41 12 535 Replace Luggage Compartment Floor And Both Side Members (Tail Panel Trim Removed)

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Read contents of BODY, GENERAL .

STRIP DOWN VEHICLE

Place vehicle on straightening bench.

Observe procedure of REPAIR STAGE 3 .

Following new body parts are required (refer to OVERVIEW OF CONSUMABLES ):

(1) Wheel arch extension, rear left and right
(2) Luggage compartment floor, left and right
(3) Side member, bottom rear left and right

Fig 1: Identifying Wheel Arch Extension, Side Member, Bottom Rear Left And Right Luggage Compartment Floor
Courtesy of BMW OF NORTH AMERICA, INC.
(4) Fixture, impact absorber, left and right
(5) Side member, top left and right
(6) Battery tray

Following CONSUMABLES are required:

Material	Quantity
Adhesive K5a	2
Blind rivets N3	17
EMC screws	6
Cleaning agent R1	1
Sealant D1

Removal of complete rear luggage compartment floor:

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

Open welded connections in area (1).

Fig 2: Identifying Rear Luggage Compartment Floor Welded Connections Area

Courtesy of BMW OF NORTH AMERICA, INC.

Open welded connections in areas (1).

Fig 3: Identifying Rear Luggage Compartment Floor Welded Connections Area

Courtesy of BMW OF NORTH AMERICA, INC.

Open welded connections in area (1).

Remove the luggage compartment floor.

NOTE: Shown without side panel for purposes of clarity.

Fig 4: Identifying Luggage Compartment Floor Welded Connections Area

Courtesy of BMW OF NORTH AMERICA, INC.

View from below.

Open welded connections in the area (1) and remove battery tray (2).

Fig 5: Identifying Battery Tray Welded Connections Area

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Open welded connections in area (1).

Fig 6: Identifying Rear Luggage Compartment Floor Welded Connections Area (1 Of 2)

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Fig 7: Identifying Rear Luggage Compartment Floor Welded Connections Area (2 Of 2)

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

IMPORTANT: Cut outer panel only.

Dimension a = 30 mm from wheel arch component edge.

Open welded connections in areas (2).

Remove side member.

New part preparation

Mark severance cut on side member in accordance with severance cut on vehicle and cut.

Prepare REINFORCEMENT PLATE for severance cut.

Adjust new parts to fit with alignment bracket or universal mount and secure.

In areas (1) and (2) set 4.2 mm dia. holes for blind rivets.

Area	Number
1	5 of
2	7

Remove new parts and deburr bore holes.

Fig 8: Identifying Reinforcement Plate Welded Connections Areas

Courtesy of BMW OF NORTH AMERICA, INC.

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

Installing side member and luggage compartment floor, left and right:

Install new parts with alignment bracket or universal mount and weld analogue to series standard:

Extension, side member
Mounting, impact absorber
Luggage compartment floor
Wheel arch extension

Installing luggage compartment floor (battery tray):

Clean all bonding surfaces with cleaning agent R1.

Apply adhesive to bonding surfaces.

Install new part and rivet with blind rivets.

After hardening of the adhesive install 6 EMC SCREWS in the areas shown (1).

Fig 9: Identifying EMC Screws Adhesive Areas

Courtesy of BMW OF NORTH AMERICA, INC.