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

Read contents of BODY, GENERAL .

Observe procedure of REPAIR STAGE 3 .

STRIP DOWN VEHICLE 

Use only approved SPOT-WELDING APPARATUS  for repairs.

Place vehicle on straightening bench.

Following new body parts are required (refer to BMW ELECTRONIC PARTS CATALOGUE ):

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

Following CONSUMABLES  are required:

Fig 1: Identifying Luggage Compartment Floor, Fixture, Extension And Reinforcement

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Removal of luggage compartment floor and both side members 

Operations described predominantly on the left side. Right side identical.

Mark severance cut (1) at component edge and cut.

Open welded connections in area (2).

Installation note: 

New part is welded overlapping in area of severance cut.

Fig 2: Identifying Severance Cut And Welded Connections Area

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Right side:

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

Measurement a = approx. 30 mm from component edge.

Open welded connections in area (2).

Installation note: 

New part is welded overlapping in area of severance cut.

Fig 3: Identifying Severance Cut Dimension

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Open welded connections in area (1).

Fig 4: Identifying Welded Connections Area

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Open welded connections in area (1).

Remove the luggage compartment floor.

Fig 5: Identifying Welded Connections Area Of Luggage Compartment Floor

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View from below.

Open welded connections in area (1).

Fig 6: Identifying Welded Connections Area

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Fig 7: Identifying Severance Cut Dimension

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Mark severance cut in accordance with Dimension a and cut.

Measurement a = approx. 45 mm.

Mark severance cuts (1) at component edge and cut.

Open welded connections in area (2).

Roughly cut luggage compartment floor along side member (3).

Remove trunk floor.

Mark severance cut in accordance with dimension and cut.

A = approx. 80 mm

Installation note: 

Weld new parts in areas (1) and (2) as standard.

Fig 8: Identifying Mark Severance Cut Dimension

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Mark severance cut (1) and cut.

Open welded connections in areas (2).

Fig 9: Identifying Severance Cut And Welded Connections Areas

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Open welded connections in area (1) and remove part section side member (2).

Fig 10: Identifying Section Side Member And Welded Connections Area

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New part preparation 

Luggage compartment floor, left:

Mark severance cut (1) in accordance with severance cut on vehicle + 15 mm extra material and cut.

Mark severance cut (2) in accordance with severance cut on vehicle and cut.

Open weld joints in area (3) and remove sheet section.

Fig 11: Identifying Severance Cut And Weld Joints Area

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Luggage compartment floor, right:

Mark severance cut (1) in accordance with severance cut on vehicle + 15 mm extra material and cut.

Mark severance cut (2) in accordance with severance cut on vehicle and cut.

For all severance cuts on side members, prepare REINFORCEMENT PLATES .

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

Fig 12: Identifying Severance Cut Of Luggage Compartment Floor

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Flatten stamping in area (1) on both sides.

Fig 13: Identifying Flatten Stamping Area

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Luggage compartment floor, middle:

Mark severance cuts on new part in accordance with severance cuts on vehicle + 20 mm extra material and cut.

Set down new part in the areas of the overlap.

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

In areas (1) to (3), set 4.2 mm diameter bore holes for blind rivets N3:

Fig 14: Identifying Mark Severance Cuts And Blind Rivets Area

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In areas (1) and (2) set 4.2 mm dia. holes for blind rivets.

Fig 15: Identifying Holes Blind Rivets Area

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In areas (1) and (2) set holes for blind rivets.

Area (1): 2 bore holes with dia. 6.8 mm  for blind rivets N1. 

Areas (2): in each case 4 bore holes with dia. 4.2 mm  for blind rivets N3. 

Prepare new parts for MAG welding in areas (3).

Remove new parts and deburr bore holes.

Fig 16: Identifying MAG Welding And Blind Rivets Area

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Installing side member and luggage compartment floor, left and right 

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

• Extension, side member
• Luggage compartment floor, left and right
• Mounting, bumper

Luggage compartment floor and side member reinforcements 

Clean all  bonding surfaces with cleaning agent R1.

Apply adhesive to bonding surfaces.

Install new parts and rivet with blind rivets.

Weld new parts in areas (1).

Fig 17: Identifying Weld Parts Areas

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After hardening of the adhesive in areas (1), install 2 EMC SCREWS .

Fig 18: Identifying Hardening Of Adhesive Areas

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