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

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: Body Parts Components

  Courtesy of BMW OF NORTH AMERICA, INC.

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: Open Brazing Solder And Weld Joints Area

Courtesy of BMW OF NORTH AMERICA, INC.

Open weld joints in areas (1).

Fig 3: Open Weld Joints Areas

Courtesy of BMW OF NORTH AMERICA, INC.

Open weld joints in area (1).

Fig 4: Open Weld Joints Area

Courtesy of BMW OF NORTH AMERICA, INC.

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

Installation: 

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

Fig 5: Open Weld Joints And Weld Part Area

Courtesy of BMW OF NORTH AMERICA, INC.

Open weld joints in area (1).

Remove crashbox (2).

Fig 6: Open Weld Joints Area And Crashbox

Courtesy of BMW OF NORTH AMERICA, INC.

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: Open Weld Joints Area

Courtesy of BMW OF NORTH AMERICA, INC.

Fig 8: Mark On Severance Cuts

Courtesy of BMW OF NORTH AMERICA, INC.

Mark severance cuts in accordance with specified measurements and cut.

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

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 REINFORCEMENT 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).

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: Open Weld Joints Areas

Courtesy of BMW OF NORTH AMERICA, INC.

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: Open Weld And Adhesive Joints Areas

Courtesy of BMW OF NORTH AMERICA, INC.

Installation: 

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

Apply adhesive in area (2).

Fig 11: Adhesive And Window Glass Adhesive Applying Area

Courtesy of BMW OF NORTH AMERICA, INC.

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: Open Weld Joints Areas

Courtesy of BMW OF NORTH AMERICA, INC.

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: Open Weld Joints And Outer Entrance Attachment

Courtesy of BMW OF NORTH AMERICA, INC.

Preparation of new part: 

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

Fig 14: Window Glass Adhesive Applying Area

Courtesy of BMW OF NORTH AMERICA, INC.

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 Both Parts Areas

Courtesy of BMW OF NORTH AMERICA, INC.