Replacing Outer Tail Panel Section (Cooper Clubman F54)

Read contents of BODY, GENERAL .

Observe procedure of REPAIR STAGE 2 !

STRIP DOWN  vehicle.

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

1. Tail cowling

Following CONSUMABLES  are required:

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Material	Quantity
Adhesive K5b	1
Blind rivet N3	22
Punch rivet N4	23
Cleaning agent R1	1
EMC screw	7
Sealant D1
Cavity wax remover

Removal 

Operation described predominantly on the left side. Right side identical.

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Rip and cut the cut (1) on the component edge of the D-pillar reinforcement (2).

Open welded connections in areas (3).

New Part Preparation 

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Cut the cut (1) as shown on the schematic diagram. Adapt the area (2) on the vehicle.

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Adjust tail cowling in combination with trunk lid and rear lamps and secure.

In areas (1) to (4), set bores 4.2 mm dia. for blind rivet.

Area	Number
1	3
2	3
3	1
4	4

Remove new part and deburr holes.

Installation 

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

Apply adhesive to bonding surfaces.

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Install the tail cowling and rivet in areas (1) to (4) using N3 blind rivets.

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

Area	Number
1	12
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.

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After the adhesive hardens, install 7 EMC SCREWS  in areas shown (1).

Area	Number
1	1
2	1
3	3

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