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

WARNING: This page is about a different car, the 2010 BMW M5, 2009 BMW M5, 2008 BMW M5, 2007 BMW M5, and 2006 BMW M5. However, it is still accessible from the selected car via links, so may be relevant.

Read contents of BODY, GENERAL and observe relevant procedures.

STRIP DOWN vehicle.

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.

Observe REPAIR STAGE 3 .

Following new body parts are required:

Luggage compartment floor
Support, luggage compartment floor, left
Support, luggage compartment floor, right

Fig 1: Identifying Luggage Compartment Floor And Supports

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Removal of luggage compartment floor:

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

NOTE: There is a visible warping of the material in areas (1). This is created during production and is not evidence of any damage.

Fig 2: Identifying Material Warping Area

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View from vehicle underbody:

Open weld joints in areas (1).

Fig 3: Identifying Locating Welded Joint Areas

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Open weld joints in areas (1).

Open adhesive bond in area (2).

Fig 4: Identifying Welded Area And Bonded Areas

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Mark severance cut in accordance with measurement a and cut frame side member on left and right.

Measurement a=150 mm from center point of bore with dia. 20 mm.

Installation note:

Weld in REINFORCING PANEL at all severance cuts.

Fig 5: Identifying Severance Cut Measurement

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Open weld joints in areas (1) and (2) on both sides of vehicle.

IMPORTANT: Do not shorten height of bushing in area (2).
Grind bushing down to nominal diameter only.

Fig 6: Open Weld Joints In Areas (1) And (2) On Both Sides Of Vehicle

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Open weld joints in areas (1).

Cut luggage compartment floor in area (2) next to spot flange.

Fig 7: Identifying Luggage Compartment Floor Cutting Area And Welded Connection Areas

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Open ADHESIVE CONNECTION on both sides of vehicle in area (1).

Installation:

Spot-weld in areas (1).

Fig 8: Spot-Weld In Areas (1)

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Installation note:

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.

Fit new part in area (1) from above.

Plug weld in area (1).

Fig 9: Plug Weld In Area (1)

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New part preparation:

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

Adjust new parts in conjunction with tail panel, tailgate and rear lights to fit and secure.

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

Area (1) 6 holes.

Area (2) 2 holes.

Fig 10: Identifying Weld Joints Areas

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

Clean bonding surfaces with cleaning agent R1.

Installation note:

Apply adhesive K5a in area (1).

Fig 11: Identifying Spot-Weld Areas

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Installation of luggage compartment floor:

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

Weld in luggage compartment floor.

In areas (1) and (2) apply adhesive K5a and rivet support on left and right.

Fig 12: Identifying Weld Joints Areas

Courtesy of BMW OF NORTH AMERICA, INC.

After adhesive has hardened, fit 2 EMC SCREWS in area of ground support points.