41 12 557 Replacing Middle Luggage Compartment Floor (Tail Panel Has Been Removed)

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Observe procedures for REPAIR STAGE 3 .

Read relevant service information under BODY, GENERAL .

STRIP DOWN VEHICLE

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

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

The following new body parts are required:

(1) Luggage compartment floor, rear
(2) Reinforcement, side member

The following CONSUMABLES are required:

Material	Quantity
Adhesive K5b	1
Blind rivets N3	40
Cleaning agent R1	1
Sealant D1

Fig 1: Identifying Rear Luggage Compartment Floor And Side Member Reinforcement

Courtesy of BMW OF NORTH AMERICA, INC.

Removal:

View from below.

Open welded connections in area (1).

Fig 2: Identifying Middle Luggage Compartment Floor Welded Connections Area

Courtesy of BMW OF NORTH AMERICA, INC.

Mark severance cut (1) approx. 6 mm from edge of component of front luggage compartment floor and disconnect.

IMPORTANT: Cut outer metal panel only.

Open welded connections in area (2).

Remove the luggage compartment floor.

Installation note:

Luggage compartment floor is installed with overlap in area of severance cut (1).

Fig 3: Identifying Middle Luggage Compartment Floor Severance Cut And Welded Connections Area

Courtesy of BMW OF NORTH AMERICA, INC.

New part preparation

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

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

Area	Number
1	5 of
2	8

Fig 4: Identifying Middle Luggage Compartment Floor Blind Rivets Holes Area

Courtesy of BMW OF NORTH AMERICA, INC.

Adjust side member to fit and secure.

In areas (1) to (4), set 4.2 mm dia. holes for blind rivets.

Area	Number
1	1
2	4
3	4
4	2

Fig 5: Identifying Middle Luggage Compartment Floor Blind Rivets Holes Area And MAG Welding Area

Courtesy of BMW OF NORTH AMERICA, INC.

In area (5) prepare new parts for MAG welding.

Remove new parts and deburr bore holes.

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

Installation:

Clean all bonding surfaces with cleaning agent R1.

Apply adhesive to bonding surfaces.

Install new parts and rivet with blind rivets.

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 6: Identifying Middle Luggage Compartment Floor MAG Welding Areas

Courtesy of BMW OF NORTH AMERICA, INC.

Weld new parts in area (5).

(1) to (4) = Adhesive riveted areas.

Fig 7: Identifying Middle Luggage Compartment Floor Adhesive Riveted Areas And Weld Area

Courtesy of BMW OF NORTH AMERICA, INC.