41 11 071 Replacing engine mount with left wheel arch in front of bulkhead

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 of 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 body parts are required:

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 (not shown)

Fig 1: Wheel Arch Inner Section Support Member

Courtesy of BMW OF NORTH AMERICA, INC.

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.

Fig 2: Severance Cut Mark And Spot-Welded Adhesive Joints Area

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).

Fig 3: Severance Cut Mark And Welded Connections Area

Courtesy of BMW OF NORTH AMERICA, INC.

Mark severance cut (1) as pictured and cut.

Open welded connections in area (2).

Fig 4: Severance Cut Area And Welded Connections Area

Courtesy of BMW OF NORTH AMERICA, INC.

Open welded connections in area (1).

Fig 5: Welded Connections Area

Courtesy of BMW OF NORTH AMERICA, INC.

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

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

Fig 6: Welded Connection Areas

Courtesy of BMW OF NORTH AMERICA, INC.

Open welded connections in area (1).

Fig 7: Welded Connections Area

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.

Fig 8: Severance Cut Mark And Welded Connections Areas

Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 9: Engine Support Residual Section And Welded Connection Areas

Courtesy of BMW OF NORTH AMERICA, INC.

New part preparation

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.

Fig 10: Metal Section Severance Cut Marks

Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 11: Welding Areas

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), engine support outer part (2) and front axle support fixture (3) must be welded in areas (4) using PLUG WELDING method.

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.

Fig 12: Wheel Arch Support, Engine Support Outer Part And Front Axle Support Fixture

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 Ø 10 mm. Transfer holes to new engine mount internal part and drill.

Fig 13: Bore Holes And Welding Areas

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: The "front axle support stand" is located in the areas (1). (See Fig 11 and Fig 12.

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).

Fig 14: Bore Hole Areas And Welding Areas

Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 15: Welded Connections Area

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.

Fig 16: Severance Cut And Welding Areas

Courtesy of BMW OF NORTH AMERICA, INC.

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).

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.

Fig 17: Weld-Joint Areas And Spot-Welded Adhesive Joints

Courtesy of BMW OF NORTH AMERICA, INC.

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

(3) = position of the cavity sealing.

Fig 18: Welding Areas

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).

Fig 19: Welding Areas

Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 20: Welding Areas

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).

Fig 21: Welding Areas

Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 22: Welding Areas

Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 23: Welding Areas

Courtesy of BMW OF NORTH AMERICA, INC.

Weld new part in area (1).

Fig 24: Welded Connections Area

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).

Fig 25: Severance Cut And Welding Areas

Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 26: Weld-Joint Areas And Spot-Welded Adhesive Joints

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).

Fig 27: Cavity Sealing And New Part Welding Areas

Courtesy of BMW OF NORTH AMERICA, INC.