41 31 100 Replacing The Roof Outer Skin Including The Panorama Glass Roof Rep-Rep-RAF5641-4131100_KLEBEN_BEV - V.1 (Cooper Se Electric 2-Door Hatchback)

Procedure OBSERVE repair stage 2!

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

Roof outer skin, panorama glass roof

Following CONSUMABLES are required:

Material	Quantity
Adhesive K5a	2
Adhesive K5b	1
Blind rivet N3	2
Punch rivet N4	14
Cleaning agent R1	1
Sealant D2	1

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Removal

Operation is partially described on the left side. Right side identical.

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Open welded connections in area (1).

Open welded connections in areas (1).

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Open bonded connection in areas (1).

Release and remove roof outer skin from cavity sealings (2) and remove.

New part preparation

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In area (1) drill a 0 4.2 mm bore for blind rivet.

Prepare areas (2) and (3) for MAG weld seams with a length of 15 mm each.

Installation note:

The MAG weld seams (2) will be carried out on the front of the sheet metal flange (3 panels).

In the areas (4), the rivet-and-bonding method is used.

In the areas (5), the bonding method is used.

Prepare the procedure for joining via bonding method in the areas (1) and (2).

The area (2) must be prepared for additional MAG weld seams (3) with a length of 15 mm.

Remove roof outer skin and deburr bores.

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IMPORTANT: Do not grind/sand new part in area of bonding surfaces.

Installation

NOTE: Comply with the processing time!
Two persons are required to apply the adhesive and the sealant.

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Clean all bonding surfaces with cleaning agent R1.

Apply adhesive in areas (1). Amount of adhesive: Same as for series production parts.

In these areas (2) and to seal cavities (3), apply the sealant D2 the same as for series production parts.

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Apply adhesive in areas (1) and (2).

IMPORTANT: The areas (1) require a sufficient distance between the applied adhesive and the future MAG welded seams! Distance depending on the adhesive 2 - 3 centimeter.

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Install roof outer skin and rivet with blind rivets N3 in area (1).

Use punch rivets N4 in the areas (2) and (3).

Area	Number
2	3
3	8

In areas (4) and (5), set MAG weld seams with a length of 15 mm.

In the areas (5), set the MAG weld seams on the front.

Set 3 MAG weld seams (2) with a length of 15 mm in the area (1).

NOTE: Slightly grind the MAG weld seams.

IMPORTANT: Do not thin section the MAG weld seams and the new part!

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Adapt step (1) between roof outer skin (2) and A-pillar with emerging adhesive. Remove excess adhesive.

IMPORTANT: Do not use any cleaning agents containing solvents.

Do not leave any sharp edges as this could compromise the tightness of the subsequent bonding of the windshields.

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Remove excess adhesive from other adhesive areas.

IMPORTANT: Do not use any cleaning agents containing solvents.

Seal adhesive areas and blind rivets with sealant D2.