Replacing Front Left Wheel Arch (Cooper Clubman F54)

Observe procedure of REPAIR STAGE 3 .

Read contents of BODY, GENERAL .

For stripping and rebuilding operations, refer to surrounding texts on KSD (FRU number 41 14 020).

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

Use only an approved SPOT WELDER for repairs!

Place vehicle on straightening bench.

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

Carrier support, outer wheel arch section
Front shock tower
Support bracket shaped part

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Removal

Mark severance cut (1) as pictured and cut.

Open welded connections in areas (2).

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

Remove partial section of carrier support.

Remove adhesive residues in the area (3).

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Open welded connections in areas (1).

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Fig 1: Front Left Wheel Arch Component Location

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Open welded connections in areas (1) to (3).

NOTE: Open welded connections for both outer panels in area (2).

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Mark severance cut (1) as pictured and cut.

Open welded connections in areas (2) and (3).

NOTE: Make severance cut (1) only on both outer panels.
Open welded connection for both outer panels in area (2).

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

NOTE: Do not drill into or through the engine mount when releasing the welded connections!

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Open spot-weld bonded joints in area (1)

IN AREAS (2), UNDO WELDED CONNECTIONS FOR BOTH EXTERNAL PANELS .

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

NOTE: Do not drill into or through the engine mount when releasing the welded connections!

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New Part Preparation

Open welded connections in areas (1).

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Open welded connections in areas (1).

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Mark severance cut (1) in accordance with severance cut on vehicle and cut. Cut through both panels in area (2). In the area (2) the width of the severance cut must be approximately 5 mm, so that both panels can be welded to the body.

Mark severance cut (3) in accordance with severance cut on vehicle and approx. 5 mm extra material and cut. (4) = Severance cut on vehicle.

Remove metal section (5).

Adjust new parts to fit with alignment bracket and universal fixture.

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Prepare the joints in areas (1) and (2) for joining by welding.

Prepare for joining by welding in areas (1).

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Prepare areas (1) to (3) for joints by welding.

NOTE: 3 panels must be welded to each other in areas (2).

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Prepare the joints in areas (1) to (4) for joining by welding.

Prepare for joining by welding in areas (1).

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

(3) = Position of cavity sealing

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Installation

Install wheel arch new part with alignment bracket or universal fixture and secure.

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

Weld new part in the areas (1).

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Weld new part in areas (1) to (3).

Weld all 3 panels together in areas (2).

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Weld new part in areas (1) to (4).

Weld new part in the areas (1).

Apply sealant to CAVITY SEALING (2). Install cavity sealing.

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Apply sealant to cavity sealing (3).

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

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