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

Observe procedure for repair stage 3. See 41 00 REPAIR TECHNIQUES, REPAIR STAGE 3 .

Read contents of 41 00... 0 CONTENTS OF BODY, GENERAL .

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

Strip down vehicle. See 41 12 535 STRIPPING OPERATIONS - REPLACING LUGGAGE COMPARTMENT FLOOR AND BOTH SIDE MEMBERS (TAIL PANEL REMOVED) .

Place vehicle on straightening bench.

Following new body parts are required (refer to 41 00... OVERVIEW OF CONSUMABLES ):

• (1) Wheel arch extension, left and right
• (2) Extension, side member, left and right
• (3) Fixture, bumper, left and right
• (4) Luggage compartment floor, rear

Following consumables are required:

Fig 1: Identifying Wheel Arch Extension, Side Member Extension And Rear Luggage Compartment Floor

Courtesy of BMW OF NORTH AMERICA, INC.

Removal of luggage compartment floor and both side members 

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

Fig 2: Identifying Luggage Compartment Floor Severance Cutting Dimension

Courtesy of BMW OF NORTH AMERICA, INC.

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

Open welded connections in area (1).

Fig 3: Identifying Welded Connections Area

Courtesy of BMW OF NORTH AMERICA, INC.

Shown without side wall for purposes of clarity.

Mark severance cut in accordance with dimension and cut side member.

Dimension a = approx. 80 mm from component edge side member.

Open welded connections in area (1).

Fig 4: Identifying Mark Severance Cut Dimension And Welded Connections Area

Courtesy of BMW OF NORTH AMERICA, INC.

Mark severance cut (1) as pictured and cut.

Open welded connections in areas (2).

Fig 5: Identifying Mark Severance Cut And Welded Connections Areas

Courtesy of BMW OF NORTH AMERICA, INC.

Open weld joints in areas (1) and remove cross-member section (2).

Fig 6: Identifying Cross-Member Section And Weld Joints Areas

Courtesy of BMW OF NORTH AMERICA, INC.

New part preparation 

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

Disconnect required components from the new component wheel arch extension.

Flatten stampings (1) on both sides.

Fig 7: Identifying Flatten Stampings On Both Sides

Courtesy of BMW OF NORTH AMERICA, INC.

Mark severance cut (1) in accordance with severance cut on vehicle and cut.

Detach welded connections and remove wheel arch section (2).

Prepare reinforcement plate for severance cuts. See 41 00... WELDING IN REINFORCEMENT PLATE (SHEET STEEL) .

Adjust new parts to fit with alignment bracket or universal mount and secure.

Fig 8: Identifying Mark Severance Cut And Wheel Arch Section

Courtesy of BMW OF NORTH AMERICA, INC.

Adjust luggage compartment well in combination with cross member and tail panel to fit and secure.

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

Fig 9: Identifying Blind Rivets Bore Holes Areas

Courtesy of BMW OF NORTH AMERICA, INC.

Remove new part and deburr holes.

Installing side members and luggage compartment floor 

Install new parts and reinforcement plates with alignment bracket or universal mount and weld analogue to series standard.

• Extension, side member
• Wheel arch extension
• Mounting, bumper

Installing luggage compartment floor, middle 

Clean all  bonding surfaces with cleaning agent R1.

Apply adhesive to bonding surfaces.

Install new part 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).

Fig 10: Identifying Luggage Compartment Floor MAG Welds Areas (Middle)

Courtesy of BMW OF NORTH AMERICA, INC.