41 34 041 Replacing Complete Tail Panel (Non-Hybrid)

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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 Joints Areas From Inside

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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: Identifying Rivet 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

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