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

Read contents of BODY, GENERAL .

Follow procedure for REPAIR STAGE 2 .

STRIP DOWN VEHICLE .

The following new parts are required:

1. Rear trim, inner
2. Rear trim, outer skin
Fig 1: Inner/Outer Rear Trim
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The following CONSUMABLES  are required:

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.

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: Outer Metal Panel Welded Connections Area

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

Open welded connections in areas (2).

Remove tail cowling section.

Fig 4: Severance Cut Marks And Welded Connections Areas

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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 Cuts

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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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Adjust new parts to fit and secure.

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

Fig 9: Rivet Areas

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

Fig 10: Rivet Areas

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View of vehicle underside:

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

Fig 11: Bore Holes Areas

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Remove new parts again and deburr bores.

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 tail cowling with punch rivets N4.

Fig 15: 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 16: EMC Screws Installation Areas

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

Fig 17: EMC Screws Installation Areas

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