Replacing Top Cowl Panel And A-Pillar, Complete Left (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 32 101).
Place vehicle on straightening bench.
Following new body parts are required (see Electronic Parts Catalog):
- Windshield panel cover
- Cowl panel, top
- Front inner A-pillar
- Middle side frame
- A-pillar, outer
A-pillar molded part
Following CONSUMABLES are required:
| Material | Quantity |
|---|---|
| Adhesive K1 | 1 |
| Cleaning agent R1 | 1 |
| Sealant D1 | |
| Cavity wax remover |
Removal
Carry out separating cuts (1) and (2) as shown.
Open welded connections in areas (3).
Open welded connections in areas (1) and remove sheet section (2).
Open welded connections in areas (1).
OPEN spot-welded adhesive joints in area (2).
Release A-pillar from cavity sealing (3) and remove.
Open welded connections in areas (1).
Open spot-welded adhesive joints in areas (2).
Detach A-pillar from the cavity sealing (3).
Remove cavity sealing (1).
Open welded connections in area (2).
Open spot-welded adhesive joints in areas (3).
Undo bonded connection (4) and remove A-pillar.
New part preparation
Remove adhesive residue from flange surfaces.
Adjust new parts to fit with alignment bracket or universal mounting.
In area (1) prepare for joining using the bonding method (structural adhesive bonding).
In areas (1) between the outer skin and the A-pillar reinforcement, prepare for joining using the bonding method (structural adhesive bonding).
Prepare all the other joining areas for joining by welding. While doing so, note that double the number of spot-welded joints as replacement for SPOT-WELDED ADHESIVE JOINTS .
OBSERVE preparation of bonding surfaces.
Installation
Clean bonding surface (1) on new part and on the vehicle using solvent cleaner R1.
Apply adhesive K1 to bonding surface (1).
Install new parts to fit with alignment bracket or universal fixture and secure.
Weld new part in the areas (2).
Apply sealant to CAVITY SEALING (3). Install cavity sealing.
Weld new parts in areas (1).
Apply sealant to cavity sealing (1).
Weld new part in the areas (2).
Clean bonding surfaces (1) on new part and on vehicle using solvent cleaner R1.
Apply sealant to cavity sealing (2).
Apply K1 adhesive to bonding surfaces (1).
Install new part and weld in areas (3).
Install new part and weld in area (1).