41 35 101 Replacing Rear Left Side Panel Rep-Rep-RAF5541-4135101_KLEBEN - V.4 (Cooper 4-Door Hatchback, 2020-2023)

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Procedure OBSERVE  repair stage 2!

Strip down vehicle.

Example illustration.

Because of the ever-increasing geometric complexity and challenging follow-up steps when working on visible severance cuts, the reinforcement plate is now welded together instead of glued. This change applies to all BMW and MINI models.

Welding is carried out in area (1) (incl. water channel).

Release the sealant in these areas (2).

Note updated PROCEDURE .

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

• *(1) Rear wall
• Reinforcement plate, door sill
• Reinforcement plate, C-pillar
• Reinforcement plate, D-pillar
• Reinforcement plate, universal

Following CONSUMABLES  are required:

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Material	Quantity
Adhesive K5b	1
Adhesive K5a	1
Blind rivet N3	4
Punch rivet N4	35
EMC screw	2
Cavity protection wax remover	1
Cleaning agent R1	1
Sealant D1	1

Removal: 

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Mark severance cuts in accordance with specified dimensions and cut.

Compare position of severance cuts with REINFORCEMENT PLATES .

Dimension a = approx. 80 mm from the center point of 25 mm dia. hole.

Dimension b = approx. 150 mm from component edge of the window frame.

Dimension c = approx. 60 mm from the center point of the hole in the molding.

Open welded connections in areas (1).

OPEN  spot-welded adhesive joints in area (2).

Loosen side wall of cavity sealing (3).

Temperature sensor 

In addition to the dimensions, the position of the separating cut can be determined with a TEMPLATE  (1).

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Cut the separating cut (1) in the water channel in the center between the welded connections (2) and sever.

Open the lower welding spot (2) and welded connections in the area (3).

(4) = Severance cut, C-pillar.

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Open welded connections in areas (1) and (2).

Take off side panel.

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Preparation of new part: 

Mark severance cuts on new part in accordance with severance cuts on vehicle and cut.

For severance cuts, prepare reinforcement plates.

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Area of water channel:

Adjust the universal reinforcement plate (1) for the severance cut in the water channel as shown and secure it by welding.

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Fit in new part.

In area (1), set three bores with a 4.2 mm dia. for the blind rivets.

Remove new part and deburr holes.

Installation: 

Clean ail bonding surfaces (1) on the new part, vehicle and reinforcement plates with cleaning agent R1!

Apply adhesive to reinforcement plates (door sill, C pillar). Install reinforcement plates.

Apply adhesive to bonding surfaces on vehicle.

Apply sealant to cavity sealing. Refer to INSTALLING CAVITY SEALING (NOT EXPANDED) REP-REP-RAGRP41-4107102 - V.4 (Cooper 4-door hatchback and 2-door hatchback, 2020-2023)  (2).

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Install the side panel and rivet with blind rivets N3 in the area (1).

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In areas (1) to (4), rivet side panel with punch rivets N4.

Area	Number
1	10
2	6
3	4
4	2

Weld the severance spot on the D pillar.

In area (5), secure side panel with gripping pliers until adhesive has hardened.

In areas (1) to (4), rivet side panel with punch rivets N4.

Area	Number
1	2
2	2
3	1
4	8

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After adhesive has hardened, install one EMC SCREW  in each case in areas (1).

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