41 34 041 Replacing Complete Tail Panel: Notes

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Read contents of BODY, GENERAL .

Observe procedures for REPAIR STAGE 2 .

STRIP DOWN VEHICLE .

The following new body parts are required :

(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 screws (1) and remove support (2).

Tightening torque 41 34 1AZ .

Version with automatic tailgate activation:

Shut down AUTOMATIC READ LID ACTUATION .

IMPORTANT:

Risk of damage to spindle drive: only move rear lid slowly by hand.

If necessary, remove spindle drive. See REMOVING LEFT SPINDLE DRIVE or REMOVING RIGHT SPINDLE DRIVE .

Fig 2: Identifying Rear Trim Panel Support And Screws

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Open welded connections in areas (1).

Open weld joints in areas (2) from inside.

Remove rear trim.

Fig 3: Identifying Rear Trim Welded Connections Areas

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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, also check the bumper guide for correct seating. See REMOVING/INSTALLING/REPLACING GUIDE FOR REAR CENTER BUMPER and 66 32 020 REMOVING AND INSTALLING/REPLACING SENSOR FOR LANE CHANGE WARNING ON LEFT OR RIGHT .

Fig 4: Sliding Rear Trim Panel

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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:

Area	Number
2	1
3	4
4	4
5	3

Fig 5: Identifying Blind Rivet Holes Area

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In area (1) set 8 holes for blind rivets N3. In so doing, drill the two outer holes from the inside outwards.

Then connect the outer holes on the outside with a line. Drill the remaining holes on the line from the outside.

Fig 6: Identifying Blind Rivet Hole Area

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In area (1) set seven 4.2 mm bore holes for N3 blind rivets.

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 Blind Rivet Holes Area

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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 Adhesive Applying Area On Rear Panel

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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 Trim Panel

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In area (1), rivet tail panel with 4 punch rivets N4.

Fig 10: Identifying Tail Panel Punch Rivet Area

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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 Adhesive Applying Area On Rear Panel

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Fig 12: Identifying EMC Screws Installing Areas

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