41 12 535 Replacing Complete Rear Luggage Compartment Floor (Tail Panel Removed)

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Read contents of BODY, GENERAL .

Place vehicle on straightening bench.

NOTE: This repair instructions comprises the procedures for repair stages 2 and 3 See 410 REPAIR TECHNIQUES, REPAIR STAGE 2 or 410 REPAIR TECHNIQUES, REPAIR STAGE 3 .

(1) Crossmember, luggage compartment floor
(2) Mounting, impact absorber
(3) Mounting, RHT (hard top)
(4) Luggage compartment floor
(5) Side member, rear
(6) Luggage compartment well
(7) Mounting, tension strut

Following CONSUMABLES are required:

CONSUMABLES REFERENCE CHART

Material	Quantity
Adhesive K5a	1
Blind rivets N1	21
CleanerR1	1
Sealing compound D1

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View from vehicle underbody:

Open weld joints in areas (1).

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Courtesy of BMW OF NORTH AMERICA, INC.

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

Mark severance cut (1) in accordance with measurement and cut.

Measurement a = 20 mm from luggage compartment floor, front.

Mark severance cut (2) and cut.

Open weld joints in area (3).

Remove trunk floor.

Installation:

Adjust luggage compartment floor to fit with straightening attachment or universal mount.

Before welding in, also adjust tail panel, rear lid and rear lights to fit.

Tension strut mounting is bonded to luggage compartment well and riveted.

Weld in REINFORCING PANEL at severance cut (2).

Weld new components in area (4) additionally.

Mark new luggage compartment well part in accordance with severance cut (1) on vehicle + 20 mm extra material and cut.

New part preparation, tension strut mounting

View from below.

Adjust tension strut mounting (1) with mounted torsion struts (2) to fit and secure.

Set twenty one 4.2 mm _ holes for blind rivets in adhesive flange area.

Remove new part again and deburr holes.

NOTE: 6 holes are sufficient for positioning the component.
Make all further holes for blind rivets if necessary on removed components.

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

Installing tension strut mounting

Clean all bonding surfaces (1) with cleaning agent R1.

Apply adhesive K5a to bonding surfaces (1).

Rivet tension strut mounting (2) and luggage compartment well (3) with blind rivets N3.

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