Preliminary fitting of BMW Cycle Module (interior) for BMW 3 Series touring (E46/3)

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BMW Installation Instructions
Preliminary fitting of BMW Cycle Module (interior) for BMW 3 Series touring (E46/3)

Preliminary fitting of BMW Cycle Module (interior) for BMW 3 Series touring (E46/3)

Technical knowledge is required

Installation time is approx. 0.5 hours, which can vary according to the condition and fittings of the vehicle.

Retrofit/Installation Kit no. 82 71 0 008 794
Retrofit/Installation Kit no. 82 71 0 008 794

Contents

Chapter

1. Preliminary work
2. Parts overview
3. Setting the rivets
4. Assembly of the bracket
5. Positioning and checking of the bracket
6. Making cut in spare wheel recess
7. Installation note

Important notes

(Only for use within the BMW trading organisation)

Installation time is approx. 0.5 hours, which can vary according to the condition and fittings of the vehicle.

Target group:

Target group for these installation instructions are technical personnel who have been trained on BMW passenger cars. All maintenance and repair work, installation and resetting operations should be executed on own authority.

All operations should be carried out with the aid of the currently valid BMW

  • repair instructions,
  • maintenance manuals,
  • operational instructions,

in a rational sequence and with the aid of the prescribed tools (special tools) while observing the currently valid health and safety regulations.

Safety instructions

Before starting on the installation, note the following instructions:

Tightening torques for screw connections must be adhered to without exception. If no tightening torques are specified, please refer to the Technical Information System (TIS) for the tightening torques required.

Installation instructions

BMW AG assumes no liability for damage which arises as a result of disregard of the work sequence and safety instructions. In addition, all rights to claim under the guarantee against BMW AG are extinguished in the event of improper assembly and handling which are at variance to the assembly and operational instructions.

Installation of the Cycling Module, Interior is not possible in association with the E46 subwoofer module. An E46 subwoofer module which is already fitted will therefore have to be removed before installation of the Cycling Module, Interior takes place.

Installation of the Cycling Module, Interior is not possible in association with the optional equipment full spare wheel!

Required tools and auxiliary materials

1/4 inch reversible ratchet
1/4 inch short extension
1/4 inch socket wrench insert SW 10
2 fork wrenches SW 10
Air saw
Drilling machine
Twist drill Ø 5 mm
Knife
Scissors
Marker pen
Adhesive tape

1. Preliminary work

TIS AW no.
Dismantle and install/replace trim panel for boot floor (touring) 51 47 131
Dismantle and install/replace hinged lid in boot trim-panel on left or right (touring) 51 47 172
Disassembly of floor covering on right
Disassembly of cover for spare wheel
Dismantle and install/replace covering and storage compartment in boot (touring) 51 47 …

2. Parts overview

Preliminary fitting of BMW Cycle Module (interior) for BMW 3 Series touring (E46/3)

a Bracket 1
b Hexagon bolt M6 x 35 2
c Hexagon bolt M6 x 15 2
d Hexagon nut M6 2
f Hexagon rivet nut 2
g Shim washer for M6 2
h Rivet plate 1
i Template 1 1
j Template 2 1

3. Setting the rivets

Preliminary fitting of BMW Cycle Module (interior) for BMW 3 Series touring (E46/3)

Insert the two hexagon rivet nuts (f) completely into the hexagon holes (1) on the right-hand side longitudinal bearer (2).

Preliminary fitting of BMW Cycle Module (interior) for BMW 3 Series touring (E46/3)

Place the rivet plate (h) with its drill holes (1) on the hexagon rivet nuts.

Preliminary fitting of BMW Cycle Module (interior) for BMW 3 Series touring (E46/3)

Screw the nuts M6 (d) onto the hexagon bolts M6 x 35 (b) until just before the thread stop. Screw the hexagon bolts (b) with the nuts (d) fully through the rivet plate (h).When fitting the rivet plate (h), press firmly on the right-hand side longitudinal bearer (1). Counter the nuts (d) on the rivet plate (h). Check whether the arrangement is fixed firmly and without play on the right-hand side longitudinal bearer (1).

Preliminary fitting of BMW Cycle Module (interior) for BMW 3 Series touring (E46/3)

Mark a continuous line (1) on the rivet plate (h), the nut (d) and the hexagon bolt (b) in each case as shown in the illustration.The marked line helps to check on the rotations which have to made to the nut (d).

Preliminary fitting of BMW Cycle Module (interior) for BMW 3 Series touring (E46/3)

When setting the rivets, the position of the bolt head should not shift when the nut is turned.The rivets must be placed in vertically.

Grip the hexagon bolts with the upper fork wrench (1) and tighten the nuts with the lower fork wrench (2) in a clockwise direction by exactly three rotations.

Repeat the procedure on the other hexagon bolts and nuts in the same sequence.

To remove the help fixture:

Loosen nuts, then screw out hexagon bolts from the hexagon rivet nuts. Remove the rivet plate.

4. Assembly of the bracket

Preliminary fitting of BMW Cycle Module (interior) for BMW 3 Series touring (E46/3)

Place the bracket (a) in accordance with its hole pattern on the hexagon rivet nuts (f). Screw the bracket (a) in each case with one shim washer (g) and one hexagon bolt M6 x 16 (c) to the righthand side longitudinal bearer (1). Do not tighten the screw connection.

Preliminary fitting of BMW Cycle Module (interior) for BMW 3 Series touring (E46/3)

Press the bracket (a) against the longitudinal bearer (1) and tighten the hexagon screws with a tightening torque of 10 Nm.

5. Positioning and checking of the bracket

Preliminary fitting of BMW Cycle Module (interior) for BMW 3 Series touring (E46/3)

When this check is carried out, the bracket (a) should not slip to the side.

Take the cross rail (boot) (1) from the parts kit of the BMW cycle module (interior). Install the cross rail (boot) (1) at its attachment points as shown in the illustration. It must be possible to assemble and disassemble the cross rail (boot) (1) at its attachment points without difficulty. If necessary, loosen the attachment screws of the bracket (a) and move the bracket (a) in its elongated holes inwards.Tighten the attachment screws to 10 Nm. Replace the cross rail (boot) (1) in the parts kit of the BMW cycle module (interior).

6. Making cut in spare wheel recess

Preliminary fitting of BMW Cycle Module (interior) for BMW 3 Series touring (E46/3)

Stand the spare wheel recess (1) on its head in such a way that the opening (2) for the cover projection points to the right, as shown in the illustration.

Take template 1 (i) from the parts kit and cut it out.

Make a fold on template 1 (i) along line A to the rear by 90°.

When template (1) (i) is placed in position, the following distance measurements must be adhered to:

  • from the edge (3) of the spare wheel recess (1) to line B of template 1 (i) 220 mm.
  • from the bottom edge (4) of the spare wheelrecess (1) to line C of template 1 (i) 50 mm.

Fix template 1 (i) with adhesive tape.Trace the outer contour of template 1 (i) with a marker pen marking the line clearly.Take off template 1 (i).

Preliminary fitting of BMW Cycle Module (interior) for BMW 3 Series touring (E46/3)

To make the cutting process easier, make a drill hole at the corners (1) inside the marked line (2). Move the air saw at a constant right angle to the recess.

Carefully separate off the inner area along the marked line (2) with the aid of the air saw.

There is a risk of injury from the cut edges. It is therefore essential that the cut edges are deburred with a knife.

6. Making cut in spare wheel recess

Preliminary fitting of BMW Cycle Module (interior) for BMW 3 Series touring (E46/3)

Place the spare wheel recess (1) on its head in such a way that the opening (2) for the cover projection is pointing to the left as shown in the illustration.

Take template 2 (j) from the parts kit and cut it out.

When placing the template in position, proceed as follows and adhere to the following distance measurements:

Place the bottom edge A of template (2) (j) in the lower radius (3) of the spare wheel recess.

  • from the vertical edge (4) of the spare wheelrecess (1) to the terminating edge B of template 2 (j) 110 mm
  • from the top edge (5) of the spare wheel recess(1) to the top edge C of template 2 (j) at position D 20 mm and at position E 10 mm.

Fix template 2 (j) with adhesive tape.Trace over the outer contour of template 2 (j) with a marker pen, marking the line clearly.Take off template 2 (j).

Preliminary fitting of BMW Cycle Module (interior) for BMW 3 Series touring (E46/3)

To make the cutting process easier, make a drill hole at the corners (1) inside the marked line (2). Move the air saw along edge A in the lower radius of the recess. Move the air saw along the edges B, C and F at right angles to the recess.

Carefully separate off the inner area along the marked line (2) with the aid of the air saw.

There is a risk of injury from the cut edges. It is therefore essential that the cut edges are deburred with a knife.

7. Installation note

Assemble the spare wheel recess.

The disassembled parts should be installed again in the vehicle in the reverse order of disassembly.

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