00 00... Body and underbody: checking for corrosion and damage
Inspect chassis, underbody and wheel arches and check for corrosion and damage.
Note. It is absolutely essential to rectify any identified faults after consulting the customer and to issue a separate invoice.
00 00... Raising BMW multi-trailer
| CAUTION | Twin-strut underfloor platforms and twin-pillar lifting platforms are suitable for raising the BMW multi-trailer. Lifting platforms with drive-on surfaces are not suitable for raising in order to carry out maintenance and repair work. |
The lifting platform must comply with the relevant statutory accident prevention regulations and be serviced according to the manufacturer's instructions. It is essential to follow the lifting platform operating instructions, in particular the safety instructions and carrying capacity!
Make sure you adhere to the BMW-recommended work area of 5 x 7 m and to an escape route of 0.6 m between two lifting platforms.
Before raising the BMW multi-trailer, please observe the following points
- Raise the trailer only when it is unloaded
- Remove a supplied loading ramp from the loading ramp frame so that all chassis areas of the BMW multi-trailer are freely accessible
- There must be sufficient clearance between the carrier arms/flat girder bridges and the GFK aprons or the front guard of the BMW multi-trailer
- The BMW multi-trailer must always be positioned in the middle of the lifting platform.
| CAUTION | You will need special additional supports for the lifting platform in order to bridge the difference in height between longitudinal member and lower edge of GFK side apron or front guard of the BMW multi-trailer. The minimum height of the additional supports is 145 mm. Use only the additional supports approved by the platform manufacturer or specified in these repair instructions. You will find appropriate examples in the repair instructions for the majority of lifting platforms present in BMW workshops. For lifting platforms that are not named, the relevant manufacturers will offer you appropriate additional supports. Please contact directly the manufacturer of the lifting platform used in your dealership. |
| CAUTION | The BMW multi-trailer may only be raised by its longitudinal members. Do not under any circumstances raise the BMW multi-trailer by the GFK aprons. Make sure the additional supports bear the longitudinal members over their entire width and no attachments or wiring harnesses are touched or jammed. Check the securing equipment of the additional supports for correct seating. Under no circumstances should any work be carried out underneath the BMW multi-trailer if it is not adequately secured against slipping off the lifting platform. |
The areas (2) on the longitudinal members (1) marked in the adjacent diagram are the best areas for attaching the additional supports.
Scheme 135
General notes on using twin-pillar lifting platforms
For the twin-pillar lifting platforms described, the BMW multitrailer is positioned in the direction of travel on the platform. For lifting platforms which do not create sufficient clearance between disk wheel and carrier arms, move the BMW multitrailer against the direction of travel onto the platform.
Becker & Sohne twin-strut underfloor platform
The BMW multi-trailer can only be raised if it is supported at right angles to the direction of travel. For raising, use the high additional supports (1) of Becker & Sohne.
Scheme 136
| CAUTION | Also lash the BMW multi-trailer to the flat girder bridges of the lifting platform. Flag the protruding tow hitch and the drawbar member of the BMW multi-trailer conspicuously so as to prevent injury, e.g. with a red cloth. |
MAHA twin-pillar lifting platform
The BMW multi-trailer can only be raised if you use the support plate attachment sleeves for transporters (1). Position the axle of the BMW multi-trailer in the direction of travel in front of the pillars of the platform in order to obtain the specified lifting ranges and to establish sufficient clearance between disk wheel and carrier arms. The long carrier arms raise the front and the short carrier arms raise the rear of the BMW multi-trailer.
Scheme 137
Romaico-Lift twin-pillar lifting platform
The BMW multi-trailer can only be raised if you use the 146 mm high attachments (1). Position the axle of the BMW multi-trailer in the direction of travel in front of the pillars of the platform in order to obtain the specified lifting ranges and to establish sufficient clearance between disk wheel and carrier arms. The long carrier arms raise the front and the short carrier arms raise the rear of the BMW multi-trailer.
Scheme 138
Working pit
The BMW multi-trailer can be serviced or repaired in conjunction with a working pit if the following measures are taken into consideration. The BMW multi-trailer must be secured against slipping/tilting sideways. The drawbar jockey wheel must be firmly secured against rolling.
86 10... Adjusting brake system
Proper adjustment of the brake system is only possible if the brake Bowden cables and all brake system moving parts move freely and are ready for operation.
The wheels must be completely fitted and able to rotate freely. Always adjust both brake sides. The left and right sides are adjusted in the same way.
Pull out overrunning equipment (1) fully in direction of arrow.
Scheme 139
Reversing lever (1) must rest directly on innerlying tow tube of overrunning brake.
Scheme 140
Screw brake linkage (1) into nut (2) until distance (3) (nut (2) - end of brake linkage (1)), is 10 - 15mm. Lock brake linkage (1) in position with nut (4).
Check distance (3) and nuts (2, 4) with brake linkage installed.
Scheme 141
Insert pull rod (1) in brake compensator (2) and screw nut (3) onto pull rod (2).
Tighten nut (3) until pull rod (1) is free of play.
Check pull rod (1) already fitted for zero play.
Scheme 142
Hook tension spring (1) to tension spring mount (2).
Installation
The brake shoes are adjusted in two work steps. In the first step, the distance between the lower half of the brake shoes and the brake drum is adjusted. In the second step, the distance between the upper half of the brake shoes and the brake drum is adjusted.
Scheme 143
Rotate road wheel (1) in direction of travel and simultaneously turn adjusting screw (2) in direction of arrow.
Tighten adjusting screw (2) until road wheel (1) can no longer be turned.
Scheme 144
Turn adjusting screw (1) in direction of arrow and release slowly until road wheel (2) can rotate.
Finish adjustment procedure when slight grinding noises can be heard in lower brake shoe halves.
Scheme 145
Firmly tighten handbrake lever three to five times.
Depending on road wheel side, tighten nut (1) or (2) until slight grinding noises can be heard in upper brake shoe halves.
Scheme 146
86 10... Adjusting spring force accumulator
The spring force accumulator requires no maintenance and generally does not need to be readjusted.
Adjustment dimension, spring force accumulator: distance between end of support tube - internal washer (1) is 90 mm.
Scheme 147
To tension spring force accumulator: turn nut (2) located in support tube (1) clockwise.
To relieve tension on spring force accumulator: turn nut (2) located in support tube (1) counterclockwise.
Scheme 148
86 10... Removing Camlock retaining cam on loading ramp
Drill out rivets (1).
Scheme 149
86 10... Removing Camlock screw cap
Bend back edges (1) of tab washer (2). Remove tab washer (2) over cross pin (3) towards bottom.
86 10... Removing and installing or replacing left or right coil spring
Release screw (1) and remove, tilt shock absorber (2) in direction of arrow towards rear.
86 10... Removing bolt on loading ramp
Insert a drift into hole (1) of bolt (2) and turn clockwise.
Scheme 150
86 10... Removing brake shoes
The wheels of the multi-trailers must be able to rotate freely. Adjust and check brake system after installing brake shoes.
Unhook tension spring (1) from tension spring mount (2).
Scheme 151
| CAUTION | Once nut (1) of pull rod (2) has been released, do not move handbrake lever. Handbrake lever can flick upwards. |
Release nut (1) on pull rod (2) and remove hexagon nut. Slide brake compensator (3) towards rear.
86 10... Removing entry profile section on loading ramp, left, right and center
| CAUTION | Before drilling out rivets, drive in rivet pins with a punch. |
Drill out rivets (1). Remove entry profile section (2) towards front.
Scheme 152
86 10... Removing left or right shock absorber
Inspect the shock absorber while installed to ascertain whether it needs to be replaced.
Replace shock absorber if it is leaking. Replace shock absorber if it can be easily pushed in or pulled out when removed.
Release screw (1) and remove. Tilt shock absorber in direction of arrow. Release screw (2) and remove shock absorber.
86 10... Removing loading ramp lock
Unscrew bolts (1).
86 10... Removing mounting bracket sealing cap
Cut out mounting bracket (3) along markings (1, 2) and lever out of apron (4).
86 10... Removing mounting bracket, center, left and right
Note. Disassembly of Camlock retaining cam, refer to 86 10... DISASSEMBLY OF CAMLOCK RETAINING CAM
Unscrew bolts (1).
86 10... Removing outer pull rod mount, left and right
Release screws (1) and remove pull rod mount (2).
86 10... Removing overrunning equipment/maintaining or replacing guide bush/installing overrunning equipment
After installing overrunning equipment, readjust brake system
refer to 86 10... ADJUSTING BRAKE SYSTEM
Check the guide bush while installed to ascertain whether it needs to be replaced. Raise ball end area and replace guide bush if play is detected in ball end area.
Note. After installing, readjust and check brake system.
Release round head screws (1) and remove running board (2) towards top.
86 10... Removing plastic bush/metal bush
Release countersunk metal screws (1).
Scheme 153
Lever out plastic bush/metal bush (1) with a screwdriver.
Scheme 154
86 10... Removing rear supports and bracket
Release screws (1) and remove rear support (2) from bracket (3).
86 10... Removing reflecting rear light
From rear side of GFK apron, drive out plastic pins (1) with a drift.
Scheme 155
86 10... Removing rest on loading ramp, left, right and center
| CAUTION | Before drilling out rivets, drive in rivet pins with a punch. |
Drill out rivets (1). Remove rest (2) towards front.
86 10... Removing shock absorber from overrunning equipment
Check the overrunning equipment shock absorber while installed to ascertain whether it needs to be replaced.
Apply handbrake. Push in and pull out tow ball end by hand. If it is very easy to pull out the tow ball end, the shock absorber must be replaced.
Note. Complete disassembly of overrunning equipment and guide bush, refer to Disassembly of overrunning equipment.
Release screw (1) and remove. Pull out internal shock absorber (2) from opening in tow tube (3) towards rear.
86 10... Removing trailing arm, removing and installing or replacing mounting
Replace bearing in trailing arm if there is play in trailing arm.
Note. Remove brake cable, refer to 86 10... REMOVING BRAKE SHOES . Remove shock absorber and coil spring, refer to removing and installing coil spring .
Release screws (1) between wheel brake (2) and trailing arm (3) and remove complete wheel brake (2).
86 10... Removing wheel bearing
The angular-contact ball bearings do not require maintenance and have lifetime lubrication. The bearings cannot be readjusted.
Remove brake drum
refer to 86 10... REMOVING BRAKE SHOES .
Lever out both snap rings (1).
86 10... Removing wooden rest on loading ramp, left, right and center
| CAUTION | Before drilling out rivets, drive in rivet pins with a punch. |
Drill out rivets (1).
Scheme 156
86 10... Repair work on GFP components with Gelcoat surface
Scratches in Gelcoat surface
Scratches in the Gelcoat surface which do not allow the GFP mat structure to show through can be touched up. Sand out scratches with water and 800 wet sandpaper. Then sand with water and 2000 wet sandpaper. Prepare repair area for polishing.
Cracks in Gelcoat surface
Sand the cracked area in a V shape beyond the end of the crack and clean.
There must be no grease or oil residues, moisture or dust remaining in the crack to be repaired.
When repairing holes such as e.g. rivet holes, deburr hole edge and heavily roughen large area around hole.
Prepare required amount of Gelcoat paste with 2% hardener and fill prepared repair area with spatula.
Apply Gelcoat paste in several applications to repair areas.
Adhere to mixture ratio (2 parts hardener to 100 parts Gelcoat paste) as precisely as possible.
Too much added hardener slows down the hardening time and changes the paint color.
The hardening period is at least 12 hours at 20°C room temperature.
The hardening period can be longer depending on the temperature.
Once the Gelcoat paste has hardened, sand the touched-up area with water and 800 wet sandpaper. Sand with water and 2000 wet sandpaper and prepare for polishing.
86 10... Replacing 12 volt socket
From underside of platform, cut through cable tie (1) and remove. Disconnect plug with grommet (2) from socket (3) towards bottom.
86 10... Replacing bar
Note. Disassembly of lashing eyes, refer to 86 10... REPLACING LASHING PLATE AND LASHING EYE .
Remove lashing eyes (1).
Scheme 157
Remove protective caps (1) on left/right.
Scheme 158
Release hexagon screws (1) and countersunk head screws (2) on left/right.
Remove bar.
86 10... Replacing drawbar members, left and right
Note. Disassembly of overrunning equipment, refer to Removing overrunning equipment/maintaining or replacing guide bush/installing overrunning equipment . Remove complete brake pull rod. Removal of position light cable, refer to 86 10... REPLACING LICENSE PLATE LIGHT .
Release screws (1) on cross-member (2). Pull out crossmember (2) towards rear.
86 10... Replacing gaiter
Position brake lever fully towards rear.
Release screws (1) and (2) and remove. Pull off towing attachment (3) in direction of arrow.
86 10... Replacing holder for chock
Pull bar (1) down in direction of arrow A. Pull out chock (2) in direction of arrow B at an angle towards bottom.
Scheme 159
Release and unscrew cheese head tapping screws (1) on holder (2).
Scheme 160
86 10... Replacing lashing plate and lashing eye
Releasing lashing eye
Pull spring bar (1) upwards in direction of arrow A. Slide lashing eye (3) in direction of arrow B and remove from lashing plate (2).
Scheme 161
Release countersunk head screws (1) and remove lashing plate.
86 10... Replacing license plate light
Release screws (1) and remove license plate light (2) from mounting.
Scheme 162
Disconnect flat connector (1) in direction of arrow.
Scheme 163
86 10... Replacing position light
Unclip cover (1) on side recess (arrow).
Scheme 164
Pull flat connector (1) from flat contact.
Scheme 165
Pull out cable (1) completely.
| CAUTION | Before drilling out rivet heads, drive in rivet pins with a punch. Drill out rivet heads (2) and remove position light housing from front. |
Scheme 166
86 10... Replacing rear light
Release thumb screws (1), slide light guard (2) in direction of middle of car and tilt out towards rear.
Scheme 167
Turn handwheel (1) counterclockwise in direction of arrow and remove base (2).
Scheme 168
Release nuts (1) and press rear light (2) out towards front.
86 21... Adjusting hood pretension - Camloc fastener with spacers
Note. At least two persons are needed to install and remove the hood. Before installing and removing the hood, secure the BMW multitrailer and the entire combination against rolling. For this purpose, use the parking brake and the chocks of the BMW multitrailer. To help adjust the hood pretension, you will need four blocks with a minimum height of 60 mm.
Locking
Press hood in lid frame downwards by hand. Turn Camloc fastener clockwise until it is heard and felt to lock into place. Wing (1) of Camloc fastener is parallel to outer edge of hood.
Scheme 169
Raise hood and place block (1) between centering pin (2) and platform. Lower hood and position centering pin (2) on block (1).
Scheme 170
Remove spring nut (1) from Camloc fastener (2).
Scheme 171
86 21... Adjusting rear lid to fit
Note. The following text describes how to adjust the rear lid to fit at one mounting point as an example. Proceed in the same way for the other mounting points.
Height adjustment of rear lid
Release screws (1) and move rear lid in direction of arrows.
Depth adjustment of rear lid
Release screws (2) and move rear lid in direction of arrows.
Scheme 172
86 21... Adjusting rotary striker lock
The following text describes how to adjust the rotary striker lock on the rear lid as an example. Proceed in the same way for the side lids. Adjust the lock while the lid is open.
Release screws (1) and adjust rotary striker lock (2) in elongated hole area in direction of arrows.
86 21... Adjusting side lid to fit
Note. The following text describes how to adjust the side lid to fit at one mounting point as an example. Proceed in the same way for all other mounting points.
Height adjustment of side lid
Release screws (1) and move side lid in direction of arrows.
86 21... Attaching/replacing BMW badge
Position of attachment: inside of rear lid
Remove plastic cover (1) from bore holes (2).
Scheme 173
Inserting a set of pointed pliers through bore holes (1), detach retaining washers (2) from pins of BMW badge.
Installation
Use only new retaining washers.
Scheme 174
| CAUTION | Instruction for removing BMW badge: Slide a blunt object (e.g. a wooden wedge) under the BMW badge and carefully lever off the badge. |
Position of attachment: outside of rear lid
The BMW badge must be attached at room temperature.
Degrease bonding area with petroleum ether.
Rub down bonding area with a dry cloth.
Peel off protective film on BMW badge (1).
Insert BMW badge (1) with pin (2) into bore hole (3). If bore holes (3) are considerably larger than pin (2), optically align BMW badge (1) exactly.
Press down BMW badge (1) firmly.
Scheme 175
Position of attachment: inside of rear lid
By inserting a 1/4" ratchet with extension and socket wrench insert (7 mm A/F) through bore holes (2), attach a retaining washer (1) in each case to pin of BMW badge. In so doing, press down on outside of rear lid with one hand on BMW badge and grip.
Push on relevant retaining washer (1) as far as it will go.
Scheme 176
Position of attachment: inside of rear lid
Insert plastic cover (1) in bore holes (2).
Scheme 177
86 21... Fitting BMW logo
Distance between hood edge and lower edge of BMW logo (1) is 100 mm.
Distance between middle of lock and lettering (2) is 300 mm.
86 21... Installing hood seal
Note. Removing old seal: In a straight area of hood, grip old seal piping with a pair of pliers and pull off horizontally. Grip detached seal with both hands and uniformly pull away from hood ridge.
Push seal piping (1) by hand onto hood ridge (2). Using a rubber hammer, gently tap seal piping (1) as far as it will go onto hood ridge (2). Make sure piping is evenly positioned especially in radii of hood ridge.
Scheme 178
86 21... Installing rubber roof strip
Note. Pull off old rubber roof strip and remove remaining traces of adhesive with universal cleaner. Rub down with a dry cloth.
Select rubber roof strip according to length of roof recess (1).
Arrange chamfered ends of rubber roof strip to match shape of roof recess (1).
Scheme 179
86 21... Installing seal for rear lid and side lid
Note. The following text describes how to install the seal for the rear lid as an example. Proceed in the same way for the side lids. Removing old seal: Open lid. Grip seal piping with both hands and pull seal off hood ridge. Remove old seal over lid.
Push seal piping (1) by hand onto hood ridge (2). Using a rubber hammer, gently tap seal piping (1) as far as it will go onto hood ridge (2). Make sure piping (1) is evenly positioned especially in radii of hood ridge.
Scheme 180
86 21... Installing sponge rubber seal
Note. Removing old sponge rubber seal: Pull off old sponge rubber seal. Remove remaining traces of adhesive with universal cleaner.
Sponge rubber seal runs along area marked gray (1).
Scheme 181
Lay sponge rubber seal (1) in middle of hood contact surface (2).
86 21... Removing ball pivot
Note. Remove gas spring, refer to 86 21... REMOVING GAS SPRING .
Note. The following text describes how to remove the ball pivot from the hinge retaining bracket on the rear lid as an example. Proceed in the same way for the other ball pivots. Make sure the attachments are reinstalled in the correct sequence. Only in this way will the gas springs open and close properly.
Grip ball pivot (1) at hexagon mount (2) and release nut (3).
86 21... Removing centering pin from mounting bracket
Note. Exclusively for removal of pin, raise the hood in the GFP area. For raising, use a wooden block with a maximum width of 35 mm and a height of 45 mm. The length must be selected depending on the lifting platform securing point. Ensure the hood is secure on the blocks.
Position block (1) so that it is only located in area of sponge rubber seal (2).
Scheme 182
Insert a mandrel into hole (1) of pin (2) and turn counterclockwise.
Scheme 183
86 21... Removing gas spring
Only remove the gas spring while the lid is open. The gas spring will then not be subjected to load and the spring piston will not jump out of the spring housing. Prop the lid open with one hand to prevent it dropping closed. Remove the gas spring with your other hand.
Note. Side lids are each fitted with a gas spring. Rear lid is fitted with two gas springs. The following text describes how to remove the gas spring at one mounting point as an example. Proceed in the same way for all other mounting points. Rear lid: Replace gas springs in pairs only.
Lever out retaining clip (1) in recess (2) and push on gas spring head (3) in direction of arrow. Detach spring head (3) from ball pivot.
86 21... Removing gas spring retaining bracket
Note. Remove gas spring, refer to 86 21... REMOVING GAS SPRING . Remove ball pivot, Refer to 86 21... REMOVING BALL PIVOT .
Release screws (1) and remove gas spring retaining bracket (2) from mounting bracket (3).
Scheme 184
86 21... Removing hinge bracket on rear lid
Note. Remove rear lid, refer to 86 21... REMOVING LID . Remove gas spring, remove gas spring on hinge side only, refer to 86 21... REMOVING GAS SPRING .
Raise edge (1) of retaining clip (2) and slide in direction of arrow towards rear.
Scheme 185
Remove plastic washer (1). Pull hinge bracket (2) in direction of arrow out of mounting bracket (3).
Scheme 186
86 21... Removing lid
Note. Adjusting side lid to fit, refer to R8621... ADJUSTING SIDE LID TO FIT . Adjusting rear lid to fit, refer to R8621... ADJUSTING REAR LID TO FIT .
Note. The text describes how to remove the lid at one rear lid mounting point as an example. Proceed in the same way for the side lids. Spare part lids are always supplied without complete locking systems.
Two persons are required for this task.
Note. Open lid.
Loosen screws (1). Remove lid (2).
86 21... Removing lock barrel
Note. The following text describes how to remove the lock barrel on the rear lid as an example. Proceed in the same way for the side lids. Remove the lock barrel while the lid is open. Remove cover, spring nut and pull rod, refer to 86 21... REMOVING ROTARY STRIKER LOCK .
Slide retainer (1) in direction of arrow away from lock barrel (2). Remove lock barrel (2).
Scheme 187
86 21... Removing lock striker fixture on rear lid
Grip rubber seal on seal piping (1) and pull off in area of lock striker fixture (2). Grip lid seal (3) on seal piping (4) and pull off in area of lock striker fixture (2).
Scheme 188
| CAUTION | Before drilling out rivets, drive in rivet pins with a punch. Drill out rivets (1+2) and remove lock striker fixture (3). |
Scheme 189
86 21... Removing plug for inside light
Note. Two different types of plugs are used for the inside light. Both types function in the same way, only their designs are different.
Type 1
Release screw (1) and separate housing plug (2).
Scheme 190
Release screws (1) and disconnect cables (2) from screw clamp.
Scheme 191
Type 2
Release screw (1) and separate housing plug (2).
Scheme 192
Remove contact parts (1+2).
86 21... Removing roof railing
Note. The text describes how to remove the roof railing at one mounting point as an example. Proceed in the same way for the other mounting points.
Open cover (1) and fold down.
Scheme 193
Unscrew bolt (1).
After releasing three retaining screws, lift off roof railing (2).
Scheme 194
86 21... Removing roof railing adapter
Note. Removing roof railing, refer to 86 21... REMOVING ROOF RAILING
Remove molded sealing part (1).
Scheme 195
86 21... Removing rotary striker lock
The following text describes how to remove the rotary striker lock on the rear lid as an example. Proceed in the same way for the side lids. Remove the lock while the lid is open.
Release screws (1) and remove cover (2). On rear lid, remove red cap (3).
Installation, rear lid only
Place red cap back on pull rod. Red cap serves to indicate rear lid emergency unlocking facility.
Scheme 196
Remove spring nut (1) from pull rod (2).
86 21... Removing side lid hinge
Note. Remove side lid, refer to 86 21... REMOVING LID . Remove gas spring, remove gas spring on hinge side only, refer to 86 21... REMOVING GAS SPRING .
Unscrew bolt (1). Remove hinge (2). If fitted, remove spacer plate(s) (3).
Scheme 197
86 21... Replacing inside light
Unclip cover (1) at side recess (arrowed) and remove towards bottom.
Scheme 198
Unclip lamp housing (1) at side recess (arrowed).
Scheme 199
Disconnect flat connector (1) from flat connector contact.
Scheme 200
| CAUTION | Before drilling out rivets, drive in rivet pins with a punch. Drill out rivets (1). Pull off inside light mounting bracket (2) over flat connector (3). |
Scheme 201
86 21... Replacing inside light power cable
Note. Remove inside light cover and lamp housing, refer to 86 21... REPLACING INSIDE LIGHT . Remove inside light plug, refer to 86 21... Removing plug for inside light .
Carefully remove adhesive bonds of power cable (1) from hood surface.