Completely Replacing The Left Carrier Support (Cooper, Cooper S, John Cooper Works)

Read contents of BODY, GENERAL .

Follow procedure for REPAIR STAGE 3 .

For stripping and rigging operations, refer to texts on KSD CD (job number 41 11 205).

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

Use only approved SPOT WELDER  for repairs.

The following new body parts are required (refer to Electronic Parts Catalog).

• (1) Outer wheel arch carrier support
• (2) Carrier support, inner wheel arch section
• (3) Carrier support bulkhead
• Support bracket shaped part

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Removal: 

Open welded connections in areas (1).

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

Release and remove carrier support outer section from cavity sealing (3).

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Mark severance cut (1) as pictured and cut.

Open welded connections in areas (2).

Undo spot-welded adhesive joints in areas (3) and remove carrier support inner section.

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

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Preparation of new part: 

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

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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: 

Install bulkhead (2) and weld in areas (1).

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

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Apply sealant to cavity sealing (3) (See CAVITY SEALING ).

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

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