41 12 557 Replacing Luggage Compartment Floor, Middle Section (Tail Panel Removed) (Hybrid)

WARNING: This page does not describe the selected car, but rather 50 other vehicles, including the 2016 BMW M5, 2016 BMW ActiveHybrid 5, 2016 BMW 550i xDrive, 2016 BMW 550i, and 2016 BMW 535i xDrive. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: High-voltage system - danger to life
Compliance with the following points is mandatory before beginning work:

DISCONNECT HIGH-VOLTAGE SYSTEM FROM POWER .
Observe SAFETY INFORMATION for handling electric vehicles.

Read contents of BODY, GENERAL .

Observe procedure for (REPAIR STAGE 3) !

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

STRIP DOWN VEHICLE

Following new body parts are required (refer to ELECTRONIC PARTS CATALOGUE ):

(1) Luggage compartment floor, rear

Following CONSUMABLES are required:

Material	Quantity
Adhesive K5a	2
Blind rivets N3	25
Cleaning agent R1	1
Sealant D1

Fig 1: Identifying Luggage Compartment Floor, Rear

Courtesy of BMW OF NORTH AMERICA, INC.

Removal of luggage compartment floor

Fig 2: Identifying Luggage Compartment Floor Severance Cutting Dimension

Courtesy of BMW OF NORTH AMERICA, INC.

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

IMPORTANT: Cut outer panel only.

Dimension a = 25 mm from component edge of luggage compartment floor, front.

Open welded connections in area (2).

Remove the luggage compartment floor.

NOTE: New part is installed with overlap in area of severance cut (1).

New part preparation

Mark new luggage compartment floor in accordance with severance cut on vehicle + 20 mm extra material and cut.

Flatten stampings (1) on both sides.

Fig 3: Identifying Flatten Stampings On Both Sides

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Set down luggage compartment well and adjust in combination with cross member and tail panel to fit and secure.

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

Area	Number
1	8 of
2	5
3	4

Fig 4: Identifying Bore Holes For Blind Rivets

Courtesy of BMW OF NORTH AMERICA, INC.

Remove new parts and deburr bore holes.

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

Installation of luggage compartment floor:

Clean all bonding surfaces with cleaning agent R1.

Apply adhesive to bonding surfaces.

Install new parts and rivet with blind rivets.

Graphic similar.

Perform MAG welding throughout to new part in area (1).

Set 20 mm MAG welds at a distance of 15 mm in area (2).

IMPORTANT: Risk of damage to adhesive area!
Avoid applying excessive heat to the neighboring adhesive areas!

Fig 5: Identifying Luggage Compartment Floor MAG Welds Areas (Middle)

Courtesy of BMW OF NORTH AMERICA, INC.