41 34 041 Complete Tail Panel Replacement

WARNING: This page is about a different car, the 2010 BMW 535xi, 2009 BMW 535xi, and 2008 BMW 535xi. However, it is still accessible from the selected car via links, so may be relevant.

Read contents of BODY, GENERAL .

Spot-weld bonding is used on this vehicle.

Observe relevant procedures in BODY, GENERAL .

Following new body parts are required:

Rear trim, outer skin
Rear trim

Fig 1: Identifying Rear Trim, Outer Skin

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Open weld joints in areas (1).

Open brazed joints in areas (2).

Fig 2: Identifying Weld Joints Area

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Open weld joints in area (1).

NOTE: Bend panel open in area (1) and open welded spot.

Fig 3: Identifying Weld Joints Area

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Open weld joints in areas (1).

Fig 4: Identifying Weld Joints Area

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Carry over the work step shown symmetrically to the other side of the vehicle.

Open weld joints in area (1).

Fig 5: Identifying Weld Joints Area

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Preparation of new part:

Carry over the work steps shown symmetrically to the other side of the car.

In area (1) set two 4.2 mm dia. bore holes for blind rivets:

Fig 6: Identifying Rivet Bore Hole Area

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

Area (1): 2 bore holes

Area (2): 2 bore holes

Area (3): Total of 4 bore holes.

In area (4) prepare new part and vehicle for MAG weld (metal active gas).

Fig 7: Identifying Rivet Bore Hole Areas

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

Area (1): 2 bore holes

Area (2): 3 bore holes through inner and outer panels

Fig 8: Identifying Rivet Bore Hole Areas

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

Area (1): 2 bore holes

Area (2): 3 bore holes through inner and outer panels

Area (3): 1 hole

Fig 9: Identifying Rivet Bore Hole Areas

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

Area (1): 2 bore holes

Area (2): 7 bore holes

Area (3): 1 hole

Remove all new parts and deburr holes.

Fig 10: Identifying Rivet Bore Hole Areas

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IMPORTANT: Do not grind/sand new part in area of bonding surfaces.

Installing tail panel:

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

Apply adhesive to bonding surfaces.

Install new parts and rivet with blind rivets.

Carry over the work steps shown symmetrically to the other side of the car.

In area (1) set 12 punch rivets N4.

In area (2) set 6 punch rivets N4.

In area (3) set 3 punch rivets N4.

Fig 11: Identifying Rivet Areas

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Weld new part in this area (1) using metal active gas welding.

3 weld seams, each with length of 15 - 20 mm.

Fig 12: Identifying Welding Area

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

Then mount support for bumper panel in order to secure rear trim panel in area (1).

Spread emerging adhesive on all adhesive areas. Remove excess adhesive.

IMPORTANT: Prevent emerging adhesive from coming into contact with support.

Seal adhesive areas and blind rivets with sealant.

Fig 13: Identifying Adhesive Areas

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After hardening of the adhesive install 4 EMC SCREWS in areas shown (1).

Carry over the work steps shown symmetrically to the other side of the car.

Fig 14: Identifying Installation Areas For EMC Screws

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After hardening of the adhesive install 6 EMC screws in the areas shown (1).

Fig 15: Identifying Installation Areas For EMC Screws

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