Replacing Front Left Wheel Arch (Cooper, Cooper S, John Cooper Works)

Observe procedure of REPAIR STAGE 3 .

Read contents of BODY, GENERAL .

Use only an approved SPOT WELDER  for repairs!

Strip down vehicle. Refer to STRIPPING OPERATIONS - REPLACING FRONT LEFT WHEEL ARCH  or STRIPPING OPERATIONS - REPLACING FRONT RIGHT WHEEL ARCH .

Place vehicle on straightening bench.

The following new parts are required (see Electronic Parts Catalog):

1. Carrier support, outer wheel arch section
2. Carrier support bulkhead
3. Wheel arch inner section support member
4. Front shock tower
5. Support bracket shaped part

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Following CONSUMABLES  are required:

Material	Quantity
Adhesive K1	1
Blind rivet N1	8
Blind rivet N7	20
Cavity sealing wax remover	1
Cleaning agent R1	1
Sealant D1	1

Removal: 

Mark severance cut (1) as pictured and cut.

Open welded connections in areas (2).

RELEASE  spot-welded adhesive joints in area (3) and remove partial carrier support section.

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Mark severance cuts (1) and (2) and cut according to schematic diagram.

Release welded connections in area (3) and remove partial inner carrier support part section.

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Courtesy of BMW OF NORTH AMERICA, INC.

Mark severance cut (1) as pictured and cut.

Open welded connections in area (2).

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Open welded connections in area (1).

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Open welded connections in areas (1) and (2).

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Release welded connections in areas (1) and (2) and remove wheel arch.

Preparation of new part: 

Center-punch welded connections in areas (1) and drill through with Ø 6.8 mm drill. Remove the remaining areas of the welded connections, which were not removed with the drill, from the inside of the engine mount by grinding them off.

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Center-punch welded connections in areas (1) and drill through with Ø 6.8 mm drill.

Remove the remaining areas of the welded connections, which were not removed with the drill, from the inside of the engine mount by grinding them off.

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Courtesy of BMW OF NORTH AMERICA, INC.

Adjust new parts to fit with alignment bracket or universal mount and secure.

Transfer Ø 6.8 mm bores to engine mount in areas (1) and (2).

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Transfer Ø 6.8 mm bores to engine mount in areas (1) and (2).

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In area (1), prepare new part for joining by welding.

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Produce REINFORCEMENT PLATE  (1) for severance cut (2) and adjust.

Adjust bulkhead (3).

In areas (4), prepare new parts for joining by welding.

Mark severance cut on carrier support inner section according to severance cut on vehicle +20 mm material extra and cut.

Adjust new part and prepare in areas (1) and (2) for joining by welding.

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Install new part in areas (1) and (2), prepare for joining by welding.

Remove new parts and deburr bores.

(3) = position of cavity sealing.

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Installation: 

Clean bonding surfaces on vehicle and on new part with cleaning agent R1.

Apply adhesive to bonding surfaces.

Install wheel arch with alignment bracket or universal mount.

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Rivet the new part with the blind rivet N7 in the areas (1).

Use the blind rivet N1 in the areas (2).

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Rivet the new part with the blind rivet N7 in the areas (1).

In area (2), use blind rivet N1.

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Weld new part in area (1).

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Install reinforcement plate (1) and weld with severance cut (2). Weld new part and bulkhead (3) in the areas (4).

Install new part, weld in areas (1) and (2).

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Apply sealant on CAVITY SEALING  (3).

Install new part, weld in areas (1) and (2).

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