41 34 060 Replacing Outer And Inner Tail Panel Sections

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Read contents of BODY, GENERAL .

Observe procedure for REPAIR STAGE 2 .

STRIP DOWN VEHICLE

Following new body parts are required (refer to BMW ELECTRONIC PARTS CATALOGUE ):

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

Following CONSUMABLES are required:

Fig 1: Identifying Rear Trim Panel

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Material	Quantity
Adhesive K5b	1
Blind rivets N3	72
Punch rivets N4	26
EMC screws	18
Cleaning agent R1	1
Sealant D1
Cavity wax remover

Removing rear trim panel

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

Open welded connections in area (1).

Fig 2: Identifying Welded Connections Area

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View from vehicle interior:

Open welded connections in areas (1).

Fig 3: Identifying Welded Connections Areas

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Mark severance cut (1) at edge of component (2) and cut.

Open weld joints in area (3) and remove rear trim panel.

Fig 4: Identifying Severance Cut And Weld Joints Area

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New part preparation

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

NOTE: On vehicles with a sensor for lane change warning, also check the bumper guide for correct seating. See GUIDE FOR REAR CENTER BUMPER and SENSOR FOR LANE CHANGE WARNING .

IMPORTANT: Version with automatic tailgate activation:
Risk of damage to spindle drive: only move rear lid slowly by hand.

Mark severance cut (1) at edge and remove sheet metal flange (2).

Open weld joints in area (3) and remove component (4).

NOTE: Rear trim panel is only bonded in area (3). Riveting is not necessary.

Fig 5: Identifying Severance Cut, Sheet Metal Flange And Weld Joints Area

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Adjust new parts to fit and secure.

In areas (1) and (2) set 4.2 mm dia. holes for blind rivets:

Area (1): 9 bore holes

Area (2): 1 hole on each side

Fig 6: Identifying Blind Rivets And Bore Holes Area

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Make sheet metal angle in accordance with specified dimensions.

Dimension a = approx. 20 - 25 mm

Dimension b = approx. 20 - 25 mm

Dimension c = approx. 30 mm

NOTE: Adapt sheet metal angle to respective shape of installation location.

Fig 7: Identifying Sheet Metal Angle Dimension

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Adapt sheet metal angle (1).

In areas (1) to (3), set 4.2 mm dia. holes for blind rivets:

Area (1): 2 bore holes

Area (2): 1 bore hole

Area (3): 4 bore holes

Fig 8: Identifying Sheet Metal Angle And Blind Rivets Bore Holes Area

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In areas (1) to (4) set 4.2 mm dia. bore holes for blind rivets:

Fig 9: Identifying Bore Holes Area For Blind Rivets

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Area	Number
1	9 (total)
2	2
3	3
4	10

Remove rear trim panel outer skin .

Fig 10: Identifying Sheet Metal Angle

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Adapt sheet metal angle (1).

For each sheet metal angle set two 4.2 mm dia. holes for blind rivets.

Remove inner rear trim panel. Deburr all bore holes.

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

Installing rear trim panel

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

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

Apply adhesive to bonding surfaces (1).

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

Fig 11: Identifying Sheet Metal Angle

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Fit inner rear trim panel and rivet with sheet metal angle (1).

Fit outer rear trim panel and secure.

Rivet new part in areas (1) and (2).

Fig 12: Identifying Rivet Part Areas

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Fit sheet metal angle (1).

Rivet new parts in areas (1) to (3).

Fig 13: Identifying Sheet Metal Angle And Rivet Parts Areas

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Rivet new parts in areas (1) to (4).

Fig 14: Identifying Rivet Parts Areas

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Fig 15: Identifying Punch Rivets N4 Areas

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Use punch rivets N4 in areas (1) and (2):

Area	Number
1	7
2	17

IMPORTANT: No blind rivets may be used in areas (4)! Areas (4) = 10 cm

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

Then install carrier for bumper trim to secure rear trim panel carrier.

IMPORTANT: Prevent emerging adhesive from coming into contact with cross-member!
Do not use any cleaning agents containing solvents.

Fig 16: Identifying Rear Trim Panel Areas

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Fig 17: Identifying EMC Screws Areas

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

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

Fig 18: Identifying EMC Screws In Areas

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