41 34 038 Replacing Outer Tail Panel Section

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Read contents of BODY, GENERAL .

Observe (REPAIR STAGE 2) procedure!

STRIP DOWN vehicle.

The following new body parts are required (refer to OVERVIEW OF CONSUMABLES ):

(1) Rear trim panel

Following CONSUMABLES are required:

Material	Quantity
Adhesive K5a	1
Adhesive K5b	1
R1 cleaning agent	1
Blind rivets N3	24
Punch rivets N4	24
EMC screws	10
Sealant D1
Cavity wax remover

Fig 1: Identifying Rear Trim Panel

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Removing rear trim panel

Fig 2: Identifying Tail Panel Outer Section And Inside Center Section Cutting Area

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT: Cut outer panel only.

Cut severance cuts (1) 15 mm below the component edge of the rear bulb mount and separate.

Open welded connections in areas (2).

NOTE: The new part is installed overlapping in the areas (1).

New part preparation

Mark severance cuts on new part in accordance with severance cuts on vehicle + 15 mm extra material and cut.

Adjust rear trim panel in combination with rear lid and rear lights to fit and secure.

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

Fig 3: Identifying Rear Trim Panel Area

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: In the areas (1) the new part may not overlap the rear lamp mounts!
In areas (1) to (4), set 4.2 mm diameter bore holes for blind rivets.

Area	Number
1	2 on each side
2	2
3	8
4	5 on each side

Remove new part and deburr holes.

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.

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

Fig 4: Identifying Rear Trim Panel And Rivet With Blind Rivets Area

Courtesy of BMW OF NORTH AMERICA, INC.

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 5: Identifying Rear Trim Panel Adhesive Areas

Courtesy of BMW OF NORTH AMERICA, INC.

Fig 6: Identifying EMC Screws Areas

Courtesy of BMW OF NORTH AMERICA, INC.

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