41 21 003 REPLACING A-PILLAR WITH REINFORCEMENT ON LEFT REP-REP-RAF6041-4121003 - V.2 (Countryman 2017-2023, except PHEV)

Procedure OBSERVE repair stage 3!

Read contents of BODY, GENERAL .

For stripping and rigging operations, refer to the surrounding text of the KSD (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.

Following new body parts are required (see Electronic Parts Catalog):

(1) A-pillar, outer
(2) Middle side frame
Upper cavity sealing for A-pillar

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Removal

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Mark and perform the separating cuts according the dimension.

IMPORTANT: Cut through outer panel only for severance cuts.

Dimension a = approx. 60 mm from the center of the 8 mm dia. bore.

Dimension b = approx. 145 mm from center of a 20 mm dia. bore.

Open welded connections in areas (1).

LOOSEN spot-welded adhesive joints in areas (2).

Release and remove A-pillar from cavity sealings (3).

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Mark severance cut in accordance with dimension and cut.

IMPORTANT: Do not damage the water drain hose of the sliding/tilting sunroof!

For this separating cut, only cut the outer panel.

Dimension a = approx. 50 mm below the previous separating cut.

Open welded connections in areas (2).

(3) = Position of inner cavity sealing.

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Mark severance cuts (1) in accordance with schematic diagram and roughly cut.

IMPORTANT: Cut only outer plates.

Remove sheet sections.

Undo welded connections in these areas (2) and remove the A-pillar reinforcement.

New part preparation

Mark severance cuts on new parts according to severance cuts on vehicle and sever.

Prepare REINFORCEMENT PLATES at severance cuts.

Prepare new parts for joining by welding.

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

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

Installation

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Apply sealant to CAVITY SEALING (1).

Install the A-pillar reinforcement and reinforcement plate with the alignment bracket or universal fixture and weld in the areas (2).

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

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Coat cavity sealings (1) with sealant.

Install outer skin for new part on A-pillar and reinforcement plates and weld in areas (2) and (3).

NOTE:

Schematic diagram:
Vehicles with sliding/tilting sunroof : Make sure water drain hose (1) is correctly installed! (watertightness).
In vehicle 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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