areas On Cavity Acoustic Baffles

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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 11: Identifying Bonding Surfaces

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Mount support carrier and rivet with blind rivets N1 (1).

Fig 12: Identifying Riveting Area

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Rivet support carrier with blind rivets N1 (1).

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

Fig 13: Identifying Riveting Area

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