41 34 060 Replacing outer and inner tail panel sections

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

Follow procedure for REPAIR STAGE 2 .

The following new body parts are required:

(1) Rear trim, outer skin
(2) Rear trim, inner

The following CONSUMABLES are required:

Fig 1: Identifying Outer Skin Rear Trim And Inner Rear Trim

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Material	Quantity
Adhesive K5b	1
Blind rivets N3	34
Punch rivets N4	35
EMC screws	12
Cavity sealing wax remover
Cleaning agent R1	1
Sealant D1

Removing the tail panel

Operation described predominantly on the left side. Right side identical.

Mark severance cuts (1) and (2) and cut according to schematic diagram.

Open welded connections in areas (3).

Remove rear trim panel.

Fig 2: Identifying Welded Connections Areas And Severance Cut Areas

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Installation note:

Changed joining sequence: New part is installed from the outside overlapping in the area of the severance cuts.

Mark severance cut (1) as pictured and cut.

Open welded connections in area (2).

Remove tail panel.

Fig 3: Identifying Mark Severance Cut Area And Welded Connections Area

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Open welded connections in the area (1) and remove tail panel section.

NOTE: Schematic diagram shown without cross member mounting for bumper for better overview.

Fig 4: Identifying Welded Connections Area

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New part preparation

Operation described predominantly on the left side. Right side identical.

Mark severance cut (1) according to severance cut on vehicle (2) + approx. 20 mm extra material and cut (1).

Mark severance cut (3) and cut.

Fig 5: Identifying Severance Cut Areas

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Adjust new parts to fit and secure.

In area (1) set seven 4.2 mm dia. bore holes for blind rivets.

Fig 6: Identifying Blind Rivet Bore Holes Area

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Set two 4.2 mm dia. holes for blind rivets in areas (1).

NOTE: Schematic diagram shown without cross member mounting for bumper for better overview.

Fig 7: Identifying Blind Rivet Bore Holes Areas

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Installation note:

Changed joining sequence: New part is installed from outside in the area (1) with overlap.

In areas (1) to (3), create 4.2 mm dia. bore holes for blind rivets N3.

Fig 8: Identifying Blind Rivet Bore Holes Areas

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Area	Number
1	6
2	1
3	1

Remove new part again and deburr bore holes.

Bend adhesive flanges (1) approx. 30° inwards.

NOTE: Also apply adhesive to these adhesive areas after installing rear trim panel.

Then bend back the adhesive flanges.

Graphic representation similar.

Fig 9: Bending Adhesive Flanges Inwards

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

Installing the tail panel

Clean all bonding surfaces on new part and on vehicle with cleaning agent R1.

Apply adhesive to bonding surfaces.

Attach rear trim panel (inner panel) and rivet using blind rivets.

NOTE: When inserting rear trim panel, make sure there is sufficient adhesive on bonding surfaces.

In area (1) use a total of 9 punch rivets N4.

NOTE: Schematic diagram shown without cross member mounting for bumper for better overview.

Fig 10: Identifying Punch Rivets Area

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Install rear trim panel outer skin and rivet with blind rivets.

In areas (1) to (3), use 18 punch rivets N4.

Fig 11: Identifying Punch Rivets Areas

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Area	Number
1	15
2	7
3	2 of

Mount support for bumper panel to secure rear trim panel.

Remove excess adhesive.

IMPORTANT: Prevent emerging adhesive from coming into contact with cross-member!
Do not use any cleaning agents containing solvents.

Seal adhesive areas and blind rivets with sealant D1.

After hardening of the adhesive in area (1), install 2 EMC SCREWS .

Fig 12: Identifying EMC Screw Installation Areas

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After hardening of the adhesive in area (1), install 3 EMC screws.

NOTE: Schematic diagram provides a better overview without cross member fixture for bumper and rear trim panel outer skin.

Fig 13: Identifying EMC Screw Installation Areas

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After hardening of the adhesive in areas (1), install 5 EMC screws.

Fig 14: Identifying EMC Screw Installation Areas

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