41 12 560 Luggage Compartment Floor Replacement (Complete With Inner Wheel Arch Section, Tail Panel Removed)

WARNING: This page does not describe the selected car, but rather 12 other vehicles, including the 2008 BMW 335xi, 2008 BMW 335i, 2008 BMW 328xi, 2008 BMW 328i, and 2007 BMW 335xi. However, it is still accessible from the selected car via links, so may be relevant.

Read contents of Body, General.

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

Spot-weld bonding is used on this vehicle. Observe specific Procedure.

Use only approved Spot-Welding Apparatus for repairs!

Place vehicle on straightening bench.

Following new body parts are required:

(1) Luggage compartment floor, upper section
(2) Rear axle carrier
(3) Wheel arch, rear, inner half, left
(4) Wheel arch, rear, inner half, right
Touring only:
(5) Bracket, tension strut, rear (2 x) (not shown)

Fig 1: Identifying New Body Parts For Luggage Compartment Floor
Courtesy of BMW OF NORTH AMERICA, INC.

Carry over the work step shown symmetrically to the other side of the vehicle.

Mark severance cut in accordance with measurement a and cut.

Measurement a=40 mm behind support, frame side member (1).

Installation:

Weld in Reinforcement Plates at severance cuts.

Fig 2: Identifying Frame Side Member Support Measurement

Courtesy of BMW OF NORTH AMERICA, INC.

Carry over the work step shown symmetrically to the other side of the vehicle.

Mark severance cut (1) and cut.

Open weld joints in areas (2).

Installation:

Weld new components in areas (3) additionally.

Fig 3: Identifying Severance Cut Mark, Weld Joint Area And New Component Area

Courtesy of BMW OF NORTH AMERICA, INC.

Carry over the work step shown symmetrically to the other side of the vehicle.

Mark severance cut (1) in accordance with measurement a and cut rear axle carrier.

IMPORTANT: Cut outer metal sheet only.

Measurement a=70 mm from rear axle bushing mounting.

Open weld joints in area (2).

Installation:

Weld in Reinforcement Plates at severance cuts.

Fig 4: Identifying Severance Cut Mark And Weld Joint Area

Courtesy of BMW OF NORTH AMERICA, INC.

Carry over the work step shown symmetrically to the other side of the vehicle.

Open weld joints in areas (1).

Fig 5: Identifying Weld Joints Areas

Courtesy of BMW OF NORTH AMERICA, INC.

Saloon and Coupe only:

Carry over the work step shown symmetrically to the other side of the vehicle.

Open weld joints in area (1).

Installation:

Weld new components in areas (2) additionally.

Fig 6: Identifying Saloon And Coupe Weld Joint And New Components Areas

Courtesy of BMW OF NORTH AMERICA, INC.

Touring only:

Carry over the work step shown symmetrically to the other side of the vehicle.

Open weld joints in area (1).

Installation:

Weld new components in areas (2) additionally.

Fig 7: Identifying Touring Weld Joint And Components Areas

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: Rear parcel shelf of Saloon and Coupe is shown removed for purposes of clarity.

Carry over the work step shown symmetrically to the other side of the vehicle.

Open weld joints in areas (1) and (2).

Fig 8: Identifying Open Weld Joints Areas

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: Rear parcel shelf of Saloon and Coupe is shown removed for purposes of clarity.

Carry over the work step shown symmetrically to the other side of the vehicle.

Open weld joints in area (1).

Installation:

Weld new component in areas (2) additionally.

Fig 9: Identifying Weld Joint And New Component Areas

Courtesy of BMW OF NORTH AMERICA, INC.

Open weld joints in area (1).

Fig 10: Identifying Weld Joints Area

Courtesy of BMW OF NORTH AMERICA, INC.

Preparation of new part:

Carry over the work step shown symmetrically to the other side of the vehicle.

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

IMPORTANT: Cut outer metal sheet only.

Measurement a=170 mm

Measurement b = 110 mm

Fig 11: Identifying Mark Severance Cuts

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

The parts separated by cutting are still needed.

Weld in Reinforcement Plates at severance cuts.

Preparation of new part:

Carry over the work step shown symmetrically to the other side of the vehicle.

Open weld joints in areas (2).

Installation:

The parts separated by cutting are still needed.

Fig 12: Identifying New Part Weld Joints Areas (1 Of 5)

Courtesy of BMW OF NORTH AMERICA, INC.

Preparation of new part:

Open weld joints in areas (1).

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

IMPORTANT: Cut outer metal sheet only.

Fig 13: Identifying New Part Weld Joints Areas And Severance Cut Marks (2 Of 5)

Courtesy of BMW OF NORTH AMERICA, INC.

Preparation of new part:

Carry over the work step shown symmetrically to the other side of the vehicle.

Open weld joints in areas (1).

Fig 14: Identifying New Part Weld Joints Areas (3 Of 5)

Courtesy of BMW OF NORTH AMERICA, INC.

Preparation of new part:

Open weld joints in areas (1).

Installation:

The parts (2) separated by cutting are still needed.

Fig 15: Identifying New Parts And Weld Joints Areas (4 Of 5)

Courtesy of BMW OF NORTH AMERICA, INC.

Preparation of new part:

Open weld joints in area (1).

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

Fig 16: Identifying Weld Joints Areas And Severance Cut Marks (5 Of 5)

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

Adjust new parts to fit with straightening attachment or universal mount.

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

Weld new components in following order:

(1) Rear axle carrier
(2) Luggage compartment floor, upper section
(3) Support, frame side member
(4) Wheel arch, rear, inner half

Fig 17: Identifying Rear Axle Carrier Components
Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: Rear parcel shelf of Saloon and Coupe is shown removed for purposes of clarity.

Installation:

For reasons of accessibility, the repair joining sequence differs from the standard joining sequence.

Fit new component from above in area (1), adjust to fit and weld.

Fig 18: Identifying New Component Area

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

Touring only:

Adjust new parts (1) to fit with tension strut and weld.

Fig 19: Identifying Touring New Part

Courtesy of BMW OF NORTH AMERICA, INC.