41 21 003 Replacing A-pillar with reinforcement on left

WARNING: This page is about a different car, the 2019 MINI Cooper, 2018 MINI Cooper, 2017 MINI Cooper, 2016 MINI Cooper, and 2015 MINI Cooper. However, it is still accessible from the selected car via links, so may be relevant.

Observe procedure for REPAIR STAGE 3 .

Read contents of BODY, GENERAL .

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:

A-pillar, outer
Middle side frame

Fig 1: Outer A-Pillar And Middle Side Frame

Courtesy of BMW OF NORTH AMERICA, INC.

Removal:

Mark severance cuts in accordance with specified dimensions and cut.

IMPORTANT: Cut outer panel only for following severance cuts.

Dimension "a" = 55 mm below center point of 8 mm dia. hole.

Dimension "b" = 135 mm before center point of 25 mm dia. hole.

LOOSEN spot-welded adhesive joints in area (1).

Open welded connections in areas (2).

Release and remove A-pillar from cavity sealings (3).

Fig 2: Severance Cuts, Welded Connections, And Cavity Sealings

Courtesy of BMW OF NORTH AMERICA, INC.

Roughly mark areas (1) as pictured and cut.

IMPORTANT: Cut outer panel only.

Do not damage bulkhead in area (2)!

Open welded connections in areas (3).

Open spot-welded adhesive joints in area (4).

Remove A-pillar reinforcement.

Fig 3: Cutting Areas, Welded Connections, And Spot-Welded Adhesive Joints

Courtesy of BMW OF NORTH AMERICA, INC.

Preparation of new part:

Carry out the severance cut on the new part "A-pillar outer skin" according to the severance cut on the vehicle.

Prepare REINFORCEMENT PLATES at severance cuts.

Remove the superfluous components from new part "center side frame".

Adjust the new parts with an alignment bracket or a universal fixture and prepare it for joining through welding.

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

Installation:

Install A-pillar with alignment bracket or universal fixture and weld in areas (1) and (2).

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

Apply repair welding spot (3) to existing welding spot on vehicle. This is necessary because the adhesive between the spot flanges acts as an insulator.

Fig 4: Bracket Welding Areas And Repair Welding Spot

Courtesy of BMW OF NORTH AMERICA, INC.

Apply sealant to CAVITY SEALINGS (1).

Install new parts and weld in areas (2).

Fig 5: Welding Areas And Cavity Sealings

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE:

Vehicles with sliding/tilting sunroof: Make sure water drain hose (1) is correctly installed! (watertightness).
In vehicles with a normal roof, a grommet is installed instead of the water drain hose.

Fig 6: Water Drain Hose Location

Courtesy of BMW OF NORTH AMERICA, INC.

Please ensure correct installation of the grommet!