41 34 060 Replace Tail Panel Outer Section And Inner Section Rep-Rep-RAF5641-4134060_KLEBEN - V.4 (Cooper 4-Door Hatchback And 2-Door Hatchback, 2020-2023)

Procedure OBSERVE repair stage 2!

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

Rear trim, inner
Rear trim, outer skin

Following CONSUMABLES are required:

Material	Quantity
Adhesive K5b	1
Blind rivet N3	36
Blind rivet N6	4
Punch rivet N4	27
EMC screw	13
Cavity sealing wax remover	1
Cleaning agent R1	1
Sealant D1	1

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Removal:

Operation is described mainly for the left side; work is identical on the right side.

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Mark severance cuts (1) and (2) and cut according to schematic diagram.

IMPORTANT: Cut outer metal panel only.

Open welded connections in area (3).

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View of passenger compartment.

Mark severance cuts (1) and (2) and cut according to schematic diagram.

Mark severance cuts (1) in accordance with schematic diagram and cut.

Open welded connections in areas (2).

Remove tail cowling section.

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Release welded connections in area (1) and remove section (2).

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Release welded connections in area (1) and remove section.

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Preparation of new part:

Operation is described mainly for the left side; work is identical on the right side.

Mark severance cut (1) according to severance cut on vehicle + 15 mm extra material and cut.

(2) = Severance cut route on vehicle.

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Area (1), disengage 15x25 mm.

Changed joining sequence: New part is joined beneath area (1) from outside with overlap.

Smooth down the separation edge if applicable. Adapt new part in transitional area (overlap).

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Adjust new parts to fit and secure.

In areas (1) to (4), drill 0 4.2 mm bores for blind rivets.

NOTE: When positioning bores in area (2), note position of panels behind.

Area	Number
1	3
2	4
3	1
4	2

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In areas (1) to (3), set bores 0 4.2 mm for blind rivet.

Area	Number
1	1
2	4
3	2

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View of vehicle underside:

Set 3 bores 0 4.2 mm for the blind rivet in the areas (1).

Remove new parts again and deburr bores.

IMPORTANT: Do not grind new parts and body in area of bonding surfaces.

Installation:

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

Apply adhesive to bonding surfaces.

When installing the new parts, make sure that there is sufficient adhesive on bonding surfaces.

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Install the new parts and rivet with the blind rivet N3 in areas (1) to (4).

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Rivet the new parts with the blind rivet in areas (1) to (3).

Area	Remarks
1	Blind rivet N3
2	Blind rivet N3
3	Blind rivet N6

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Rivet the new parts with the blind rivet N3 in the areas (1).

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

Area	Number
1	10
2	7
3	9

Mount support for bumper cover to secure tail cowling.

IMPORTANT: Prevent emerging adhesive from coming into contact with cross-member!
Remove emerging adhesive.
Do not use any cleaning agents containing solvents.

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

After harden of the adhesive install 3 EMC screws in areas (1).

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