Replace Tail Panel Outer Section And Inner Section (Cooper, Cooper S, John Cooper Works)

Procedure OBSERVE repair stage 2!

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

Rear trim, inner
Rear trim, outer skin

Following CONSUMABLES are required:

Material	Quantity
Adhesive K5b	1
Blind rivet N3	13
Blind rivet N6	2
Punch rivet N4	28
EMC screw	7
Cavity sealing wax remover	1
Cleaning agent R1	1
Sealant D1	1

Removal

For the most part, the operations are described for the left side of vehicle. The work is identical on the right side.

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

IMPORTANT: Severance cut (1): Cut outer metal panel only.
Severance cut (2): Separate tail panel outer section and tail panel inner section only!

Open welded connections in areas (3).

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View of passenger compartment.

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

IMPORTANT: Severance cut (2): Cut outer metal panel only.

Detach welded connections in areas (3) and remove the loosened sheet metal part.

Release welded connections in areas (1) and remove bulkhead (2).

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Open welded connections in areas (1) to (3). Remove the loosened sheet metal parts (4) and (5).

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Release welded connections in area (1) and remove

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New part preparation

For the most part, the operations are described for the left side of vehicle. The work is identical on the right side.

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Cut out area (1).

a = 55 mm.

b = 25 mm.

Changed joining sequence: New part is joined beneath area (1) from outside with overlap.

Smooth down the separation edge if applicable. Adapt new part in transitional area (overlap).

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Produce recess (1) approx. 20 x 5 mm for MAG welded connection by grinding.

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Cut out areas (1) for MAG welded connections on bulkhead.

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Produce a bore dia. 8 millimeter on bulkhead.

a = 15 mm.

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Adjust new parts to fit and secure.

In areas (1) and (2), drill ø 4.2 mm bores for blind rivet.

Area	Number
1	3
2	2

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In areas (1) and (2), drill ø 4.2 mm bores for blind rivet.

Area	Number
1	4
2	2

Prepare 2 x plug-welds in the areas (3).

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NOTE: The tail panel inner section is hidden for purposes of clarity!

Prepare for MAG welding in areas (1).

IMPORTANT: Mark area (2) on tail panel. No adhesive must be applied to this area during installation!

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Prepare for MAG welding in area (1).

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Prepare for MAG welding in area (1).

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Produce a reinforcement plate approx. 60 x 60 mm for area (1).

Prepare reinforcement plate and area (1) for joining by bonding.

NOTE: The tail panel inner section is hidden for purposes of clarity!

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View of vehicle underside:

Set 3 bores ø 4.2 mm for the blind rivet in the areas (1).

Remove new parts again and deburr bores.

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

Installation

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

Apply adhesive to bonding surfaces.

Do not apply adhesive to joining areas which welding operations will be performed in.

When installing the new parts, make sure that there is sufficient adhesive on bonding surfaces.

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Do not apply adhesive to marked area (1).

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Install new parts and rivet them in the areas (1) and (2) using blind rivet N3.

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Rivet the new parts in the areas (1) and (2) using blind rivet.

Area	Remarks
1	Blind rivet N3
2	Blind rivet N6

Spot-weld in areas (3).

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Rivet the new parts with the blind rivet N3 in the areas (1).

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In areas (1) to (4) rivet new parts with punch rivets N4.

Area	Number
1	9
2	7
3	8
4	2 each

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IMPORTANT: For purposes of clarity, the tail panel inner section is hidden in this schematic diagram.

MAG-weld the new parts in the areas (1).

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MAG-weld new part in area (1).

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MAG-weld new part in area (1).

Mount support for bumper cover to secure tail cowling.

IMPORTANT: Prevent emerging adhesive from coming into contact with support.
Remove emerging adhesive.
Do not use any cleaning agents containing solvents.

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After harden of the adhesive install 7 EMC SCREWS in the areas shown.