41 34 060 Replace Tail Panel Outer Section And Inner Section

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Read contents of BODY, GENERAL .

STRIP DOWN vehicle

Observe procedure of REPAIR STAGE 3 .

Following new body parts are required (see OVERVIEW OF CONSUMABLES ):

(1) Rear trim, outer skin
(2) Rear trim, inner
(3) Luggage compartment floor, left and right

Following CONSUMABLES are required:

Fig 1: Identifying Luggage Compartment Floor, Left And Right

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Material	Quantity
Adhesive K5a	1
Adhesive K5b	1
Blind rivet N3	26
Punch rivetN4	24
EMC screw	10
Cleaning agent R1	1
Sealant D1
Cavity wax remover

Remove tail panel outer section and inner section

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

Open welded connections in area (1).

Completely drill through welded connections in these areas (2).

Roughly cut out tail panel outer section and inner section.

Fig 2: Identifying Tail Panel Outer Section And Inner Section Welded Connections Area

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Open welded connections in areas (1).

Fig 3: Identifying Tail Panel Outer Section And Inner Section Welded Connections Area

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Open welded connections in areas (1).

Fig 4: Identifying Rear Trim Panel Outer Skin Welded Connections Areas

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Fig 5: Identifying Exterior And Interior Tail Part Welded Connections Area

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View from vehicle interior.

Open welded connections in areas (1).

Remove exterior and interior tail part.

New part preparation

NOTE: The outer skin of the rear trim panel is bonded using the bonding riveting process. All other components are welded.

IMPORTANT: Version with automatic tailgate actuation:
Risk of damage to spindle drive: only move rear lid slowly by hand.

Undo welded connections and disconnect the rear trim panel support (1) from the luggage compartment floor.

Fig 6: Identifying Rear Trim Panel Support From Luggage Compartment Floor

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Mark severance cut (1) as pictured and cut.

Remove metal section (2).

Shown on left side. Right side as mirror image.

Fig 7: Identifying Metal Section

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Fig 8: Identifying Bore Holes For Blind Rivets Areas

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Adjust new parts to fit and secure.

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

Area	Number
1	2
2	8
3	8 on each side

Remove new part and deburr holes.

IMPORTANT: Do not grind new parts and body in area of bonding surfaces.

Installing inner rear trim panel and support of rear trim panel

Install and weld new parts.

NOTE: The inner rear trim panel is welded to the outer skin of the rear trim panel in this area (1).

Fig 9: Identifying Outer Skin Of Rear Trim Panel Weld Area

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Installing the outer skin of the rear trim panel

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

Apply adhesive to bonding surfaces.

When inserting rear trim panel, make sure there is sufficient adhesive on bonding surfaces.

Fig 10: Identifying Outer Skin Of Rear Trim Panel Punch Rivets Areas

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Install rear trim panel and rivet with blind rivets.

Use N4 punch rivets in areas (1) to (3).

Area	Number
1	11
2	7
3	3 on each side

Weld the outer skin of the rear trim panel and the inner rear trim panel to the side wall in these areas (4).

IMPORTANT: Risk of damage!
Avoid exposing neighboring adhesive areas to excessive heat!

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

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

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 Areas

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Fig 12: Identifying EMC Screws Areas

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After hardening of the adhesive install 10 EMC SCREWS in the areas shown (1).