41 34 060 Replacing Outer And Inner Tail Panel Sections

WARNING: This page is about a different car, the 2011 BMW X6 and 2010 BMW X6. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: High-voltage system - danger to life!

WARNING: The following points must be strictly observed prior to starting work :

DE-ENERGIZE THE HIGH-VOLTAGE SYSTEM
Observe SAFETY INSTRUCTIONS for handling with hybrid cars

Read contents of BODY .

STRIP DOWN VEHICLE .

Procedure OBSERVE repair stage 2!

Following new body parts are required (see BMW Electronic Parts Catalogue):

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

Following CONSUMABLES are required:

Fig 1: Identifying Rear Trim Panel And Inner Rear Trim

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Material	Quantity
Adhesive K5b	1
Adhesive K5a	1
Blind rivets N3	31
Punch rivets N4	37
EMC screws	15
Cavity sealing wax remover
Cleaning agent R1	1
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 connection in area (2).

Open spot-weld adhesive joints in area (3)

Remove outer rear trim panel section.

Fig 2: Identifying Welded Connections Areas, Brazed Connection Area And Spot-Weld Adhesive Joints Area

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Open welded connections in areas (1) to (3).

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

Fig 3: Identifying Welded Connections Areas

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Open welded connections in areas (1) and (2).

Fig 4: Identifying Welded Connections Areas

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Open welded connections in areas (1) to (3).

Remove inner rear trim panel section.

Fig 5: Identifying Welded Connections Areas

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New part preparation:

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 6: Adjusting Rear Trim Panel Inner Section

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Set eleven Ø 4.8 mm holes in total for blind rivets in area (1).

Set 3 bore holes for blind rivets in area (2).

In area (4) prepare new part and vehicle for MAG weld (metal active gas).

Installation note:

N4 In area (3) 2 punch rivets are used.

Fig 7: Identifying Blind Rivets Area, Blind Rivets Area, Mag Weld Area And Punch Rivets Area

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

Installation note:

Area (1) not present on all vehicles.

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

Fig 8: Identifying Welded Connections Areas

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Set five 4.8 mm holes for blind rivets in each of areas (1).

In areas (2), set 4 holes for blind rivets.

Remove new parts again and deburr holes.

Fig 9: Identifying Blind Rivets Areas And Blind Rivets Hole Area

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IMPORTANT: Do not grind/sand new part 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.

Mount inner rear trim panel section and rivet with blind rivets in areas (1) and (2).

Use 2 punch rivets N4 in area (3).

Weld new part in this area (4) using metal active gas welding. 2 weld seams, each with length of 20 mm.

Fig 10: Identifying Blind Rivets Area, Blind Rivets Area, Mag Weld Area And Punch Rivets 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 11: Identifying Welded Connections Areas

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Use 3 punch rivets in area (1).

NOTE: In areas (2) only bonded connection.

Fig 12: Identifying Welded Connections Areas

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Install outer rear trim panel section and secure with blind rivets.

Use 11 punch rivets in area (1).

Use 14 punch rivets in area (2).

Fig 13: Identifying Punch Rivets Areas

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

Install support for bumper trim until the adhesive has hardened.

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

Fig 14: Identifying Rear Trim Panel Areas

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After hardening of the adhesive in illustrated areas (1) and (2), install 3 EMC SCREWS .

Fig 15: Identifying Adhesive Areas

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After hardening of the adhesive in areas (1), install one EMC screw.

Fig 16: Identifying Adhesive Areas

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Fig 17: Identifying Adhesive Areas

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