41 21 003 Replacing A-Pillar With Reinforcement On Left Rep-Rep-RAF5541-4121003 - V.1 (Cooper 4-Door Hatchback, 2020-2023)

Procedure OBSERVE repair stage 3!

Read contents of BODY, GENERAL .

For stripping and rigging operations, refer to the surrounding text on the KSD CD (FRU number: 41 21 003).

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 (see Electronic Parts Catalog):

A-pillar, outer
Middle side frame

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Removal:

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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).

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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.

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:

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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.

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Apply sealant to cavity sealings. Refer to INSTALLING CAVITY SEALING (NOT EXPANDED) REP-REP-RAGRP41-4107102 - V.4 (Cooper 4-door hatchback and 2-door hatchback, 2020-2023) (1).

Install new parts and weld in areas (2).

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.
Please ensure correct installation of the grommet!

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