41 34 060 Replacing outer and inner tail panel sections

Read contents of SAFETY INFORMATION and BODY, GENERAL .

STRIP DOWN VEHICLE

Procedure observe REPAIR STAGE 2 .

Following new body parts are required:

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

Following CONSUMABLE are required:

Fig 1: Identifying Rear Trim Panel And Inner Rear Trim

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Material	Quantity
Adhesive K5b	1
Blind rivets N3	24
Punch rivets N4	27
EMC screws	10
Cavity sealing wax remover
Cleaning agent R1	1
Sealant D1

Removing the tail panel

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

Open welded connections in area (1).

Fig 2: Identifying Tail Panel Welded Connection Areas

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Open welded connections in area (1).

Roughly mark severance cut (2) and cut.

Remove tail panel.

Fig 3: Identifying Tail Panel Welded Connection Areas

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Open welded connections in area (1).

NOTE: Schematic diagram shown without cross member mounting for bumper for better overview.

Fig 4: Identifying Bumper Cross Member Mounting Welded Connection Areas

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New part preparation

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

Disconnect section (1) according to schematic diagram.

Changed joining sequence: New part is installed from outside in the area (2) with overlap.

Set area (2) on the new part and on the vehicle.

Fig 5: Identifying Rear Trim Panel Installation Areas

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Adjust rear trim panel and outer skin rear trim panel to fit and secure them.

Set 4 4.2 mm diameter bore holes for blind rivets in area (1).

Fig 6: Identifying Tail Panel Hardened Adhesive Area

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

NOTE: Schematic diagram shown without cross member mounting for bumper for better overview.

Fig 7: Identifying Area For Setting Blind Rivet Bore Holes

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Changed joining sequence: Fit new part from the outside in area (1) and install with overlap.

In areas (1) to (3), create 4.2 mm dia. bore holes for blind rivets N3.

Fig 8: Identifying Area For Setting Blind Rivet Bore Holes

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Area	Number
1	3 of
2	1 of
3	4

Remove new part again and deburr bore holes.

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

NOTE: Also apply adhesive to these adhesive areas after installing rear trim panel.

Then bend back the adhesive flanges.

Fig 9: Bending Adhesive Flanges Inwards

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

Installing the tail panel

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

Apply adhesive to bonding surfaces.

Attach rear trim panel (inner panel) and rivet using blind rivets.

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

In area (1) use a total of 9 punch rivets N4.

NOTE: Schematic diagram shown without cross member mounting for bumper for better overview.

Fig 10: Identifying Bumper Cross Member Mounting Rivet Punching Area

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Install rear trim panel outer skin and rivet with blind rivets.

Use 18 punch rivets N4 in areas (1) and (2).

Area	Number
1	11
2	7

Fig 11: Identifying Rear Trim Panel Outer Skin Rivet Punching Areas

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Mount support for bumper panel to secure rear trim panel.

IMPORTANT: Prevent emerging adhesive from coming into contact with cross-member.

Fit an EMC SCREW after adhesive has hardened in area (1).

Fig 12: Identifying Tail Panel Hardened Adhesive Area

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

NOTE: Schematic diagram shown without cross member mounting for bumper for better overview.

Fig 13: Identifying Bumper Cross Member Mounting Rivet Punching Area

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After hardening of the adhesive in areas (1), install 5 EMC screws.

Fig 14: Identifying Installation Areas For EMC Screws

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