Replacing Rear Left Side Panel (Cooper, Cooper S, John Cooper Works)

Read contents of BODY, GENERAL .

Strip down vehicle. Refer to STRIPPING OPERATIONS - REPLACING REAR QUARTER PANEL, LEFT  or STRIPPING OPERATIONS - REPLACING REAR QUARTER PANEL, RIGHT .

Procedure OBSERVE  repair stage 2!

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

(1) Rear wall

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Following CONSUMABLES  are required:

Material	Quantity
Adhesive K5A	2
Blind rivets N3	4
Punch rivets N4	8
Cavity sealing wax remover
Cleaning agent R1	1
Sealant D1

Removal 

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Open welded connections in areas (1).

OPEN  spot-welded adhesive joints in area (2). Loosen side wall of cavity sealing (3).

Open welded connections in area (1).

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Open welded connections in area (1) and remove side panel.

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New part preparation 

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Adjust side panel and secure.

In area (1) prepare for joining by welding.

Prepare area (2) for joining via bonded rivet technology. (3 x punch rivet N4)

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Prepare areas (1) to (4) for joining by rivet bonding technology.

In areas (1) and (3): Punch rivet N4.

Drill bores ø 4.2 mm for blind rivet in areas (2) and (4).

Area	Number
2	1
4	3

In area (1) prepare for joining by welding.

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In area (1) prepare for joining by welding.

Remove new part and deburr holes.

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Installation 

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

Apply adhesive to bonding surfaces.

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

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Apply sealing compound to cavity sealing (1).

Adjust new part and secure with locking pliers. When adjusting, make sure the bores for the blind rivet match.

Rivet new part with 3 x punch rivet N4 in area (2).

Fix new part in area (3) using locking pliers until the adhesive is hardened.

Weld new part in area (4).

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Rivet the new part in the areas (2) and (4) using blind rivet N3.

Rivet the new part with punch rivet N4 in areas (1) and (3).

Area	Number
1	2
3	3

Weld new part in area (1).

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Weld new part in area (1).

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Apply sealant in area (1) in same way as on opposite side.

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