Replacing Luggage Compartment Floor And Side Member On The Left (Rear Quarter Panel And Tail Panel Removed) (Cooper, Cooper S, John Cooper Works)

Read contents of BODY, GENERAL .

Follow procedure for REPAIR STAGE 3 .

Strip down vehicle. Refer to STRIPPING OPERATIONS - REPLACING LUGGAGE COMPARTMENT FLOOR AND LEFT SIDE MEMBER (REAR QUARTER PANEL AND TAIL PANEL REMOVED)  or STRIPPING OPERATIONS - REPLACING LUGGAGE COMPARTMENT FLOOR AND SIDE MEMBER ON RIGHT (REAR QUARTER PANEL AND TAIL PANEL REMOVED) .

Spot-weld bonding is used on this vehicle. Observe specific PROCEDURE .

Place vehicle on straightening bench.

The following new parts are required (see Electronic Parts Catalog):

1. Rear wheel arch
2. Side member, rear
3. Luggage compartment floor

Courtesy of BMW OF NORTH AMERICA, INC.

Following CONSUMABLES  are required:

Material	Quantity
Adhesive K5a	2
Blind rivet N3	25
EMC screw	5
Cleaning agent R1	1
Sealant D1

Removal: 

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

Dimension a = 30 mm from component edge, cross-member.

Open welded connections in areas (2).

Remove the luggage compartment floor.

Courtesy of BMW OF NORTH AMERICA, INC.

Courtesy of BMW OF NORTH AMERICA, INC.

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

Dimension a = 82 mm from 8 mm dia. hole.

Courtesy of BMW OF NORTH AMERICA, INC.

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

Mark severance cut (2) in accordance with dimension a and cut.

Dimension a = 10 - 12 mm from the edge of the embossing.

Open welded connections in areas (3).

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

Dimension a = approx. 145 mm from component edge, reinforcement.

Release welded connections in areas (2) and remove side member.

(3) = severance cut from prior operation.

Courtesy of BMW OF NORTH AMERICA, INC.

New part preparation 

Courtesy of BMW OF NORTH AMERICA, INC.

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

Prepare REINFORCEMENT PLATE  for severance cut (1).

Mark severance cut (2) in accordance with severance cut on vehicle and cut.

Mark and perform the separating cut (3) in accordance with the severance cut on the vehicle + 15 mm extra material.

Open welded connections in areas (4).

(5) = Severance cut route on vehicle.

Prepare new part for joining by welding.

OBSERVE  the specific procedure in the repair

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

Prepare reinforcement plate for severance cut (1).

Prepare new part for joining by welding.

Adjust new parts side member and wheel arch using alignment bracket or universal mount and secure.

Courtesy of BMW OF NORTH AMERICA, INC.

Mark severance cut on new part in accordance with severance cut on vehicle + 15 mm for extra material and cut.

Adjust luggage compartment floor in combination with tail panel to fit and secure.

In areas (1) and (2), set 4.2 mm dia. bores for blind rivets.

Courtesy of BMW OF NORTH AMERICA, INC.

Area	Number
1	11
2	7 of

Remove new parts and deburr bores.

Installing side members and wheel arch 

Install new parts using an alignment bracket or universal mount.

Courtesy of BMW OF NORTH AMERICA, INC.

Weld new parts and reinforcement plates in area of severance cut (1).

Weld new parts and reinforcement plate at severance cuts (1) and in areas (2).

Courtesy of BMW OF NORTH AMERICA, INC.

Courtesy of BMW OF NORTH AMERICA, INC.

Weld new parts in areas (1) and (2).

Installation of luggage compartment floor 

Clean all  bonding surfaces with CLEANING AGENT R1 .

Apply adhesive to bonding surface (1).

Courtesy of BMW OF NORTH AMERICA, INC.

Install the luggage compartment floor and rivet areas (1) and (2) with the blind rivet N3.

Courtesy of BMW OF NORTH AMERICA, INC.

Remove excess adhesive.

AFTER HARDENING OF THE ADHESIVE, INSTALL 5 EMC SCREWS IN THE AREAS (1) .

Courtesy of BMW OF NORTH AMERICA, INC.