Replacing Luggage Compartment Floor And Side Member On The Left (Rear Quarter Panel And Tail Panel Removed) (Cooper Clubman F54)

Read contents of BODY, GENERAL .

Observe procedure of REPAIR STAGE 3 .

STRIP DOWN  vehicle.

Place vehicle on straightening bench.

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

1. Luggage compartment floor
2. Side member, rear
3. End plate side member
4. Luggage compartment floor, left
5. Rear wheel arch extension

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Following CONSUMABLES  are required:

Material	Quantity
Adhesive K5a	2
Blind rivet N3	18
Cleaning agent R1	1
Sealant D1

Removal 

Open welded connections in area (1).

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Open welded connections in area (1).

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

Remove luggage compartment floor.

Open welded connections for 2 panels in area (2).

Removing the left luggage compartment floor.

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

Dimension a = 28 mm from component edge, cross-member.

Open welded connections in areas (2).

Remove luggage compartment floor.

Carry out severance cut (1) on side member in accordance with schematic diagram.

Open welded connections in areas (2).

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

Dimension a = 45 mm

Open welded connections in areas (2).

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Mark and perform severance cut (1) through hole.

Open welded connections in area (2).

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New part preparation 

Mark severance cuts on side members in accordance with severance cuts on vehicle and cut.

For all severance cuts on side members, prepare REINFORCEMENT PLATES .

New part for middle luggage compartment floor: Mark new part according to severance cut on vehicle + 20 mm extra material and cut.

Adjust new parts with alignment bracket or universal mount and in conjunction with side wall and tail panel and secure.

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Drill bores ø 4.2 mm for blind rivet in areas (1) and (2).

Area	Number
1	8
2	5 of

Prepare for joining by welding in areas (3).

Prepare all other new parts for joining by welding.

Remove new part and deburr holes.

Installing side members 

Install new parts and reinforcement plates with alignment bracket or universal mount and weld analogue to series standard:

1. Side member, rear
2. End plate side member

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Installing luggage compartment floor, middle 

Clean all bonding surfaces with cleaning agent R1.

Apply adhesive to bonding surfaces.

When installing the new parts, make sure that all bonding surfaces have sufficient adhesive.

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Clean bonding surfaces (1) and (2) using SOLVENT CLEANER R1! 

Apply adhesive to bonding surfaces (1) and (2).

Install the new part and fasten in areas (1) and (2) with blind rivets N3.

In areas (3) weld new part.

Remove excess adhesive.

Installation of luggage compartment floor on left 

Install the new parts and weld them in area (1).

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Weld new parts in area (1).

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

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