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

WARNING: This page does not describe the selected car, but rather 18 other vehicles, including the 2015 BMW Alpina B7L xDrive, 2015 BMW Alpina B7 xDrive, 2015 BMW 750i xDrive, 2015 BMW 750Li xDrive, and 2015 BMW 740Li xDrive. However, it is still accessible from the selected car via links, so may be relevant.

Read contents of BODY, GENERAL .

Observe procedures for REPAIR STAGE 3 .

STRIP DOWN VEHICLE

Use only approved SPOT-WELDING APPARATUS for repairs.

Place vehicle on straightening bench.

The following new body parts are required :

(1) Luggage compartment floor, rear
(2) Side member, left and right
(3) Extension, side member, left and right
(4) Luggage compartment floor, left and right
(5) Fixture, bumper, left and right

Fig 1: Identifying Luggage Compartment Floor, Side Member, Extension And Bumper Fixture

Courtesy of BMW OF NORTH AMERICA, INC.

Following CONSUMABLES are required:

Material	Quantity
Adhesive K5a	1
Adhesive K5b	1
Blind rivets N3	78
EMC screws	8
Cleaning agent R1	1
Sealant D1

Removing side members and luggage compartment floor

Operation is partially described on the left side.

Right side identical.

Open welded connections in area (1).

Fig 2: Identifying Welded Connections Area

Courtesy of BMW OF NORTH AMERICA, INC.

Open welded connections in area (1).

Fig 3: Identifying Welded Connections Area

Courtesy of BMW OF NORTH AMERICA, INC.

Roughly mark severance cut (1) and cut.

Open welded connections in area (2).

Remove luggage compartment floor (3).

Fig 4: Identifying Luggage Compartment Floor, Severance Cut Mark And Welded Connections Area

Courtesy of BMW OF NORTH AMERICA, INC.

View from below.

Open welded connections in area (1).

Fig 5: Identifying Welded Connections Area

Courtesy of BMW OF NORTH AMERICA, INC.

Fig 6: Identifying Outer Metal Panel Severance Cut Mark And Welded Connections Area

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT: Cut outer metal panel only.
Mark severance cut (1) approx. 6 mm from edge of component of front luggage compartment floor and disconnect.
Open welded connections in area (2).
Remove trunk floor.

Installation note:

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

Mark severance cut (1) flush with side member and cut.

After cutting side member extension (2), open weld joints in area (3).

Fig 7: Identifying Side Member Extension, Severance Cut Mark And Welded Joints Area

Courtesy of BMW OF NORTH AMERICA, INC.

Mark severance cut (1) flush with side member and cut.

Remove side member extension (2).

Open welded connections in area (3).

Fig 8: Identifying Side Member Extension, Severance Cut Mark And Welded Connection Area

Courtesy of BMW OF NORTH AMERICA, INC.

New part preparation

Operation is partially described on the left side.

Right side identical.

Open welded connections in area (1).

Fig 9: Identifying Welded Connections Area

Courtesy of BMW OF NORTH AMERICA, INC.

Open welded connections in area (1).

Remove metal section (2).

Fig 10: Identifying Metal Section And Welded Connections Area

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: To adjust new parts to fit, bend side member end plate (1) outwards slightly.

Adjust new parts, side members to fit with alignment bracket or universal mount.

Fig 11: Bending Side Member End Plate

Courtesy of BMW OF NORTH AMERICA, INC.

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 12: Identifying Blind Rivets Hole Areas

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 13: Identifying Blind Rivet Areas

Courtesy of BMW OF NORTH AMERICA, INC.

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

Adjust boot floor laterally (1) to fit and secure.

Set 5 4.2 mm dia. bore holes in area (2).

Fig 14: Identifying Boot Floor And Bore Hole Area

Courtesy of BMW OF NORTH AMERICA, INC.

Set 3 4.2 mm dia. bore holes in area (1).

Fig 15: Identifying Welded Connections Area

Courtesy of BMW OF NORTH AMERICA, INC.

Set 11 4.2 mm dia. bore holes in area (1).

Remove new parts and deburr bore holes.

Fig 16: Identifying Welded Connections Area

Courtesy of BMW OF NORTH AMERICA, INC.

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

Installation of side member

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

Extension, side member
Extension, end plate side member
Mounting, bumper

Weld extension for end plate side member (2) in areas (3) and (4) the same as series.

Fig 17: Identifying Side Member Extension, Severance Cut Mark And Welded Joints Area

Courtesy of BMW OF NORTH AMERICA, INC.

Weld extension for side member (2) in areas (3) and (4) the same as series.

Fig 18: Identifying Side Member Extension, Severance Cut Mark And Welded Connection Area

Courtesy of BMW OF NORTH AMERICA, INC.

Installing luggage compartment floor, center, left and right

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 19: Identifying MAG Welding Application Areas

Courtesy of BMW OF NORTH AMERICA, INC.

Weld new parts in area (5).

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

Fig 20: Identifying Blind Rivet Areas

Courtesy of BMW OF NORTH AMERICA, INC.

After hardening of the adhesive install 4 EMC SCREWS in the areas (1).

Fig 21: Identifying Adhesive Applying Areas On EMC Screws

Courtesy of BMW OF NORTH AMERICA, INC.