Replacing Middle Luggage Compartment Floor (Tail Panel Has Been Removed) (Cooper, Cooper S, John Cooper Works)

Read contents of BODY, GENERAL .

Follow procedure for REPAIR STAGE 2 .

STRIP DOWN VEHICLE .

Following new body parts are required (see Electronic Parts Catalog):

1. Luggage compartment floor

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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 = 25 mm from component edge, cross-member.

Open welded connections in areas (1).

Remove luggage compartment floor.

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Preparation of new part: 

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.

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Area	Number
1	11
2	7 of

Remove new part and deburr holes.

Installation of luggage compartment floor: 

Clean all  bonding surfaces with CLEANING AGENT R1 .

Apply adhesive to bonding surface (1).

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

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Remove excess adhesive.

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

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