41 31 100 Replacing The Roof Outer Skin Including The Panorama Glass Roof Rep-Rep-RAF5541-4131100_KLEBEN - V.4 (Cooper 4-Door Hatchback, 2020-2023)

Procedure OBSERVE repair stage 2!

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

Roof outer skin, panorama glass roof

Following CONSUMABLES are required:

Material	Quantity
Adhesive K5b	2
Blind rivet N3	14
Punch rivet N4	8
Cleaning agent R1	1
Sealant D2	1

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Removal

Operation is partially described on the left side. Right side identical.

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Open welded connections in area (1).

Open welded connections in areas (1).

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OPEN bonded connections in areas (1).

Release the sealant in these areas (2).

Release and remove roof outer skin from cavity sealings (3) and remove.

New part preparation

Operation is partially described on the left side.

Right side identical.

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In areas (1), set 4.2 mm dia. bores for the blind rivet according to the schematic diagram.

NOTE: The bores must be set centrally between the existing installation holes.

It may be necessary to adapt the seal (2) in these areas (3) (blind rivet positions).

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In areas (1) to (3), set 4.2 mm dia. bores for the blind rivet according to the schematic diagram.

NOTE: The bores (1) must be set centrally between the existing installation holes. Adjust the seal if necessary.

The bore (2) is located on the line (4) of the C-pillar. Check of position (2): There is a 22 mm dia. hole in the vehicle interior.

The bore (3) is located at the end of the roof outer skin.

Prepare the procedure for joining via bonding method in the areas (1) and (2).

The area (2) must be prepared for additional MAG weld seams (3) with a length of 10 mm.

Remove roof outer skin and deburr bores.

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

Installation

Operation is partially described on the left side. Right side identical.

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Clean all bonding surfaces with cleaning agent R1.

Apply adhesive K5b in areas (1).

Apply sealant D2 in areas (2).

NOTE: Observe the drying time of the materials!

Two persons are required to apply the adhesive and the sealant at the same time.

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Apply adhesive in areas (1).

Apply sealant to D2 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) in areas (2).

IMPORTANT: In area (1) of the trunk lid, keep sufficient distance between the adhesive application and the later MAG weld seams! Distance depending on the adhesive application approx. 3 - 4 cm.

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Install roof outer skin and rivet with blind rivets N3 in area (1).

In this area (2), use 8 N4 punch rivets.

In area (3), secure the roof outer skin with gripping pliers until the adhesive has hardened.

Set 3 MAG weld seams (2) with a length of 10 mm in the area (1).

NOTE: Risk of damage to adjoining adhesive areas! Avoid excessive application of heat.
Slightly grind the MAG weld seams.

IMPORTANT: Do not thin section the MAG weld seams and the new part!

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Adapt step (1) between roof outer skin (2) and A-pillar with emerging adhesive. Remove excess adhesive.

IMPORTANT: Do not use any cleaning agents containing solvents.

Do not leave any sharp edges as this could compromise the tightness of the subsequent bonding of the windshields.

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Remove excess adhesive.

IMPORTANT: Do not use any cleaning agents containing solvents.

Seal adhesive areas and blind rivets with sealant D2.