4111023 Replacing Front Section Of Engine Support To Left Wheel Arch
Observe procedure for REPAIR STAGE 3 .
Read contents of BODY, GENERAL .
Place vehicle on straightening bench.
- Wheel arch, front
- Carrier support, wheel arch, outer
Following CONSUMABLES are required:
| Material | Quantity |
|---|---|
| Adhesive K1 | 1 |
| Blind rivets N1 | 41 |
| Punch rivets N5 | 39 |
| EMC screws | 2 |
| CleanerR1 | 1 |
| Cavity sealing wax remover | 1 |
| Sealant D1 |
Mark severance cut (1) in front of holder (2) and cut (holder (2) remains on vehicle).
Open welded connections in area (3).
Installation note:
Mark severance cut (1) in on new part and cut. Take off holder (2).
Apply sealant to cavity sealing . See 4100... INSTALLING A CAVITY ACOUSTIC BAFFLE (EXPANDED) or 4100... INSTALLING A CAVITY ACOUSTIC BAFFLE (NOT EXPANDED) (4).
Mark severance cut (1) in accordance with measurement a and cut engine support.
Measurement a=130 mm from front edge of bush
Installation note:
Weld in REINFORCEMENT PLATES at all severance cuts.
Open welded connections in areas (1).
Open welded connections in areas (1).
Open welded connections in area (1).
Installation note:
If units compartment partition wall (2) is damaged, cut along line (3).
Mark new part in accordance with severance cut on vehicle + 20 mm extra material and cut.
Bond both parts overlapping and rivet. Depending on accessibility, use punch rivets N4 and blind rivets N3.
Open welded connections in area (1).
Preparation of new part
Make severance cut on new carrier support part in accordance with severance cut on vehicle.
Mark new part in accordance with severance cut on car and cut.
Open welded connections in areas (1) on both sides.
Open welded connections in area (2).
Detach remainder of reinforcement from engine support.
Preparation of new part
Open welded connections in areas (1).
Take off holder.
Installation note:
Adjust new parts to fit with alignment bracket or universal mount and secure.
In area (1) set ten 6.8 mm dia. holes for blind rivets N1.
Installation note:
In area (2) 2 N5 punch rivets are used later.
In areas (1) and (2) set 6.8 mm dia. holes for blind rivets N1:
- Area (1): 3 holes
Area (2): 2 holes
In area (1) set seven 6.8 mm dia. holes for blind rivets N1.
Installation note:
In area (2) 1 N5 punch rivet is used later.
In areas (1) to (4) set 6.8 mm dia. holes for blind rivets N1:
Open welded connections in area (1).
- Area (1): 5 holes
Area (2): 2 holes
Area (3): 1 hole
Area (4): 9 holes
Installation note:
After adhesive has hardened, install 2 EMC SCREWS in areas (1) and (4).
Set two 6.8 mm dia. holes for blind rivets N1 in area (1).
Remove all new parts and deburr holes.
Installing wheel arch
Clean bonding surfaces with adhesive cleaning agent R1.
Apply adhesive K1 to bonding surfaces.
Install new parts and rivet with blind rivets.
In area (1) rivet new part on both sides offset with 4 punch rivets N5.
Use 14 punch rivets N5 in area (2).
Use 18 punch rivets N5 in area (3).
Installation note:
Vehicles with spring strut dome plate insert:
Different plate inserts are fitted, depending on the model.
- Version (A) riveted
- Version (B) screwed
Riveted version:
If damaged, the plate inserts must always be replaced with screwed versions on both sides of the vehicle.
Glued version:
Adhesive/contact surfaces of plate insert must be free of sealant, final paint coat and underbody protection.
Do not grind off primer.
Use adhesive gun 41 3 102 in conjunction with adhesive K3.
Apply K3 adhesive in areas (1). Do not apply any adhesive in area (2).
Secure plate insert with 3 screws and nuts for 2 hours at min. 20 °C.