Replacing Outer Tail Panel Section (Cooper, Cooper S, John Cooper Works)

Read contents of BODY, GENERAL .

Procedure OBSERVE  repair stage 2!

STRIP DOWN VEHICLE .

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

1. Tail cowling

Following CONSUMABLES  are required:

Material	Quantity
Adhesive K5b	1
Blind rivet N3	14
Punch rivet N4	25
EMC screw	7
Cavity sealing wax remover	1
Cleaning agent R1	1
Sealant D1	1

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Removal 

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

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

Open welded connections in areas (2) and remove tail cowling.

New part preparation 

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Mark and perform separating cut (1) on new part according to separating cut on the vehicle + 15 mm added material.

(2) = Severance cut route on vehicle.

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Adjust tail cowling to fit and secure.

In areas (1) and (2), set 4.2 mm dia. bores for blind rivets.

Area	Number
1	5
2	2

Remove new part again and deburr bores.

Installation 

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

Apply adhesive to bonding surfaces (1).

Install tail cowling and rivet with blind rivets.

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In areas (1) to (4) rivet tail cowling with punch rivets N4.

Area	Number
1	6
2	7
3	8
4	2 each

Mount support for bumper cover to secure tail cowling.

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