41 34 060 Replacing Tail Panel

Refer to relevant service information in BODY, GENERAL .

STRIP DOWN VEHICLE

Observe procedures in REPAIR STAGE 2 .

The following new body parts are required:

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

Fig 1: Identifying Inner Rear Trim And Outer Skin Rear Trim
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Removing rear trim panel:

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

Mark severance cut (1) and cut.

IMPORTANT: Cut outer metal panel only.

Open brazed joint in area (2) by grinding.

Open welded connections in area (3).

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

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View from vehicle interior:

Open welded connections in area (1).

Remove rear trim panel.

Fig 3: Identifying Weld Joints Area

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Preparation of new part:

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).

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

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Open welded connections in areas (1).

Remove plates (2).

Adjust inner rear trim panel and roof outer skin rear trim panel to fit and secure.

Fig 5: Identifying Weld Joints In Areas And Plates

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Operation is described on the right side. Left is identical.

Set 10 holes with 4.2 mm dia. for blind rivets in area (1).

Fig 6: Identifying Holes For Blind Rivets Area

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In areas (1), set 7 4.2 mm dia. holes for blind rivets.

Remove new parts again and deburr holes.

Fig 7: Identifying Holes For Blind Rivets Areas

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

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

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

Fig 8: Bending Adhesive Flange

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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 9: Identifying 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.

Apply adhesive to adhesive flange (2).

Bend back adhesive flange and rivet with blind rivets (2).

Fig 10: Identifying Rear Trim Panel And Rivet With Blind 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 11: Identifying Bonding Surfaces

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

Fig 12: Identifying Rear Trim Panel And Rivet With Blind Rivets N3

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

Area	Number
1	14
2	4
3	3
4	2

Mount carrier for bumper trim to secure rear trim panel.

IMPORTANT:

Prevent emerging adhesive from coming into contact with cross-member!

Remove emerging adhesive.

Do not use any cleaning agents containing solvents.

Fig 13: Identifying Rivet Rear Trim Panel With Punch Rivets N4

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After hardening of the adhesive install 6 EMC SCREWS in the areas shown.

Fig 14: Identifying Areas For Adhesive And EMC Screws

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

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

Fig 15: Identifying Areas For Adhesive And EMC Screws

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