BMW 7 Series: Replace Luggage Compartment Floor And Both Side Members (Tail Panel Trim Removed)

Read contents of BODY, GENERAL.

STRIP DOWN VEHICLE.

Place vehicle on straightening bench.

These repair instructions comprise the procedures for REPAIR STAGE 3.

Following new body parts are required:

1. Luggage compartment floor, rear
2. Side member, left and right
3. Extension, side member, left and right
4. Luggage compartment floor, left and right
5. Fixture, bumper, left and right

Following consumables are required:

MATERIAL CHART

Fig. 153: Identifying, Rear Luggage Compartment Floor And Side Member, Left And Right

Removing side members and luggage compartment floor

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

Open weld joints in area (1).

Fig. 154: Identifying Weld Joints Area

Open weld joints in area (1).

Fig. 155: Identifying Weld Joints Area

Roughly mark severance cut (1) and cut.

Open weld joints in area (2).

Remove luggage compartment floor (3).

Fig. 156: Identifying Luggage Compartment Floor And Weld Joints Area

View from below.

Open weld joints in area (1).

Fig. 157: Identifying Weld Joints Area

Fig. 158: Identifying Weld Joints Area And Severance Cuts

Mark severance cut (1) approx. 6 mm from edge of component and disconnect.

Mark severance cuts (2) in accordance with measurement and cut.

IMPORTANT: Cut outer metal sheet only.

Measurement a = 25 mm

Open weld joints in area (3).

Remove the luggage compartment floor.

Installation note: Changed joining sequence: Place new component in the areas (1) and (2) from above and install so that it overlaps them.

Mark severance cut (1) flush with side member and cut.

After cutting side member extension (2), open weld joints in area (3).

Installation note: Additionally weld new parts in area (4).

Fig. 159: Identifying Side Member Extension And Weld Joints Area

Mark severance cut (1) flush with side member and cut.

Remove side member extension (2).

Open weld joints in area (3).

Installation note: Additionally weld new parts in area (4) all round.

Fig. 160: Identifying Side Member Extension And Weld Joints Area

New part preparation

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

Fig. 161: Identifying Severance Cut And Stampings Fitting Area

Mark severance cut (1) in radius and cut.

Fit stampings in area (2) on the vehicle.

Open weld joints in area (1).

Fig. 162: Identifying Welded Connections Area

Open weld joints in area (1).

Remove metal section (2).

Fig. 163: Identifying Metal Section And Weld Joints Area

NOTE: To adjust new parts to fit, bend side member end panel (1) outwards slightly.

Adjust new parts, side members to fit with alignment bracket or universal mount.

Fig. 164: Bending Side Member End Panel

Set down luggage compartment well (1) from above and adjust in combination with cross member (2) and tail panel to fit and secure.

In areas (1) to (4), set 4.2 mm dia. holes for blind rivets.

BLIND RIVETS HOLES AREA CHART

Fig. 165: Identifying Luggage Compartment Well And Cross Member Blind Rivets Holes Area

Installation note: After adhesive has hardened install 2 EMC SCREWS each in areas (1) and (4).

Adjust side member to fit and secure.

In areas (1) to (4), set 4.2 mm dia. holes for blind rivets.

BLIND RIVETS HOLES AREA CHART

Fig. 166: Identifying Side Member Blind Rivets Holes Area

Installation note: New parts are later welded in the area (5).

IMPORTANT: Risk of damage to adjoining adhesive areas! Avoid excessive application of heat.

Adjust boot floor laterally (1) to fit and secure.

Set 5 4.2 mm dia. bore holes in area (2).

Fig. 167: Identifying Boot Floor Laterally And Bore Holes Area

Set 3 4.2 mm dia. bore holes in area (1).

Fig. 168: Identifying Bore Holes Area

Set 11 4.2 mm dia. bore holes in area (1).

Remove new parts and deburr bore holes.

Fig. 169: Identifying Bore Holes Area

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

Installation of side member

Adjust new parts to fit with straightening attachment or universal mount and weld.

• Extension, side member
• Extension, end plate side member
• Mounting, bumper

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.

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