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

WARNING: This page is about a different car, the 2011 BMW X6 and 2010 BMW X6. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: High-voltage system - danger to life!

WARNING: The following points must be strictly observed prior to starting work :

Disconnect HIGH-VOLTAGE SYSTEM FROM POWER
Observe SAFETY INFORMATION for handling with hybrid cars

Read contents of BODY .

STRIP DOWN VEHICLE

Place vehicle on straightening bench.

Observe (REPAIR STAGE 3) procedure!

Following new body parts are required (see BMW Electronic Parts Catalogue):

(1) Wheel arch, rear left and right
(2) Side member, rear left and right
(3) Side member, top left and right
(4) Luggage compartment floor

Following CONSUMABLES are required:

Fig 1: Identifying Wheel Arch, Rear Left And Right Side Member, Side Member Top Left And Right And Luggage Compartment Floor

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Material	Quantity
Adhesive K5b	1
Blind rivets N3	57
EMC screws	13
Cleaning agent R1	1
Sealant D1

Removing luggage compartment floor:

Most of operation is described on the left side. Right side identical.

Open welded connections in area (1).

Fig 2: Identifying Welded Connections Area

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Open welded connections in area (1).

NOTE: Side wall hidden for purposes of clarity.

Fig 3: Identifying Welded Connections Area

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Open welded connections in area (1).

Remove middle lashing rail mounting (2).

Fig 4: Identifying Welded Connections Area And Middle Lashing Rail Mounting

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View from below:

Open welded connections in area (1).

Fig 5: Identifying Welded Connections Area

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Mark severance cut (1) in accordance with dimension a and cut.

Dimension a = 10 mm

Open welded connections in area (2).

Fig 6: Identifying Severance Cut And Welded Connections Area

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Mark severance cut (1) in accordance with previous severance cut and cut.

Fig 7: Identifying Severance Cut

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Preparation of new part:

Mark side member new parts in accordance with severance cuts on vehicle and cut.

Adjust side member new parts to fit with alignment bracket or universal mount and with tail panel.

Prepare REINFORCEMENT PLATES at severance cuts on side members.

Most of operation is described on the left side. Right side identical.

Position and secure luggage compartment floor middle section from below.

In areas (1) to (3), set 4.2 mm dia. bore holes for blind rivets.

Area	Number
1	9
2	6
3	6

Adjust luggage compartment floor to fit and secure.

In areas (1) to (3), set 4.2 mm dia. bore holes for BLIND RIVETS N3 :

Fig 8: Identifying Blind Rivets Areas

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Area	Number
1	1
2	1
3	3

Fig 9: Identifying Bore Holes For Blind Rivets N3

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In areas (1) to (3), set 4.2 mm dia. bore holes for blind rivets N3:

Area	Number
1	4
2	4
3	1

Fig 10: Identifying Bore Holes For Blind Rivets N3

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Set four 4.2 mm dia. bore holes for blind rivets N3 in area (1).

Remove new parts again and deburr holes.

NOTE: Side wall hidden for purposes of clarity.

Fig 11: Identifying Blind Rivets N3 Area

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

Installing side members:

Weld in reinforcement plates on side member new parts.

Installing luggage compartment floor:

Clean all bonding surfaces on new part and on vehicle with cleaning agent R1 .

Apply adhesive on all bonding and riveting surfaces.

When installing the new parts, make sure that all bonding surfaces have sufficient adhesive.

Install new parts and rivet with blind rivets.

After hardening of adhesive install 2 EMC SCREWS in areas (1) and (2).

Fig 12: Identifying EMC Screws Areas

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Fit an EMC screw after adhesive has hardened in area (1).

NOTE: Side wall hidden for purposes of clarity.

Fig 13: Identifying Adhesive Hardened Area

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After hardening of adhesive install 7 EMC screws in areas (1) and (2).

Install EMC screws in area (1) from inside luggage compartment.

Fig 14: Identifying Luggage Compartment EMC Screws Area

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