Replacing Engine Mount With Left Wheel Arch In Front Of Bulkhead (Cooper, Cooper S, John Cooper Works)

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2021 MINI Cooper, 2020 MINI Cooper, 2019 MINI Cooper, 2018 MINI Cooper, and 2017 MINI Cooper. However, it is still accessible from the selected car via links, so may be relevant.

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 11 071).

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

Use only an approved SPOT WELDER for repairs!

Place vehicle on straightening bench.

Courtesy of BMW OF NORTH AMERICA, INC.

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

Carrier support, outer wheel arch section
Wheel arch inner section support member
Carrier support bulkhead
Front shock tower
Engine mount, inner
Wheel arch carrier support shaped part

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.

Courtesy of BMW OF NORTH AMERICA, INC.

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.

NOTE: New part is installed with overlap in area of severance cut (2).

Courtesy of BMW OF NORTH AMERICA, INC.

Courtesy of BMW OF NORTH AMERICA, INC.

Mark severance cut (1) as pictured and cut.

Open welded connections in area (2).

Courtesy of BMW OF NORTH AMERICA, INC.

Open welded connections in area (1).

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

NOTE: 3 panels are welded in area (2). Open welded connection for both outer panels.

Courtesy of BMW OF NORTH AMERICA, INC.

Open welded connections in area (1).

Courtesy of BMW OF NORTH AMERICA, INC.

Courtesy of BMW OF NORTH AMERICA, INC.

Mark severance cut (1) as pictured and cut.

Remove welded connections in areas (2) and (3) and remove engine mount with wheel arch.

NOTE: Three panels are welded in areas (3). Open welded connection for both outer panels.

Remove welded connection in areas (1) and remove residual section of engine mount (2).

Courtesy of BMW OF NORTH AMERICA, INC.

New part preparation

Courtesy of BMW OF NORTH AMERICA, INC.

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).

Prepare new parts and vehicle for joining by welding.

Adjust new part for engine mount internal part using alignment bracket or universal fixture. Prepare new part for joining by welding in areas (1).

Courtesy of BMW OF NORTH AMERICA, INC.

Adapt new part for spring support using alignment bracket or universal fixture.

NOTE: Inner part of engine mount new part is hidden for a better overview.

Wheel arch support (1),

Motor support outer part (2) and Front axle support (3) need to be in the fields (4) by means of

HOLE POINT WELDING PROCESS be blended.

Courtesy of BMW OF NORTH AMERICA, INC.

In areas (4) drill 2 x holes Ø 10 mm. Do not spot-drill or drill through front axle support stand (3)!

In area (5), prepare new part for joining by welding.

Courtesy of BMW OF NORTH AMERICA, INC.

Prepare new parts in areas (1) up to (3) for joints through welding.

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

Increase size of holes in areas (3) (open welded connections) top 0 10 mm. Transfer holes to new engine mount internal part and drill.

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: The "front axle support stand" is located in the areas (1). (See figures RB41 03111 and RB41 03112)
The "front axle support stand" component must be welded in the areas (1) using plug welding method.

The positions of the bores (2) can be found on the removed part and transferred to the new part.

Do not drill in or drill through "front axle support stand" component!

In areas (2), set 4 x Ø 10 mm bores. Prepare the new part for joining by welding in this area (3).

Courtesy of BMW OF NORTH AMERICA, INC.

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

Courtesy of BMW OF NORTH AMERICA, INC.

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.

NOTE: Follow PROCEDURE for replacement of spot-welded adhesive joints in area (2).

Courtesy of BMW OF NORTH AMERICA, INC.

Remove adhesive residues in the area (2).

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

Remove new parts and deburr bores.

NOTE: Follow procedure for replacement of spot-welded adhesive joints in area (2).

(3) = position of the cavity sealing.

Courtesy of BMW OF NORTH AMERICA, INC.

Installation

Install new engine mount internal part with alignment bracket or universal fixture and weld into areas (1).

Courtesy of BMW OF NORTH AMERICA, INC.

Weld new engine mount internal part in areas (1) and (2).

Courtesy of BMW OF NORTH AMERICA, INC.

Install new spring support part with alignment bracket or universal fixture and weld into areas (1) and (2).

Courtesy of BMW OF NORTH AMERICA, INC.

Weld new parts in areas (1) and (2).

Courtesy of BMW OF NORTH AMERICA, INC.

Weld new parts in areas (1) and (2).

Courtesy of BMW OF NORTH AMERICA, INC.

Weld new part in area (1).

Courtesy of BMW OF NORTH AMERICA, INC.

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

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

Courtesy of BMW OF NORTH AMERICA, INC.

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

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

Courtesy of BMW OF NORTH AMERICA, INC.