41 34 037 Replacing outer tail panel section

Read contents of BODY, GENERAL .

Observe procedure for REPAIR STAGE 2

The following new body parts are required:

The following CONSUMABLES are required:

Fig 1: Identifying Outer Skin Rear Trim

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MATERIAL QUANTITY SPECIFICATION

Removing rear trim panel

Open brazed joint in areas (1) by grinding.

Open welded connections in area (2).

Remove rear trim.

Fig 2: Identifying Brazed Joint And Welded Connections Areas

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New part preparation

Open welded connections in areas (1).

Remove plates (2).

Fig 3: Identifying Plates And Welded Connections Areas

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Adjust rear trim panel to fit and secure.

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

Remove new part again and deburr bore holes.

Fig 4: Identifying Area For Blind Rivet Bore Holes

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

Installing rear trim panel

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

Apply K5a adhesive to bonding surfaces (1).

Fig 5: Identifying Bonding Surfaces

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

NOTE: After adhesive has hardened: Fit an EMC screw in the center of the adhesive flange (1).

Fig 6: Identifying Area For Blind Rivets

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In area (1) rivet rear trim panel with 8 punch rivets N4.

Fig 7: Identifying Area For Punch Rivets

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