41 21 201 Replacing B-Pillar With Reinforcement On Left Rep-Rep-RAF5541-4121201 - V.2 (Cooper 4-Door Hatchback, 2020-2023)

Procedure OBSERVE repair stage 3!

Read contents of BODY, GENERAL .

For stripping and rigging operations, refer to surrounding text on the KSD CD (FRU number 41 21 201).

Use only an approved SPOT WELDER for repairs!

Place vehicle on straightening bench.

The following new parts are required (see Electronic Parts Catalog):

Side frame, outer
Middle side frame
Reinforcement plate, sill

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Removal:

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Mark severance cuts in accordance with specified dimensions and cut.

NOTE: Cut outer panel only for following severance cuts.

Dimension a = approx. 145 mm after center point of 25 mm dia. hole.

Dimension b = approx. 85 mm before center point of 25 mm dia. hole.

Dimension c = approx. 90 mm below center point of 8 mm dia. hole.

Open welded connections in areas (1).

Release B-pillar from cavity sealings (2) and remove.

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Mark severance cut in accordance with specified dimension and cut.

NOTE: Cut outer panel only.

Dimension a = approx. 90 mm below previous severance cut.

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

Remove B-pillar reinforcement.

NOTE: Open welded connection for both outer panels in area (2). Do not damage the third panel that is located behind it.

Preparation of new part:

Carry out the severance cuts on the new parts according to the severance cut on the vehicle.

Prepare REINFORCEMENT PLATES at severance cuts.

Take out superfluous components from the new parts.

B-pillar reinforcement: Make 15x8 mm recesses for MAG weld seams in areas (1).

Prepare the new part in the lower area for plug-weld. Take the positions of the plug spot welded connections from the series part and transfer them to the new part.

Adjust new parts and reinforcements plates with alignment bracket or universal mount.

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

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Installation:

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Install new part and reinforcement plate with alignment bracket or universal fixture and weld in designated areas (1).

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

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Coat CAVITY SEALINGS (1) with sealant.

Install new part and reinforcement plate and weld in area (2).