Replace The Left Side Frame Completely (Front Side Panel And Rear Quarter Panel Removed) (Cooper, Cooper S, John Cooper Works)

Observe procedure for REPAIR STAGE 3 .

Read contents of BODY, GENERAL .

Spot-weld bonding is used on this vehicle. Observe specific PROCEDURE .

Use only approved SPOT WELDER  for repair.

For stripping and rebuilding operations, refer to surrounding texts on KSD (FRU number 41 21 685).

Place vehicle on straightening bench.

Following new body parts are required (see Electronic Parts Catalog):

1. A-pillar, outer
2. windshield panel cover
3. Middle side frame

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Following CONSUMABLES  are required:

Material	Quantity
Adhesive K1	1
Cleaning agent R1	1
Sealant D1
Cavity wax remover

Removal 

Open the welded connections in area (1) and remove the cowl panel.

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Courtesy of BMW OF NORTH AMERICA, INC.

Open welded connections in areas (1).

OPEN  spot-welded adhesive joints in area (2).

Release bonded connections in areas (3) and remove A-pillar.

Release A-pillar from cavity sealing (4) and remove.

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Open welded connections in areas (1).

Open spot-welded adhesive joints in areas (2).

Release the side frame from the cavity sealing (3).

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Open welded connections in areas (1).

Open spot-welded adhesive joints in areas (2).

Release the side frame from the cavity sealing (3).

View of A-pillar vehicle interior.

Open the MAG welded connection (1).

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Courtesy of BMW OF NORTH AMERICA, INC.

Open bonded connection in areas (1).

Remove side frame.

New part preparation 

Remove adhesive residues completely from flange surfaces of the vehicle.

Adjust the new components with the alignment bracket or universal fixture and in combination with the installed parts.

Installation 

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

Apply K1 adhesive to bonding surfaces (1).

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Apply sealant on the cavity sealing (3) and on the cavity sealing on the B-pillar (See CAVITY SEALINGS ).

Install new part with alignment bracket or universal mount and secure.

Weld new part in the areas (1) and (2).

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Weld new part in the areas (1) and (2).

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Apply sealant to cavity sealing (4).

Apply K1 adhesive to bonding surfaces (3).

Install the new part A-pillar and weld in the areas (1) and (2).

MAG weld the new parts in area (1).

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Install new part and weld in area (1).

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