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

WARNING: This page is about a different car, the 2011 BMW M3, 2010 BMW M3, 2009 BMW M3, and 2008 BMW M3. However, it is still accessible from the selected car via links, so may be relevant.

Read general 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.

Use only approved SPOT-WELDING APPARATUS for repairs.

Place vehicle on straightening bench.

Follow procedure for REPAIR STAGE 3 .

Following new body parts are required:

(1) Luggage compartment floor, left section
(2) Frame side member, left
(3) Frame side member, top left
(4) Frame, luggage compartment floor
(5) Frame side member, top right
(6) Frame side member, right
(7) Luggage compartment floor, right
(8) Mounting for left and right bumper

Fig 1: Identifying Frame Side Member And Luggage Compartment Floor

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Following CONSUMPTION MATERIALS are required:

CONSUMABLES REFERENCE CHART

Material	Quantity
Adhesive K5b	1
R1 cleaning agent	1
Blind rivets N3	14
Punch rivets N5	8
EMC screws	2
Sealant D1
Cavity wax remover

Removing luggage compartment floor:

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

Mark severance cuts (1) at edge of 20 mm diameter bore hole.

Cut frame side member (2).

Fig 2: Identifying Reinforcement Plate Severance Cuts

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Mark severance cuts (1) and cut.

IMPORTANT: Cut only outer panels.

Open welded connections in areas (2) and remove luggage compartment floor (3).

Fig 3: Identifying Luggage Compartment Floor Severance Cuts And Welding Areas

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Saloon and Coupe only:

Open welded connections in area (1).

Fig 4: Identifying Adhesive Applying Areas (Saloon And Coupe Only)

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Touring only:

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

Fig 5: Identifying Adhesive Applying Areas (Touring Only)

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Open welded connections in area (1).

Installation note:

Adjust new parts to fit with alignment bracket or universal mounting.

Before welding in side member, also adjust tail panel, tailgate and rear lights to fit.

Fig 6: Identifying Adhesive Applying Areas

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Weld in REINFORCEMENT PLATES at severance cuts.

Cut side member (2).

Fig 7: Identifying Reinforcement Plate Severance Cuts

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Preparation of new part

Mark new luggage compartment floor part in accordance with severance cut on vehicle + 20 mm extra material and cut.

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

Adjust new parts in combination with tail panel to fit and secure.

Saloon and Coupe only:

In area (1) set seven 4.2 mm diameter bore holes for blind rivets.

Remove new parts and deburr bore holes.

Fig 8: Identifying Adhesive Applying Areas (Saloon And Coupe Only)

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Touring only:

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

Remove new parts and deburr bore holes.

Fig 9: Identifying Adhesive Applying Areas (Touring Only)

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Installation of luggage compartment floor

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

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

Clean bonding surfaces with cleaning agent R1.

Apply adhesive K5b.

Installing luggage compartment floor:

Replace along similar lines to LUGGAGE COMPARTMENT FLOOR, CENTRE .

Fig 10: Identifying Luggage Compartment Floor Severance Cuts And Welding Areas

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Apply adhesive K5b in areas (1) and (2).

Fig 11: Identifying Adhesive Applying Areas

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Saloon and Coupe only:

In area (1) apply adhesive K5b and set 7 blind rivets N3.

Fig 12: Identifying Adhesive Applying Areas (Saloon And Coupe Only)

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Touring only:

In areas (1) and (2) apply adhesive K5b and set 6 blind rivets N3.

Fig 13: Identifying Adhesive Applying Areas (Touring Only)

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In areas (1) and (2) secure luggage compartment floor to side member.

Fig 14: Identifying Adhesive Applying Areas

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