41 12 535 Replacing luggage compartment floor and both side members (tail panel removed)

Read contents of SAFETY INFORMATION and BODY, GENERAL .

Strip down vehicle. See STRIPPING OPERATIONS or STRIPPING OPERATIONS (ALL-WHEEL DRIVE VEHICLE) .

Spot-weld bonding is used on this vehicle.

Observe specific procedure: See SPOT-WELD BONDING STEEL COMPONENTS or OPENING BONDED CONNECTIONS .

Place vehicle on straightening bench.

Observe procedure for (REPAIR STAGE 3) .

Following new body parts are required:

(1) Luggage compartment floor, rear
(2) Side member, rear left and right
(3) Rear wheel arch, inner half, left and right

Following CONSUMABLE are required:

Fig 1: Identifying Rear Luggage Compartment Floor

Courtesy of BMW OF NORTH AMERICA, INC.

Material	Quantity
Adhesive K5a	2
Blind rivets N6	16
EMC screws	4
Cleaning agent R1	1
Sealant D1

Removal of luggage compartment floor and both side members

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

View from below.

Open spot-welded adhesive joints in area (1)

Remove the luggage compartment floor.

Fig 2: Identifying Luggage Compartment Floor Holes Boring Area

Courtesy of BMW OF NORTH AMERICA, INC.

Mark severance cut (1) as pictured and cut.

IMPORTANT: Cut outer panel only.

Fig 3: Identifying Severance Cut On Outer Panel

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Open welded connections in areas (1).

Open spot-welded adhesive joints in area (2)

Installation note:

Weld new components in area (3) additionally.

Fig 4: Identifying Side Members Welded Connection Areas

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Open welded connections in areas (1) and (2).

Remove side member and wheel arch.

Fig 5: Identifying Side Member And Wheel Arch Welded Connection Areas

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New part preparation

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

IMPORTANT: Cut outer panel only.

Open welded connections in areas (2).

Fig 6: Identifying Severance Cut On Outer Panel

Courtesy of BMW OF NORTH AMERICA, INC.

Open welded connections in areas (1).

Remove components not needed.

Fig 7: Identifying Outer Panel Welded Connection Areas

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Open welded connections in area (1).

Remove components not needed.

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

Fig 8: Identifying Alignment Bracket Welded Connection Area

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Fit luggage compartment floor from underneath and adjust in conjunction with tail panel and secure.

Set 16 4.2 mm dia. bore holes for blind rivets in area (1).

Remove new part and deburr holes.

Fig 9: Identifying Luggage Compartment Floor Holes Boring Area

Courtesy of BMW OF NORTH AMERICA, INC.

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

Installation of side members, inner wheel arch halves

Install new parts with alignment bracket or universal mount and weld.

Installation of luggage compartment floor:

Clean all bonding surfaces with CLEANING AGENT R1 .

Apply adhesive to bonding surfaces.

Install new part and rivet with blind rivets

After hardening of the adhesive, install 4 EMC SCREWS in the areas (1).

Fig 10: Identifying Luggage Compartment Floor Screws Installation Areas

Courtesy of BMW OF NORTH AMERICA, INC.