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41 12 535 Stripping Operations - Replacing Luggage Compartment Floor And Both Side Members (Tail Panel Removed) (Hybrid)

WARNING: This page does not describe the selected car, but rather 50 other vehicles, including the 2016 BMW M5, 2016 BMW ActiveHybrid 5, 2016 BMW 550i xDrive, 2016 BMW 550i, and 2016 BMW 535i xDrive. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: High-voltage system - danger to life
Compliance with the following points is mandatory before beginning work:
NOTE: Owing to the different engine variants and equipment specifications, not all the components are taken into consideration.
The following list basically represents the removal sequence.
  • Remove Battery (61 21 010 )
  • Remove High-Voltage Battery Unit (61 25 010 )
  • Remove front and rear spare wheel well trim panel
  • Remove rear left floor panel
  • Remove left and right rear wheel arch covers (51 71 041 )
  • Remove exhaust system (18 00 020 )
  • Remove heat shield

Release wiring harness (1) and place to one side.

Disconnect plug connections for control units.

Remove holder (2) for control units.

Release latch mechanisms and remove rear ventilation (3).

Installation note: 

The rear ventilation must not be damaged. (watertightness).

All latch mechanisms must engage audibly.

Fig 1: Identifying Rear Ventilation, Holder, Plug Connections, Wiring Harness
G09916015Courtesy of BMW OF NORTH AMERICA, INC.

Undo wiring harness (1) from holder.

Undo screw connections (2) and raise holder with control unit (3).

Fig 2: Identifying Holder With Control Unit, Screw Connections, Wiring Harness
G09916016Courtesy of BMW OF NORTH AMERICA, INC.

Disconnect plug connections (1) on control unit (2).

Remove holder with control unit.

Fig 3: Identifying Holder And Plug Connections For Control Unit
G09916017Courtesy of BMW OF NORTH AMERICA, INC.

Undo cable channel (1) and wiring harness (2) and place to one side.

Undo plastic nut (3) and remove insulating mat (4).

Undo grommet (5) and feed wiring harness inwards.

NOTE: Wiring harness must be released beforehand at rear axle ride height sensor and wheel speed sensor (wheel arch plug connection).
Ensure correct installation of the grommet (5)! (watertightness).
Fig 4: Identifying Wiring Harness, Cable Channel, Grommet, Plastic Nut
G09916018Courtesy of BMW OF NORTH AMERICA, INC.

Remove POWER DISTRIBUTION BOX in passenger compartment (1).

Release wiring harness (2) and place to one side.

Remove CONTROL UNIT (3) for automatic tailgate activation.

Release latch mechanisms and remove rear ventilation (4).

Release rivet connections and remove luggage compartment (5).

Installation note: 

Fig 5: Identifying Wiring Harness, Control Unit, Rear Ventilation, Rivet Connections, Luggage Compartment
G09916019Courtesy of BMW OF NORTH AMERICA, INC.

Renew luggage compartment well (5).

Undo nut and place ground connection (1) to one side. Tightening torque 41 34 2AZ .

Undo screws and place relay (2) to one side.

Release wiring harness (3) and place to one side.

Release positive battery cables (4) and lay to one side.

Fig 6: Identifying Positive Battery Cables, Wiring Harness, Ground Connection
G09916020Courtesy of BMW OF NORTH AMERICA, INC.
Fig 7: Identifying Plug Connection, Upholstery, Cable Channel, Wiring Harness, Negative Terminal Battery Cable
G09916021Courtesy of BMW OF NORTH AMERICA, INC.

Release wiring harness (1) and place to one side.

Open cable channel (2). Remove wiring harness and place to one side. Remove cable channel.

Disconnect plug connection (3).

Remove upholstery (4).

Remove NEGATIVE TERMINAL BATTERY CABLE (5).

Release plastic nuts and place control unit (6) to one side.

Push wiring harness with grommet outwards.

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