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

Read contents of BODY, GENERAL .

These repair instructions comprise the procedures for REPAIR STAGE 3 .

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

STRIP DOWN VEHICLE 

Place vehicle on straightening bench.

The following new body parts are required:

• (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
  Fig 1: Identifying New Body Parts Required

  Courtesy of BMW OF NORTH AMERICA, INC.

Following CONSUMABLES  are required:

Removal of luggage compartment floor and both side members 

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

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

Fig 2: Identifying Welded Connections And Severance Cut Dimension

Courtesy of BMW OF NORTH AMERICA, INC.

Open welded connections in area (1).

Fig 3: Identifying Welded Connections

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 Welded Connections And Severance Cut Dimension

Courtesy of BMW OF NORTH AMERICA, INC.

Mark severance cut (1) as pictured and cut.

Open welded connections in areas (2).

Fig 5: Identifying Severance Cut Line And Welded Connections

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

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 Stampings

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 cut.

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

Fig 8: Identifying Wheel Arch Section And Severance Cut Line

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 Areas For Blind Rivet Bore Holes

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 MAG-Welding Areas

Courtesy of BMW OF NORTH AMERICA, INC.