41 34 060 Replacing Outer And Inner Tail Panel Sections

WARNING: This page is about a different car, the 2013 BMW X5, 2012 BMW X5, and 2011 BMW X5. However, it is still accessible from the selected car via links, so may be relevant.

Read contents of SAFETY INFORMATION and BODY, GENERAL .

STRIP DOWN VEHICLE

Procedure OBSERVE repair stage 2!

The following new body parts are required:

(1) Rear trim panel
(2) Rear trim, inner

Following CONSUMABLES are required:

Fig 1: Identifying Inner Rear Trim And Rear Trim Panel

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Material	Quantity
Adhesive K5b	1
Adhesive K5a	1
Blind rivets N3	41
Punch rivets N4	39
Cavity sealing wax remover
Cleaning agent R1	1
EMC screws	15
Sealant D1

Removing outer and inner tail panel sections:

Most of operation is described on the left side. Right side identical.

Open welded connections in areas (1).

Open brazed connections in areas (2).

Fig 2: Identifying Welded And Brazed Connection Areas

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Open welded connections in area (1).

Open bonded connections in areas (2).

Remove outer rear trim panel section.

Fig 3: Identifying Welded And Brazed Connection Areas

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Open welded connections in areas (1).

Fig 4: Identifying Welded Connection Areas

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Open welded connections in areas (1).

Fig 5: Identifying Welded Connection Areas

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Open welded connections in areas (1).

Remove inner rear trim panel section.

NOTE: The new part is joined during installation in areas (1) by plug-welding.

Fig 6: Identifying Welded Connection Areas

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Preparation of new part:

Adjust rear trim panel inner section (1) and rear trim panel outer section in combination with tailgate and rear lights to fit and secure.

Fig 7: Adjusting Rear Trim Panel Inner Section

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In areas (1) to (4), set 4.3 mm dia. holes for blind rivets.

Area	Number
1	11
2	3
3	3
4	2

Installation note:

Set rivets from the outside in the area (3).

Fig 8: Identifying Blind Rivet Bore Hole Areas

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In area (1) prepare new part and vehicle for MAG weld (metal active gas).

Fig 9: Identifying MAG Welding Area

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In areas (1) and (2) prepare new part and vehicle for MAG weld (metal active gas).

Installation note:

In area (3) one punch rivet N4 is used.

Area (1) not present on all vehicles.

Fig 10: Identifying MAG Welding Areas And Punch Rivet Area

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In areas (1) to (3), set 4.3 mm dia. holes for blind rivets.

Area	Number
1	3
2	2
3	2

Fig 11: Identifying Blind Rivet Bore Hole Areas

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Prepare new part for plug welding in areas (1).

Remove new parts again and deburr holes.

Fig 12: Identifying Welded Connection Areas

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

Installing outer and inner tail panel sections:

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

Apply adhesive to bonding surfaces.

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

Install rear trim panel inner section and rivet with blind rivets.

Use 2 punch rivets N4 in area (1).

Fig 13: Identifying Blind Rivet Bore Hole Areas

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Weld new part in this area (1) using metal active gas welding.

2 weld seams, each with length of 20 mm.

Fig 14: Identifying MAG Welding Area

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MAG weld new part in areas (1) and (2). For this purpose, set one weld seam with length of 20 mm in each case.

In area (3) use one punch rivet N4.

NOTE: Area (1) not present on all vehicles.

Fig 15: Identifying MAG Welding Areas And Punch Rivet Area

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Use 3 punch rivets in area (1).

NOTE: No riveting in areas (2).

Fig 16: Identifying Punch Rivet Area And No-Riveting Areas

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Mount rear trim panel outer section and rivet with blind rivets.

Use 22 punch rivets in area (1).

Use 15 punch rivets in area (2).

Fig 17: Identifying Punch Rivet Areas

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Press rear trim panel in areas (1) and (2) and remove emerging adhesive.

Until the adhesive hardens:

In area (1) install hinges for lower section of tailgate.

In the area (2) install support for bumper panel.

IMPORTANT: Prevent emerging adhesive from coming into contact with support and hinges.

Fig 18: Installing Hinges And Support For Bumper Panel

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Install 4 EMC SCREWS in area (1).

Fig 19: Identifying EMC Screws Installation Area

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In area (1) install one EMC screw.

Fig 20: Identifying EMC Screw Installation Area

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In area (1) install one EMC screw.

Fig 21: Identifying EMC Screw Installation Area

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After hardening of the adhesive in areas shown (1), install 4 EMC screws.

Fig 22: Identifying EMC Screws Installation Area

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