41 34 038 Outer Of Tail Panel Section Replacement

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:

1. Rear trim, outer skin

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 Brazed Joints Areas

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Open weld joints in area (1).

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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Open weld joints in area (1).

Fig 5: Identifying Weld Joints Area

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Preparation of new part: 

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

Area (1): 2 bore holes

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

Fig 6: Identifying Rivet Bore Hole Areas

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

Area (1): 2 bore holes

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

Area (3): 1 bore hole

Fig 7: Identifying Rivet Bore Hole Areas

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

Area (1): 2 bore holes Area (2): 7 bore holes

Area (3): 1 bore hole

Remove new part and deburr holes.

Fig 8: Identifying Rivet Bore Hole Areas

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Installing tail panel outer section: 

Adjust outer panel in combination with tailgate and rear lights to fit and secure.

Clean bonding surfaces with cleaning agent R1.

Apply K5 adhesive.

Install new parts and rivet with blind rivets.

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 9: Identifying Rivet Areas

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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.

Seal adhesive areas and blind rivets with sealant.

Fig 10: Identifying Adhesive Areas

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

Fig 11: Identifying Installation Areas For EMC Screws

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