41 34 041 Replacing Tail Panel

Read contents of BODY, GENERAL  and observe relevant procedures.

STRIP DOWN  vehicle.

Observe REPAIR STAGE 2 .

Following new body parts are required:

1. Rear trim, complete
   Fig 1: Identifying Rear Trim, Complete

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Removing tail panel: 

Open weld joints in area (1).

Open brazed joints in areas (2).

Remove tail panel.

Fig 2: Identifying Brazed Joints Areas

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Preparation of new part: 

Slide in rear trim panel (1) from bottom upwards. Adjust in combination with tailgate and rear lights to fit and secure.

Fig 3: Sliding In Rear Trim Panel

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In areas (1 and 2) set 4.2 mm dia. bore holes for blind rivets:

Area (1): 2 bore holes

Area (2): 3 bore holes

Fig 4: Identifying Bore Hole Areas (Left Side)

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In areas (1 to 3) set 4.2 mm dia. bore holes for blind rivets:

Area (1): 2 bore holes

Area (2): 3 bore holes

Area (3): 1 bore hole

Fig 5: Identifying Bore Hole Areas (Right Side)

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In areas (1 and 2) set 4.2 mm dia. bore holes for blind rivets:

Area (1): 7 bore holes

Area (2): 1 bore hole

Remove new part and deburr holes.

Fig 6: Identifying Bore Hole Areas (Center)

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Installing tail panel: 

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

Apply adhesive to bonding surfaces.

Slide in rear trim panel (1) from bottom upwards.

In so doing, pay attention to adhesive.

Rivet rear trim panel with blind rivets.

Fig 7: Sliding In Rear Trim Panel

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In area (1) set 6 punch rivets N4.

In area (2) set 4 punch rivets N4.

Fig 8: Identifying Punch Rivet Locations

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Press rear trim panel in area (1) and remove emerging adhesive.

Then mount support for bumper panel in order to secure rear trim panel in area (1).

Spread emerging adhesive on all adhesive areas. Remove excess adhesive.

Seal adhesive areas and blind rivets with sealant.

Fig 9: Pressing Rear Trim Panel In Area (1)

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After hardening of the adhesive in areas shown (1), install 8 EMC SCREWS .

Fig 10: Identifying Adhesive Application Areas

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