41 34 041 Replacing tail panel

Read contents of BODY, GENERAL .

STRIP DOWN VEHICLE .

Observe procedure for REPAIR STAGE 2

The following new body parts are required:

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

The following CONSUMABLES are required:

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

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MATERIAL QUANTITY SPECIFICATION

Material	Quantity
Adhesive K5b	1
Blind rivets N3	30
Punch rivets N4	14
EMC screw	2
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) and cut.

Cut outer metal panel only.

Open welded connections in areas (2).

Fig 2: Identifying Severance Cut Mark And Welded Connections Area

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View from vehicle interior:

Open welded connections in area (1).

Roughly cut C-pillar reinforcement along line (2).

Remove plate (3).

Fig 3: Identifying Plate, Cutting Area, And Welded Connections Areas

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Open welded connections in area (1).

Remove rear trim.

Fig 4: Identifying Welded Connections Area

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New part preparation

Mark severance cut (1) and cut.

Adjust inner rear trim panel and roof outer skin rear trim panel to fit and secure.

Fig 5: Identifying Severance Cut Mark

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

Fig 6: Identifying Area For Blind Rivet Bore Holes

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Set 9 4.2 mm dia. holes for blind rivets in areas (1).

Remove new parts again and deburr holes.

Fig 7: Identifying Areas For Blind Rivet Bore Holes

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

NOTE: Apply adhesive to these adhesive flanges only after installing rear trim panel.

Fig 8: Identifying Adhesive Flanges

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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 K5b to bonding surfaces (1).

Fig 9: Identifying Bonding Surfaces

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

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

Fig 10: Identifying Area For Blind Rivets

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Apply adhesive to adhesive flanges (2).

Bend back adhesive flanges and rivet with blind rivets (2).

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

Apply adhesive K5b to bonding surfaces (1).

Fig 11: Identifying Bonding Surfaces

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

Fig 12: Identifying Areas For Blind Rivets

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In area (1) rivet rear panel with 14 punch rivets.

Mount carrier for bumper trim to secure rear trim panel.

Fig 13: Identifying Area For Punch Rivets

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

After adhesive has hardened in area (1), fit an EMC SCREW .

Fig 14: Identifying Adhesive Area

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