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

WARNING: This page is about a different car, the 2010 BMW 550i, 2009 BMW 550i, and 2008 BMW 550i. However, it is still accessible from the selected car via links, so may be relevant.

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.

Spot-weld bonding is used on the E60. Observe specific procedure .

Place vehicle on straightening bench.

Following new body parts are required:

A-pillar, outer
Attachment, entrance, outer
Crashbox
Connection, side frame, bottom
Connection, side frame, top
Attachment, endplate
Connection, A-pillar/roof frame
Shaped section, A-pillar, inner

Fig 1: Identifying Front Left Door Pillar Parts
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Open brazing solder and weld joints in area (1).

Remove endplate attachment (2).

Open weld joints in areas (3).

Installation:

Replace brazed seams with MAG weld seams in area (1).

Fig 2: Weld Joints Area And Endplate Attachment

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Open weld joints in areas (1).

Fig 3: Weld Joints Areas

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Open weld joints in area (1).

Fig 4: Weld Joints Areas

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Open weld joints in areas (1) and (2).

Installation:

Weld new part in area (2) from outside with MAG weld seam.

Fig 5: Weld Joints Areas

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Open weld joints in area (1).

Remove crashbox (2).

Fig 6: Weld Joints Area And Crashbox

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

Measurement a = approx. 200 mm from edge of hole (2) dia. 20 mm.

Open weld joints in area (3).

Installation:

Weld in reinforcement plate at severance cut.

Fig 7: Mark Severance Cut On Outer Entrance Attachment

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Fig 8: Mark Severance Cuts In Accordance With Specified Measurements

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Mark severance cuts in accordance with specified measurements and cut.

Measurement a = approx. 100 mm before hole dia. 6 mm.

IMPORTANT: Only cut outer metal plate on both severance cuts.

Measurement b = approx. 180 mm below roof edge.

Measurement c = approx. 100 mm below severance cut b.

Open weld joints in areas (1) and (3).

Remove metal section (2).

Installation:

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

Weld in reinforcing panels at all severance cuts.

Bond and rivet new part in area (3).

Use Hemlock 813 blind rivet

Double number of rivets with respect to welding spots in area (3).

IMPORTANT: For following severance cut, do not damage sunroof water drain hose.

Mark severance cut (1) at A-pillar/roof frame connection and cut.

Measurement a = approx. 210 mm from roof edge.

Open weld joints in areas (2).

Weld in reinforcement plate at severance cut.

Fig 9: Mark Severance Cuts In Accordance With Specified Measurements

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Open weld joints in areas (1).

Open adhesive joints in areas (1) and (2).

Installation:

Replace adhesive in areas (1) with plug welding.

Fig 10: Weld Joints Areas And Adhesive Joints Areas

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Installation:

Apply window glass adhesive to cavity acoustic baffles (1).

Apply adhesive in area (2).

Fig 11: Window Glass Adhesive Applying Area To Cavity Acoustic Baffles

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Preparation of new part:

Open weld joints in areas (2).

Mark A-pillar/roof frame connection (1) in accordance with vehicle and cut.

Fig 12: Cutting Mark And Weld Joints Area

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Preparation of new part:

Open weld joints (1) at outer entrance attachment (2).

Mark severance cut (3) in accordance with vehicle and cut.

Cut off metal section (4) in accordance with measurement a from new part.

A = approx. 100 mm

Fig 13: Weld Joints Area At Outer Entrance Attachment And Cutting Marks On Metal Section

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Preparation of new part:

Apply window glass adhesive to cavity acoustic baffle (1).

Fig 14: Window Glass Adhesive Applying Area To Cavity Acoustic Baffle

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Preparation of new part:

Place A-pillar/roof frame (1) in outer A-pillar (2) and adapt.

Weld both parts in areas (3).

Fig 15: Weld Joints Area

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