41 34 038 Replacing outer tail panel section: Notes

Read contents of BODY, GENERAL .

Follow procedure for REPAIR STAGE 2 .

STRIP DOWN VEHICLE .

The following new parts are required:

1. Tail cowling
Fig 1: Tail Cowling
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The following CONSUMABLES  are required:

Removal 

Operation described predominantly on the left side. Right side identical.

Mark severance cut (1) in accordance with specified measurements and cut.

Dimension "a" = approx. 15 mm from component edge, side panel.

Dimension "b" = approx. 20 mm from component edge, side panel.

Open welded connections in areas (2) and remove tail cowling.

Fig 2: Severance Cut Mark And Welded Connections

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New part preparation 

Cut and sever the severance cut (1) on the new part according to the severance cut on the vehicle + 15 mm added material.

(2) = Severance cut route on vehicle.

Fig 3: Severance Cuts

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Adjust tail cowling to fit and secure.

Drill bores 4.2 mm for blind rivet in areas (1) and (2).

Fig 4: Blind Rivet Areas

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Remove new part again and deburr bores.

Installation: 

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

Apply adhesive to bonding surfaces (1).

Install tail cowling and rivet with blind rivets.

Fig 5: Bonding Surfaces

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Rivet the tail cowling with punch rivets N4 in the areas (1) to (4).

Fig 6: Rivet Areas

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Mount support for bumper cover to secure tail cowling.

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

Fig 7: EMC Screws Installation Areas

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