41 21 201 REPLACING B-PILLAR WITH REINFORCEMENT ON LEFT REP-REP-RAF6041-4121201 - V.2 (Countryman 2017-2023, except PHEV)

Procedure OBSERVE repair stage 3!

Read contents of BODY, GENERAL .

For stripping and rigging operations, refer to surrounding text on the KSD (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):

(1) Side frame, outer
(2) Middle side frame

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Removal

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Mark severance cuts in accordance with specified dimensions and cut.

IMPORTANT: Cut through outer panel only for the following separating cuts.

Dimension a = approx. 125 mm past center point of 20 mm dia. hole.

Dimension b = approx. 110 mm before center point of 20 mm dia. hole.

Dimension c = approx. 210 mm from edge of roof outer skin.

Open welded connections in areas (1) and remove B-pillar.

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Mark severance cut in accordance with specified dimension and cut.

IMPORTANT: Cut outer panel only.

Dimension a = approx. 70 mm below previous severance cut.

Open welded connections in areas (1) and remove B-pillar reinforcement.

New part preparation

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

Prepare REINFORCEMENT PLATES at severance cuts.

Remove unnecessary components from new part.

Lower B-pillar reinforcement: Produce holes for plug-weld connections using die grinder or belt sander.

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

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

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 B-pillar outer skin must be taken into consideration depending on the manufacturer of the straightening system.

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Install new part and reinforcement plate and weld in area (1).

IMPORTANT: Risk of damaging the cavity sealings (2). Avoid excessive application of heat.