41 12 557 Replacing Luggage Compartment Floor, Middle Section (Tail Panel Removed)

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Read contents of BODY, GENERAL .

Follow procedure for REPAIR STAGE 3 .

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

STRIP DOWN VEHICLE

The following new body parts are required:

(1) Luggage compartment floor, rear

Following CONSUMABLES are required:

Material	Quantity
Adhesive K5a	2
Blind rivets N3	25
Cleaning agent R1	1
Sealant D1

Fig 1: Identifying Rear Luggage Compartment Floor

Courtesy of BMW OF NORTH AMERICA, INC.

Removal of luggage compartment floor

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

IMPORTANT: Cut outer panel only.
Dimension "a" = 25 mm from component edge of luggage compartment floor, front.
Open welded connections in area (2).
Remove the luggage compartment floor.

NOTE: New part is installed with overlap in area of severance cut (1).

Fig 2: Identifying Welded Connections And Severance Cut Dimension

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.

Flatten stampings (1) on both sides.

Fig 3: Identifying Stampings

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Set down luggage compartment well and adjust in combination with cross member and tail panel to fit and secure.

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

Area	Number
1	8 of
2	5
3	4

Fig 4: Identifying Areas For Blind Rivet Bore Holes

Courtesy of BMW OF NORTH AMERICA, INC.

Remove new parts and deburr bore holes.

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

Installation of luggage compartment floor:

Clean all bonding surfaces with cleaning agent R1.

Apply adhesive to bonding surfaces.

Install new parts and rivet with blind rivets.

Graphic similar.

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 5: Identifying MAG-Welding Areas

Courtesy of BMW OF NORTH AMERICA, INC.