Replacing Outer And Inner Tail Panel Sections (Cooper Clubman F54)

Read contents of BODY, GENERAL .

Observe procedure of REPAIR STAGE 2 !

STRIP DOWN VEHICLE .

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

1. Tail cowling
2. Rear trim, inner

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Following CONSUMABLES  are required:

Material	Quantity
Adhesive K5a	1
Adhesive K5b	1
Blind rivet N3	36
Punch rivet N4	25
EMC screw	7
Cleaning agent R1	1
Sealant D1
Cavity wax
remover

Removal: 

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

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

Dimension a approximately 30 mm from the opening of the side member.

Mark severance cuts (2) in accordance with schematic diagram and cut.

Loosen the welded connections in these areas (3) and remove the tail panel.

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Carry out the cut (1) on the reinforcement (2) as per the schematic diagram.

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View from vehicle interior:

Loosen the welded connections in these areas (1) and (2) and remove the (3) sheet metal section.

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

Preparation Of New Part: 

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Sand down the protruding area (1) of the disconnected reinforcement (2) with a belt sander.

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Cut area (1).

Bores (1) can be enlarged by a maximum of 10 mm in diameter as necessary.

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Adjust tail panel to outer skin.

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Adjust and fix tail cowling inner part in combination with trunk lid and tail light. In areas (1) to (4), set bores 4.2 mm dia. for blind rivet.

Area	Number
1	2
2	3
3	1
4	4

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Schematic diagram without tail panel outer section to improve transparency.

Adapt the new part in this area (1) and prepare for joining by welding.

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

Area	Number
1	2
2	3

Prepare the new part for joining by welding in this area (3).

In areas (1), set three 4.2 mm dia. bores for blind rivet.

In area (2) prepare for joining by welding.

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Installation: 

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

Apply adhesive to bonding surfaces.

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

Install and secure the outer skin tail panel.

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Mount and fix tail cowling inner part. Rivet the new parts in areas (1) to (4) using N3 blind rivets.

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In areas (1) and (2), rivet new parts with blind rivet N3.

Weld new part in area (3).

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

Weld new part in area (2).

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Schematic diagram without tail panel outer section to improve transparency.

Weld new part in area (1).

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Rivet the new part with punch rivet N4 in areas (1) and (2).

Area	Number
1	14
2	11

Press tail cowling in areas (1) and remove emerging adhesive.

Then install carrier for bumper trim to secure tail cowling carrier.

Do not use any cleaning agents containing solvents.

After hardening of the adhesive in the illustrated areas (1) to (3): install ELECTROMAGNETIC COMPATIBILITY (EMC) SCREWS .

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Area	Number
1	1
2	1
3	3

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