41 34 060 Replacing tail panel outer section and inner section: Notes

Read contents of BODY, GENERAL .

Observe procedure for REPAIR STAGE 2 .

STRIP DOWN  vehicle.

The following new parts are required:

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

The following CONSUMABLES  are required:

Fig 1: Inner/Outer Rear Trim

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Removal: 

Operation is described mainly for the left side; work is identical on the right side.

Mark severance cuts (1) and (2) and cut according to schematic diagram.

Attention!

Cut outer metal panel only.

Open WELDED CONNECTIONS  in area (3).

Fig 2: Severance Cut Marks And Welded Connections Area

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View of passenger compartment.

Mark severance cuts (1) and (2) and cut according to schematic diagram.

Fig 3: Severance Cut Marks

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Mark severance cuts (1) in accordance with schematic diagram and cut.

Open WELDED CONNECTIONS  in areas (2).

Fig 4: Severance Cut Marks And Welded Connections Areas

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Remove rear trim panel section.

Release WELDED CONNECTIONS  in area (1) and remove section (2).

Fig 5: Welded Connections Area

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Release WELDED CONNECTIONS  in area (1) and remove section.

Fig 6: Welded Connections Area

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Preparation of new part: 

Operation is described mainly for the left side; work is identical on the right side.

Mark severance cut (1) according to severance cut on vehicle + 15 mm extra material and cut.

(2) = Severance cut route on vehicle.

Fig 7: Severance Cut Route On Vehicle

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Area (1), disengage 15 x 25 mm.

Changed joining sequence: New part is joined beneath area (1) from outside with overlap.

Smooth down the separation edge if applicable. Adapt new part in transitional area (overlap).

Fig 8: New Part Joining Area

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In areas (1) to (4), drill 4.2 mm bore holes for blind rivets.

Fig 9: Rivet Areas

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In areas (1) to (3), set bore holes 4.2 mm for blind rivet.

Fig 10: Rivet Areas

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View of vehicle underside:

Set 3 bore holes 4.2 mm for the blind rivet in the areas (1).

Remove new parts again and deburr bore holes.

Fig 11: Bore Holes Areas

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Attention  !

Do not grind new parts and body in area of bonding surfaces.

Installation: 

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

Apply adhesive to bonding surfaces.

When installing the new parts, make sure that there is sufficient adhesive on bonding surfaces.

Install the new parts and rivet with the blind rivet N3 in areas (1) to (4).

Fig 12: Rivet Areas

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Rivet the new parts with the blind rivet in areas (1) to (3).

Fig 13: Rivet Areas

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Rivet the new parts with the blind rivet N3 in the areas (1).

Fig 14: Bore Holes Areas

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In areas (1) to (3) rivet rear trim panel with punch rivets N4.

Fig 15: Rear Trim Panel With Punch Rivets N4 Areas

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Mount support for bumper panel to secure rear trim panel.

Attention  !

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

Remove emerging adhesive.

Do not use any cleaning agents containing solvents.

After hardening of the adhesive install 7 EMC SCREWS  in the areas shown.

Fig 16: EMC Screws Installation Areas

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After hardening of the adhesive install 3 EMC screws in areas (1).

Fig 17: EMC Screws Installation Areas

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