41 35 101 Replacing Rear Left Side Panel Rep-Rep-RAF5641-4135101_KLEBEN - V.3 (Cooper 2-Door Hatchback, 2020-2023)

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Strip down vehicle. Refer to 41 35 111 STRIPPING OPERATIONS - REPLACING REAR QUARTER PANEL, RIGHT REP-REP-RAF5641-4135111_RUESTEN_KLEBEN - V.1 (Cooper 2-door hatchback, 2020-2023) .

Procedure OBSERVE repair stage 2!

Following new body parts are required (see Electronic Parts Catalog):

Rear wall

Following CONSUMABLES are required:

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Material	Quantity
Adhesive K5b	1
Blind rivet N3	12
Punch rivet N4	32
EMC screw	2
Cavity sealing wax remover	1
Cleaning agent R1	1
Sealant D1	1

Removal

Open welded connections in areas (1).

Heat cavity sealing (2) with hot air blower and release from side wall.

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

Take off side panel.

IMPORTANT: In area (1), the welded connections must be detached from the side wall.

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New part preparation

Adjust side panel and secure. Feed in the side panel, starting at the C-pillar.

Prepare area (1) for three 15 millimeter long MAG weld seams (2).

Installation note:

The MAG weld seams (2) will be placed on the front side of the 3-sheet metal flange.

If an approved spot welder is available, spot welding can also be set in area (1) instead of the MAG weld seams.

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

Area	Number
1	1
2	4

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

Area	Number
1	2
2	1
3	4

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Remove new part again and deburr bores.

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

Installation:

Clean ail bonding surfaces (1) and (2) on new part and on vehicle with cleaning agent R1!

Apply adhesive to bonding surfaces.

Also apply adhesive to the new part in the areas (2).

Coat cavity sealings. Refer to INSTALLING CAVITY SEALING (NOT EXPANDED) REP-REP-RAGRP41-4107102 - V.4 (Cooper 4-door hatchback and 2-door hatchback, 2020-2023) (3) with sealant.

IMPORTANT: The area around the B-pillar requires a sufficient distance between the adhesive application and the subsequent welded connections. Distance depending on the adhesive 2 - 3 centimeter.

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Install the side panel and rivet areas (1) and (2) with the blind rivet N3.

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Rivet the side panel with the blind rivet N3 in areas (1) to (3).

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In areas (1) to (3), rivet the side panel with punch rivets N4.

IMPORTANT: Punch rivets N4 may only be installed in area (3) at the three moldings in the wheel arch panel!

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Area	Number
1	5
2	5
3	3

In area (4), set three 15 mm long MAG weld seams or three spot welding according to the new part preparation.

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

In areas (1) to (3), rivet the side panel with punch rivets N4.

Area	Number
1	8
2	4
3	2

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Fit an EMC SCREW after adhesive has hardened in area (1).

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Fit an EMC screw after adhesive has hardened in area (1).

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