41 14 020 REPLACING FRONT LEFT WHEEL ARCH REP-REP-RAF6041-4114020 - V.2 (Countryman 2017-2023, except PHEV)

Observe procedure of REPAIR STAGE 3 .

Read contents of BODY, GENERAL .

For stripping and rebuilding operations, refer to surrounding texts on KSD (FRU number 41 14 020).

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):

• (1) Carrier support, outer wheel arch section
• (2) Front shock tower
• Support bracket shaped part

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Removal 

Mark severance cut (1) as pictured and cut.

Open welded connections in areas (2).

Open. Refer to OPENING BONDED CONNECTIONS REP-ALG-RAGRP41-4105702 - V.3 (Countryman 2017-2023, except PHEV)  spot-welded adhesive joints in area (2).

Remove partial section of carrier support.

Remove adhesive residues in the area (3).

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Open welded connections in areas (1).

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Open welded connections in areas (1) to (3).

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Mark severance cut (1) as pictured and cut.

Open welded connections in areas (2) and (3).

Open welded connection for both outer panels in area (2).

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

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Open spot-weld bonded joints in area (1)

In areas (2), undo welded connections for both external panels. Refer to OPENING BONDED CONNECTIONS REP-ALG-RAGRP41-4105702 - V.3 (Countryman 2017-2023, except PHEV) .

Release welded connections in areas (1) and remove wheel arch.

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New part preparation 

Open welded connections in areas (1).

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Open welded connections in areas (1).

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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).

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Install the new part with an alignment bracket or a universal fixture and prepare part for joining by welding in the areas (1) and (2).

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Prepare areas (1) to (3) for joints by welding.

Prepare for joining by welding in areas (1).

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Prepare the joints in areas (1) to (4) for joining by welding.

Prepare for joining by welding in areas (1).

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Install the new part and prepare areas (1) and (2) for joining by welding.

(3) = Position of cavity sealing

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Installation 

Install wheel arch new part with alignment bracket or universal fixture and secure.

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Weld new part in the areas (1) and (2).

Weld new part in the areas (1).

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Weld new part in areas (1) to (4).

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Weld new part in areas (1) to (3).

Weld all 3 panels together in areas (2).

Weld new part in the areas (1).

Apply sealant to CAVITY SEALING  (2).

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Apply sealant to cavity sealing (3).

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

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