41 12 560 Replacing Luggage Compartment Floor (Complete With Both Inner Wheel Arch Sections, Tail Panel Removed)

Read contents of BODY, GENERAL .

Remove or cover those vehicle components in the repair area which are susceptible to heat or dust.

Use only approved SPOT-WELDING APPARATUS  for repairs.

Place vehicle on straightening bench.

Following new body parts are required (see CONSUMABLES ):

• (1) Upper part of the luggage compartment floor
• (2) Rear axle support
• (3) Wheel arch, rear, inner half, left
• (4) Wheel arch, rear, right inner half

  Courtesy of BMW OF NORTH AMERICA, INC.

Removal of luggage compartment floor 

Carry over the work steps shown symmetrically to the other side of the car.

Mark severance cut in accordance with Dimension a and cut.

Dimension a = 40 mm behind side member support (1).

Courtesy of BMW OF NORTH AMERICA, INC.

Mark severance cut (1) and cut.

Open welded connections in areas (2).

Installation note: 

Weld new components in areas (3) additionally.

Courtesy of BMW OF NORTH AMERICA, INC.

Mark severance cut (1) in accordance with dimension a and disconnect rear axle support.

Dimension a = 70 mm from the rear axle bushing fixture.

Open welded connections in area (2).

Courtesy of BMW OF NORTH AMERICA, INC.

Open welded connections in area (1).

Installation note: 

Weld new components in area (2) additionally.

Courtesy of BMW OF NORTH AMERICA, INC.

Coupe only: 

Open welded connections in area (1).

Installation note: 

Weld new components in area (2) additionally.

Courtesy of BMW OF NORTH AMERICA, INC.

Open welded connections in areas (1) and (2).

Courtesy of BMW OF NORTH AMERICA, INC.

Open welded connections in area (1).

Installation note: 

Additionally weld new part in this area (2).

Courtesy of BMW OF NORTH AMERICA, INC.

Open welded connections in area (1).

Remove trunk floor.

Courtesy of BMW OF NORTH AMERICA, INC.

New part preparation 

Mark severance cuts on new parts according to severance cuts on vehicle and sever.

Prepare REINFORCEMENT PLATES  at severance cuts.

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

Dimension a=170 mm

Measurement b = 110 mm

Installation note: 

The disconnected parts will still be required.

Courtesy of BMW OF NORTH AMERICA, INC.

Open welded connections in area (2).

Installation note: 

The disconnected parts will still be required.

Courtesy of BMW OF NORTH AMERICA, INC.

Open welded connections in areas (1).

Mark severance cut (2) in accordance with vehicle and cut.

Courtesy of BMW OF NORTH AMERICA, INC.

Open welded connections in areas (1).

Installation note: 

The disconnected parts (2) will still be required.

Courtesy of BMW OF NORTH AMERICA, INC.

Open welded connections in area (1).

Mark severance cuts (2) in accordance with severance cuts on vehicle and disconnect.

Insert new parts using an alignment bracket or a universal mount and fit as a combination of tail panel, tailgate and rear lights.

Courtesy of BMW OF NORTH AMERICA, INC.

Installation of luggage compartment floor 

Install new parts and reinforcement plates with alignment bracket or universal mount and weld.

Weld new parts in the following sequence:

• (1) Rear axle support
• (2) Upper part of the luggage compartment floor
• (3) Support, frame side member
• (4) Wheel arch, rear, inner half

  Courtesy of BMW OF NORTH AMERICA, INC.

For reasons of accessibility, the sequence to fit the components during repair work differs from that during series production.

In this area (1) insert new part from top, adjust and weld.

Courtesy of BMW OF NORTH AMERICA, INC.