Additional Holes For Roof Rails In Roof Outer Skin Rep-Rep-RAF5641-4131XXX - V.4 (Cooper 4-Door Hatchback And 2-Door Hatchback, 2020-2023)

Special tools required:

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Read contents of BODY, GENERAL .

Follow procedure for REPAIR STAGE 1 .

When replacing the roof outer skin, assembly holes for the roof rails must also be drilled.

Following tools are required:

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There are recesses in the side frame through which the holes for assembling the roof rails are drilled.

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Insert the drill bushing (1) into the recess and hold in position with locking pliers.

Use the 0 6.4 mm drill to drill mounting holes through the drill bushing (1) and into the roof outer skin.

Courtesy of BMW OF NORTH AMERICA, INC.

Courtesy of BMW OF NORTH AMERICA, INC.

With the roof rails, check if the holes are centered above the recesses in the roof frame.

If necessary, rework the holes slightly until all threaded bolts are centered through the holes.

Mark diameter for enlargement of bores (1).

Remove roof rails.

Use conical drill to enlarge bores according to mark (1).

Maximum diameter of the holes 13.5 mm; if necessary, measure the diameter of the holes on the damaged roof outer skin.

NOTE: If the diameter of the bore is too small, this can lead to a creaking.
If the diameter is too large, this leads to leaks!

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Place roof rails on roof outer skin for checking purposes.

Deburr bores.

Carry out corrosion protection.