Body - Repair - Cooper & Cooper S (R56)

• Body, General
  • Safety Information For Working On Vehicles With Automatic Engine Start-Stop System (MSA)
  • 41 00... Blind rivets
    • 1.0 Recommended tools and equipment
    • Setting blind rivets
  • 41 00... Bonding on painted surfaces
    • Notes
    • Overview of topics
    • 1.0 Equipment
    • 2.0 Expiry date of consumables
    • 3.0 Preparation of surface
      • 3.1 Preparation of the surface on the vehicle (series status)
      • 3.2 Preparation of the surface on the vehicle (replacement of a bonded component)
      • 3.3 Preparation of surface on new part
    • 4.0 Adhesive application
    • 5.0 Hardening times
    • 6.0 Subsequent treatment
    • 7.0 Disposal of adhesive
  • 41 00... Bonding Steel Parts
  • 41 00... Corrosion Protection
  • 41 00... EMC screws
    • Notes
    • Purpose
    • Procedure, aluminium front end
    • Procedure, steel body
  • 41 00... Frame Alignment Control Dimensions, Body
  • 41 00... Gap Dimensions, Body
  • 41 00... General Cementing Instructions
  • 99 00... General instructions on paintwork
  • 51 14... General notes for labelling with adhesive films
    • Notes
    • Preparation
    • Procedure for applying labels
  • 41 00... Grinding aluminium components
    • 1.0 Recommended tools and equipment
    • 2.0 Grinding outer shell and structure
  • 41 00... Grinding Steel Parts
  • 41 00... Handling airbags and restraint systems
  • 41 00... Handling electrical and electronic equipment
  • 41 00... Information/warning labels
  • 41 00... Information On Hazards
  • 41 00... Information on metal filler
    • Notes
    • Storage
    • Shelf life
    • Surface pre-treatment
    • Processing
    • Applying filler
    • Hardening time
    • Post-processing
    • Paintwork
    • Metal filler disposal
  • 64 00... Information on using cleaning agent/paints (personal protection equipment)
  • 41 00... Information On Vehicle Protection
  • 41 00... Installation solution for straight shank/hexagon rivet nut
    • Notes
    • Hexagon/straight shank rivet nut (up to thread 8) with hand rivet gun ZS308
    • Hexagon / straight shank rivet nut (up to thread M12) with hand rivet gun MB512
  • 41 00... Installing a cavity sealing with 2-component PU cavity foam
  • 41 00... Installing a cavity acoustic baffle (expanded)
  • 41 00... Installing a cavity sealing (not expanded)
  • 41 00... Materials Science
  • 41 00... Notes on adhesive K1
    • Notes
    • Storage
    • Shelf life
    • Surface pre-treatment
    • Required cartridge gun
    • Preparing the glue cartridge
    • Adhesive application
    • Hardening time
    • Disposal of adhesive
  • 41 00... Notes on adhesive K2
    • Notes
    • Storage
    • Shelf life
    • Surface pre-treatment
    • Required cartridge gun
    • Preparing the glue cartridge
    • Adhesive application
    • Hardening time
    • Disposal of adhesive
  • 41 00... Notes on adhesive K3
    • Notes
    • Storage
    • Shelf life
    • Surface pre-treatment
    • Required cartridge gun
    • Preparing the glue cartridge
    • 2-component adhesive application
    • Hardening time
    • Adhesive disposal
  • 41 00... Notes on adhesive K4
    • Notes
    • Storage
    • Shelf life
    • Surface pre-treatment
    • Required cartridge gun
    • Preparing the glue cartridge
    • 2-component adhesive application
    • Hardening time
    • Disposal of adhesive
  • 41 00... Notes on adhesive K5
    • Notes
    • Storage
    • Shelf life
    • Surface pre-treatment
    • Required cartridge gun
    • Preparing the glue cartridge
    • Adhesive application
    • Hardening time
    • Disposal of adhesive
  • 41 00... Notes on cleaning agent R1
  • 61 00... Notes on handling the high pressure cleaner
  • 41 00... Notes On Repairing Threads
  • 41 00... Notes on the water drain hose of the slide/tilt sunroof
  • 99 00... Notes on using temperature-controlled infra-red radiators
  • 41 00... Opening bonded connections
  • 41 00... Opening brazed connections
  • 41 00... Opening riveted connections
    • Notes
    • Opening blind rivets
      • 1.1 Opening blind rivets (N1 and N2)
      • 1.2 Opening blind rivets (N3 and N6)
    • Opening punch rivets
      • 2.1 Opening punch rivets by extraction
      • 2.2 Opening punch rivets by drilling out
  • 41 00... Opening welded connections
    • Opening welding spots (resistance pressure spot welding)
    • Opening MAG weld seams and MIG brazing seams
    • Opening laser weld seams
  • 41 00... Overview of adhesive cartridge guns
  • 41 00... Overview of consumables (Electronic Parts Catalogue)
    • 1.0 Adhesives
    • 1.1 Primer
    • 1.2 Cleaning agent
    • 1.3 Fillers
    • 2.1 Rivets
    • 2.2 Plastic nuts
    • 3.0 Primer
    • 4.0 Sealant
    • 5.0 Cavity preservation
    • 6.0 Cavity foam
    • 7.0 EMC screw (electromagnetic compatibility)
    • 8.0 Twist drill
  • 41 00... Position Of Shaped Parts For Cavity Acoustic Baffle
  • 41 00... Punch rivets
    • Notes
    • 1.0 Recommended tools and equipment
    • Setting punch rivets
  • 41 00... Quality Standard
  • 41 00... Repair solution for straight shank/hexagon rivet nut
    • Notes
    • Hexagon / straight shank rivet nut (up to thread M8) with hand rivet gun ZS308
    • Hexagon / straight shank rivet nut (up to thread M12) with hand rivet gun MB512
  • 41 0 Repair techniques, repair stage 1
  • 41 0 Repair techniques, repair stage 2
  • 41 0 Repair techniques, repair stage 3
  • 41 00... Repairing plastic components
    • 1.0 General information
    • 2.0 Shaping plastic parts
    • 3.0 Bonding plastic parts
  • 41 00... Riveting Steel Parts
  • 41 00... Safety At Work
  • 41 00... Setting blind rivet nuts and bolts
  • 41 00... Spot-weld bonding steel components
  • 41 00... Spray gun for cavity sealant
    • Notes
    • 1.0 Scope of delivery
    • 2.0 Start-up
    • 3.0 Mode of operation
    • 4.0 Application examples
    • 5.0 Safety instructions
  • 41 00... Stamping Vehicle Identification Number
  • 41 00... Straightening aluminium component on the outer skin
    • 1.0 Recommended tools
    • 2.0 Straightening outer skin
  • 41 00... Straightening aluminium components in structure
  • 41 00... Straightening Steel Parts
  • 99 00... Touching up paintwork damage
  • 41 00... Use Of Materials In Outer Skin
  • 41 00... Vehicle Identification Number, General
  • 41 00... Welding steel components
    • Notes
    • General information
    • Work materials
    • Preparations for MAG and spot-welding
    • Welding
    • Subsequent treatment of weld joints
  • 41 00... Welding In Reinforcement Plate (Sheet Steel)
  • 41 00... Working with 2-component PU cavity foam
    • Notes
    • Information on dangers/hazards
    • Application instructions
  • 41 00... Workshop Equipment
• Support Members
  • 41 11 028 Replacing Left Engine Support (Partial Replacement Before Front Axle)
  • 41 11 043 Replacing Front Section Of Left Engine Support
  • 41 11 043 Stripping operations - Replacing front section of left engine support
  • 41 11 141 Replacing Cover For Left Or Right Longitudinal Member
  • 41 11 300 Replacing Cover For Longitudinal Member With Left Or Right Door Pillar (Partial Replacement B-Pillar, Rear Side Panel Removed)
  • 41 11 720 Replacing Rear Left Side Member (Partial Replacement, Rear Panel And Side Panel At Rear Left Removed)
• Luggage Compartment
  • 41 12 535 Replacing Complete Rear Luggage Compartment Floor (Tail Panel Removed)
    • Notes
    • Preparation of new part
  • 41 12 535 Replacing Complete Rear Luggage Compartment Floor
• Wheel Wells
  • 41 14 021 Replacing Front Left Wheel Arch
  • 41 14 511 Replacing Complete Rear Left Wheel Arch (Rear Left Side Panel Removed)
  • 41 14 021 Stripping Operations - Replacing Front Left Wheel Arch
• Side Frame And Door Pillars
  • 41 21 511 Replacing Front Left Door Pillar (Front Side Panel Removed)
• Roof Outer Skin
  • 41 31... Installing Roof Rack Reinforcement
  • 41 31 010 Replacing Roof Outer Skin (Version With Slide/Tilt Sunroof)
  • 41 31 001 Replacing Roof Outer Skin (Version With Slide/Tilt Sunroof)
  • 41 31 000 Stripping Operations - Replacing Roof Outer Skin (Normal Roof)
  • 41 31 001 Stripping Operations - Replacing Roof Outer Skin (Version With Slide/Tilt Sunroof)
• Dash Cowl
  • 41 32 000 Replacing Left Or Right Cowl Panel (Partial Replacement Before Roof Connection)
• Front Trim Panel
  • 41 33... Removing And Installing Complete Front Panel (For Engine Removal)
  • 41 33 040 Replacing Front Wall
  • 41 33 600 Moving Front Panel Into Assembly Position
  • 41 33 695 Removing And Installing Lock Bridge
• Rear Trim Panel
  • 41 34 121 Replacing complete tail panel and luggage compartment floor
  • 41 34 042 Replacing outer section of rear apron (partial replacement - middle)
    • Notes
    • Removing rear trim panel
    • Preparation of new part
    • Installing rear trim panel
  • 41 34 037 Replacing outer section of rear apron (partial replacement)
    • Notes
    • Removing rear trim panel
    • Preparation of new part
    • Installing rear trim panel
  • 41 34 060 Replacing Tail Panel
  • 41 34 042 Stripping operations - Replacing tail panel outer section (partial replacement, center)
  • 41 34 037 Stripping-down operations - Replacing tail panel outer section (partial replacement)
  • 41 34 060 Stripping operations - Replacing tail panel
• Side Panels
  • 41 35 000 Removing And Installing/Replacing Side Panel, Front Left Or Right
  • 41 35 105 Replacing Rear Left Side Panel
    • Notes
    • Preparation of new part
    • Installing side wall
  • 41 35 105 Stripping operations - Replacing rear left side panel
• Front And Rear Side Doors
  • 41 5.... Adjusting Door
    • Notes
    • Adjusting lock striker
    • After setting
  • 41 51 080 Removing and installing door
  • 41 5.... Replace door
• Front Lid
  • 41 61 000 Removing and installing engine compartment lid
  • 41 61 001 Replacing engine bonnet/hood
  • 41 61 014 Adjust engine compartment lid
• Rear Lid
  • 41 62 000 Removing And Installing Rear Lid
  • 41 62 014 Adjusting Rear Lid To Fit
• Other Flaps
  • 41 63 000 Removing And Installing Flap For Fuel Filler Neck
  • 41 63 003 Replacing Cover Bowl