41 34 041 Replacing Tail Panel

Read contents of body, general; refer to CONTENTS OF BODY, GENERAL .

STRIP DOWN  vehicle.

Follow procedure for REPAIR TECHNIQUES, REPAIR STAGE 2 .

Following new body parts are required (refer to appropriate parts information ):

1. Rear trim panel

The following consumables are required (refer to OVERVIEW OF CONSUMABLES (ELECTRONIC PARTS CATALOG) .

Material	Quantity
Adhesive K5b	1
Blind rivets N3	20
Punch rivets N4	8
Punch rivets N5	8
EMC screws	6
Cleaning agent R1	1
Sealant D1
Cavity wax remover

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Removing rear trim panel 

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

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Open welded connections in area (1).

Release the welded connections in areas (1) and remove the tail panel.

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New part preparation 

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

The bore holes (1) can be enlarged slightly if necessary.

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

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In area (1) set seven 4.2 mm dia. bore holes for blind rivets.

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In area (1) create three 4.2 mm dia. bore holes for blind rivets:

Installation note: 

When installing, insert the blind rivets from the outside to the inside.

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On both vehicle sides, prepare areas (1) for MAG welding.

Remove new part and deburr holes.

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Installing rear trim panel: 

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

Apply adhesive to bonding surfaces.

Do not apply adhesive on either vehicle side in area (1).

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Mount rear trim panel (1) and secure with blind rivets.

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

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In area (1) use 8 punch rivets N5 offset on both sides.

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In area (1) set 4 punch rivets N4.

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

Then install carrier for bumper panel to secure rear trim panel.

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On each vehicle side, introduce 2 MAG weld seams (1). Length approx. 20 mm.

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After hardening of the adhesive install 6 EMC screws in the areas (1); refer to EMC SCREWS .