Replacing A-Pillar With Reinforcement On Left (Cooper Clubman F54)

Observe procedure of REPAIR STAGE 3 !

Read contents of BODY, GENERAL .

For stripping and rigging operations, refer to the surrounding text of the KSD (FRU number: 41 21 003).

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

Use only an approved SPOT WELDER for repairs!

Place vehicle on straightening bench.

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

(1) A-pillar, outer
(2) Middle side frame
Upper cavity sealing for A-pillar

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Removal

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

IMPORTANT: Cut through outer panel only for severance cuts.

Open welded connections in areas (3).

RELEASE spot-welded adhesive joints in the areas (4).

Release and remove A-pillar from cavity sealing (5).

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Mark separating cut (1) approx. 30 mm from previous separating cut and cut.

IMPORTANT: For this separating cut, only cut the outer panel.

Open welded connections in areas (2).

(3) = Position of inner cavity sealing.

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Open welded connections in areas (1).

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Mark severance cuts (1) in accordance with schematic diagram and roughly cut.

IMPORTANT: Cut only outer plates.

Remove sheet sections.

Undo welded connections in these areas (2) and remove the A-pillar reinforcement.

New Part Preparation

Mark severance cuts on new parts according to severance cuts on vehicle and sever.

Prepare REINFORCEMENT PLATES at severance cuts.

Prepare new parts for joining by welding.

Adjust new parts to fit with alignment bracket or universal mounting.

NOTE: When adjusting the new part, the panel thickness of the A-pillar outer skin must be taken into consideration depending on straightening system manufacturer.

Installation

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Apply sealant to CAVITY SEALING (1).

Install the A-pillar reinforcement and reinforcement plate with the alignment bracket or universal fixture and weld in the areas (2).

NOTE: When installing the new part, the panel thickness of the A-pillar outer skin must be taken into consideration depending on straightening system manufacturer.

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Weld new part in the areas (1).

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Coat cavity sealings (1) with sealant.

Install outer skin for new part on A-pillar and reinforcement plates and weld in areas (2) and (3).

NOTE:

Schematic diagram:
Vehicles with Sliding/Tilting Sunroof: Make sure water drain hose (1) is correctly installed! (watertightness).
In vehicle with a Normal Roof , a grommet is installed instead of the water drain hose.
Please ensure correct installation of the grommet!

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