41 34 060 Replacing tail panel

WARNING: This page is about a different variant/trim than selected.

Read contents of BODY, GENERAL .

STRIP DOWN VEHICLE .

NOTE: Observe new procedure for bonding and riveting (REPAIR STAGE 2) .

Following new body parts are required:

(1) Rear trim, outer skin
(2) Rear trim, inner

Fig 1: Identifying Rear Trim, Inner & Rear Trim, Outer Skin

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Following CONSUMABLES are required:

CONSUMABLES MATERIAL REFERENCE CHART

Material	Quantity
Adhesive K5b	1
Blind rivets N3	31
Punch rivets N4	23
Cavity sealing wax remover
CleanerR1	1
Sealing compoundD1

Removing rear trim panel

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

Mark severance cut (1) and cut.

IMPORTANT: Cut outer metal sheet only.

Open brazed joint in area (2) by grinding.

Open weld joints in area (3).

Fig 2: Identifying Brazed, Welded Joint Areas And Severance Cut

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View from vehicle interior:

Open weld joints in area (1).

Remove rear trim panel.

Fig 3: Removing Rear Trim Panel

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New part preparation

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

Mark severance cut (1) on new part in accordance with shape of side panel and cut.

Severance cut (2) of rear trim panel on car.

Open weld joints and remove component (3).

Adjust new parts to fit and secure.

Fig 4: Identifying Severance Cut Of Rear Trim Panel And Weld Joint Component

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Operation is described on the right side. Left is identical. In areas (1) and (2) set 4.2 mm dia. holes for blind rivets.

Area	Number
1	total of 9
2	3

Fig 5: Setting 4.2 mm Diameter Holse For Blind Rivets

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Fig 6: Identifying Holes For Blind Rivets Area

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Set seven 4.2 mm dia. holes for blind rivets in areas (1).

Remove new parts again and deburr holes.

Bend adhesive flange (1) approx. 30° inwards.

NOTE: Apply adhesive to this adhesive flange only after installing rear trim panel.

Fig 7: Bending Adhesive Flange

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IMPORTANT: Do not grind new parts and body 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 (1).

Fig 8: Applying Adhesive To Bonding Surfaces

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Mount rear trim panel and rivet with blind rivets (1).

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

In areas (1) and (2) rivet rear trim panel with punch rivets:

Area	Number
1	7
2	3

Fig 9: Riveting Rear Trim Panel With Punch Rivets

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

Apply adhesive to bonding surfaces (1).

Fig 10: Identifying Bonding Surfaces

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Fig 11: Identifying Rear Trim Panel And Rivet With Blind Rivets N3

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Mount rear trim panel and rivet with blind rivets N3 (1).

Fig 12: Identifying Rivet Rear Trim Panel With Punch Rivets N4

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In areas (1) to (4) rivet rear trim panel with punch rivets N4.

Refer to table below for number.

RIVET NUMBERS REFERENCE CHART

Area	Number
1	8
2	4
3	3
4	2

Mount carrier for bumper trim to secure rear trim panel. (Remove carrier for bumper trim again after adhesive has dried).

IMPORTANT: Prevent emerging adhesive from coming into contact with crossmember!

Remove emerging adhesive.

Do not use any cleaning agents containing solvents!

After hardening of the adhesive install 6 EMC screws in the areas shown. See Fig 13.

Fig 13: Installing 6 EMC Screws

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After hardening of the adhesive install 3 EMC screws in areas (1).

Fig 14: Installing 3 EMC Screws

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