41 21 003 Replacing A-Pillar With Reinforcement On Left Rep-Rep-RAF5641-4121003 - V.4 (Cooper 2-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):

Middle side frame
Outer front side frame
Door sill, outer

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Removal:

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Open welded connections in areas (1).

OPEN spot-welded adhesive joints in area (2).

Release A-pillar outer part from cavity sealing (3) and remove.

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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:

Open welded connections for components (1) which are not required. Remove components (1) which are not required.

Adjust new parts to fit with alignment bracket or universal mounting.

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.

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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 sealing compound to cavity sealing. Refer to INSTALLING CAVITY SEALING (NOT EXPANDED) REP-REP-RAGRP41-4107102 - V.4 (Cooper 4-door hatchback and 2-door hatchback, 2020-2023) (3).

Install new parts and weld in areas (1) and (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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