41 12 535 Replacing luggage compartment floor and both side members (tail panel removed)

WARNING: This page is about a different car, the 2016 MINI Cooper Paceman, 2015 MINI Cooper Paceman, 2014 MINI Cooper Paceman, and 2013 MINI Cooper. However, it is still accessible from the selected car via links, so may be relevant.

Read contents of BODY, GENERAL .

Strip down vehicle. See STRIPPING OPERATIONS or STRIPPING OPERATIONS (ALL-WHEEL DRIVE VEHICLE) .

Spot-weld bonding is used on this vehicle. Observe specific procedures for SPOT-WELD BONDING STEEL COMPONENTS and OPENING BONDED CONNECTIONS .

Place vehicle on straightening bench.

Follow procedure for REPAIR STAGE 3 .

The following new body parts are required:

(1) Luggage compartment floor, rear
(2) Side member, rear left and right
(3) Rear wheel arch, inner half, left and right

The following CONSUMABLES are required:

Fig 1: Identifying Luggage Compartment Floor, Side Member And Rear Wheel Arch Inner Half

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Material	Quantity
Adhesive K5a	2
Blind rivets N6	16
EMC screws	4
Cleaning agent R1	1
Sealant D1

Removal of luggage compartment floor and both side members

Most of operation is described on the left side. Right side identical.

View from below.

Open spot-welded adhesive joints in area (1)

Remove the luggage compartment floor.

Fig 2: Identifying Spot-Welded Adhesive Joints Area

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Mark severance cut (1) in accordance with specified dimension and cut.

IMPORTANT: Cut outer panel only.

Dimension a = approx. 45 mm past center point of 18 x 12 mm hole.

Fig 3: Identifying Severance Cut Dimension

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Open welded connections in areas (1).

Open spot-welded adhesive joints in area (2)

Installation note:

Weld new components in area (3) additionally.

Fig 4: Identifying Spot-Welded Adhesive Joints Area, Welded Connections Area, And New Components Welding Area

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

Remove side member and wheel arch.

Fig 5: Identifying Welded Connections Areas

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New part preparation

Mark severance cut (1) in accordance with vehicle and cut.

IMPORTANT: Cut outer panel only.

Open welded connections in areas (2).

Fig 6: Identifying Severance Cut Area And Welded Connections Areas

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Open welded connections in areas (1).

Remove components not needed.

Fig 7: Identifying Welded Connections Areas

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Open welded connections in area (1).

Remove components not needed.

Adjust new parts to fit with alignment bracket or universal mount and secure.

Fig 8: Identifying Welded Connections Area

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Fit luggage compartment floor from underneath and adjust in conjunction with tail panel and secure.

Set 16 4.2 mm dia. bore holes for blind rivets in area (1).

Remove new part and deburr holes.

Fig 9: Identifying Spot-Welded Adhesive Joints Area

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IMPORTANT: Do not grind new parts and body in area of bonding surfaces.

Installation of side members, inner wheel arch halves

Install new parts with alignment bracket or universal mount and weld.

Installation of luggage compartment floor:

Clean all bonding surfaces with CLEANING AGENT R1 .

Apply adhesive to bonding surfaces.

Install new part and rivet with blind rivets.

After hardening of the adhesive, install 4 EMC SCREWS in the areas (1).

Fig 10: Identifying EMC Screw Installation Areas

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