41 34 038 Replacing Outer Tail Panel Section Rep-Rep-RAF5641-4134038_KLEBEN - V.3 (Cooper 4-Door Hatchback And 2-Door Hatchback, 2020-2023)

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	18
Punch rivet N4	24
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 severance cut (1) in accordance with specified measurements and cut.

Dimension a = approx. 15 mm from component edge, side panel.

Dimension b = approx. 20 mm from component edge, side panel.

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

New part preparation 

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Cut and sever the severance cut (1) on the new part according to the severance 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.

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

Area	Number
1	2
2	7

Remove new part again and deburr bores.

Installation: 

Clean all  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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Rivet the tail cowling with punch rivets N4 in the areas (1) to (4).

Area	Number
1	8
2	7
3	9

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.