41 34 041 Replacing Complete Tail Panel (Hybrid)

WARNING: This page does not describe the selected car, but rather 50 other vehicles, including the 2016 BMW M5, 2016 BMW ActiveHybrid 5, 2016 BMW 550i xDrive, 2016 BMW 550i, and 2016 BMW 535i xDrive. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: High-voltage system - danger to life
Compliance with the following points is mandatory before beginning work:

DISCONNECT HIGH-VOLTAGE SYSTEM FROM POWER .
Observe SAFETY INFORMATION for handling electric vehicles.

Read contents of BODY, GENERAL .

Observe (REPAIR STAGE 2) procedure! STRIP DOWN VEHICLE

Following new body parts are required (refer to ELECTRONIC PARTS CATALOGUE ):

(1) Rear trim panel

Following CONSUMABLES are required:

Fig 1: Identifying Rear Trim Panel

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Material	Quantity
Adhesive K5b	1
Blind rivets N3	40
Punch rivets N4	8
EMC screws	10
Cavity sealing wax remover
Cleaning agent R1	1
Sealant D1

Removing rear trim panel:

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

Release rivet connections (1) and disassemble support (2).

Version with automatic tailgate activation:

Shut down . See 61 20 900 DISCONNECTING AND CONNECTING BATTERY NEGATIVE LEAD or 61 35 196 REMOVING AND INSTALLING (REPLACING) CONTROL UNIT FOR AUTOMATIC REAR LID ACTUATION automatic tailgate actuation.

IMPORTANT: Risk of damage to spindle drive: only move rear lid slowly by hand.
If necessary, remove spindle drive . See 51 24 351 REMOVE AND INSTALL/REPLACE SPINDLE DRIVE AT RIGHT (AUTOMATIC TAILGATE OPERATION) or 51 24 350 REMOVING AND INSTALLING/REPLACING LEFT SPINDLE DRIVE (AUTOMATIC LUGGAGE COMPARTMENT LID ACTUATION) .

Fig 2: Identifying Rivet Connections And Support

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Open welded connections in areas (1).

Open weld joints in areas (2) from inside.

Remove rear trim.

Fig 3: Identifying Weld Joint Areas

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Preparation of new part:

Slide in rear panel (1) from below in upward direction and adjust to fit and secure in conjunction with rear lid and rear lights.

NOTE: On vehicles with a sensor for lane change warning . See 51 12 825 REMOVING AND INSTALLING/REPLACING GUIDE FOR REAR CENTER BUMPER or 66 32 020 REMOVING AND INSTALLING/REPLACING SENSOR FOR LANE CHANGE WARNING , also check the bumper guide for correct seating.

Fig 4: Sliding Rear Panel From Below

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IMPORTANT: Retaining screws must not be used in area (1)

In areas (2 to 5) set 4.2 mm dia. holes for blind rivets N3:

Fig 5: Identifying Holes For Blind Rivets (N3) - 1 Of 3

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Area	Number
2	1
3	4
4	3
5	3

In area (1) set 8 holes for blind rivets N3. When doing so, drill from inside of tail panel outwards.

Fig 6: Identifying Holes For Blind Rivets (N3) - 2 Of 3

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Set six 4.2 mm dia. holes for N3 blind rivets in area (1).

IMPORTANT: No blind rivets may be used in areas (2)!
Dimension A = 10 cm

Remove new part again and deburr bore holes.

Fig 7: Identifying Holes For Blind Rivets (N3) - 3 Of 3

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

Installing rear trim panel:

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

Apply adhesive to bonding surfaces.

Make sure adhesive application is closed in area (1)! (watertightness).

Fig 8: Identifying Rear Trim Panel Adhesive Applying Area

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

Rivet rear panel.

NOTE: When sliding in rear trim panel, make sure there is sufficient adhesive on bonding surfaces.

Fig 9: Sliding Rear Panel From Below

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In area (1), rivet tail panel with 4 punch rivets N4.

Fig 10: Riveting Tail Panel Areas

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

Before the adhesive has hardened, install the support for the bumper trim.

IMPORTANT: Prevent emerging adhesive from coming into contact with support.
Do not use any cleaning agents containing solvents.

Fig 11: Identifying Rear Trim Panel Adhesive Applying Area

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Fig 12: Identifying Rear Trim Panel Adhesive Applying Area

Courtesy of BMW OF NORTH AMERICA, INC.

After hardening of the adhesive install 10 EMC SCREWS in the areas shown.