41 34 040 Replace inner tail panel outer section and center section

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

Read contents of BODY, GENERAL .

STRIP DOWN VEHICLE .

Procedure OBSERVE repair stage 2!

Following new body parts are required:

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

Following CONSUMABLES are required:

Fig 1: Identifying Rear Trim (Inner And Outer Skin)

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Material	Quantity
Adhesive K5b	1
Blind rivets N3	24
Punch rivets N4	17
EMC screws	12
Cavity sealing wax remover
Cleaning agent R1	1
Sealant D1

Removing rear trim panel

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

Mark severance cut (1) as pictured 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 Cutting Mark, Welded Connection Areas, And Brazed Joint Area

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

Mark severance cut (1) as pictured and cut.

Open welded connections in areas (2).

Remove rear trim panel.

Fig 3: Identifying Severance Cut And Welded Connection Areas

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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).

Fig 4: Identifying Cutting Areas

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

Mark new severance cut (1) on part in accordance with severance cut (2) on vehicle + 20 mm extra material and cut.

Install new parts and secure.

Fig 5: Identifying Severance Cuts

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

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

Fig 6: Identifying Blind Rivet Areas

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Area	Number
1	total of 9
2	2
3	2

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

Remove new parts again and deburr holes.

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

Graphic representation similar.

Fig 7: Identifying Area For Blind Rivet Bore Holes

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

Fig 8: Identifying 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 surface (1).

Install rear trim panel inner section and rivet with blind rivets.

Fig 9: Identifying Bonding Surface

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

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

Fig 11: Identifying Rear Trim Panel Punch Rivet Areas

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Area	Number
1	8
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 support.
Remove emerging adhesive.
Do not use any cleaning agents containing solvents.

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

Fig 12: Identifying Installation Areas For EMC Screws

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

After adhesive has hardened, install 3 EMC screws in areas (1) and (2).

Fig 13: Identifying Installation Areas For EMC Screws

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