41 00... Overview Of Front End Repair Elements

Fig 1: Overview Of Front End Repair Elements

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FRONT END REPAIR ELEMENTS REFERENCE CHART

Component	Repair element	Part number	Matching
(1) Engine carrier	Repair kit, lug, radiator bracket	41 11 7 165 339	Mounting, carrier, bumper
	Threaded bolt, short Threaded bolt, long	07 14 6 951 379 07 14 6 951 380	Mounting, carrier, bumper
	Screw, self-tapping	51 16 8 220 001	Bracket, washer fluid reservoir Bracket, secondary air pump
	Helicoil thread insert	07 14 6 958 589	Bushing, front axle, front/middle
(2) Support carrier	Blind rivet nut	41 12 8 223 082	Support carrier, wheel arch, front right
	Blind rivet nut, countersunk head	41 32 8 257 508	Support carrier, wheel arch, front left
	Flange nut Shim	07 14 6 949 832 41 35 7 001 794	Support carrier, wheel arch, outer
(3) Spring support	M8 Helicoil thread insert	07 14 6 958 587	V-strut on spring support
	Blind rivet bolt with coarse thread Blind rivet nut	41 12 8 244 333 32 41 1 094 185	Spring support, right
(4) Bulkhead	M8 Helicoil thread insert	07 14 6 958 587	Cross-member, bulkhead
	Flange nut Shim	07 14 6 949 832 41 35 7 001 794	Mounting, wiper system
Repair solution, threaded bolt	Expander rivet Cable strap	51 11 1 908 077 32 41 1 112 282
Various repairs	M8 hexagon nut M6 hexagon nut M5 hexagon nut with shim	07 11 9 904 024 07 12 9 904 859 07 12 9 904 381
	M5 Helicoil thread insert M6 Helicoil thread insert M10 Helicoil thread insert	07 14 6 958 585 07 14 6 958 586 07 14 6 958 587

For a detailed depiction for using the repair elements, see below.

All the repair elements for the weight-reduced aluminum front end are depicted in the following.

Read contents of see BODY, GENERAL .

Repair kit, lug, radiator bracket

Mark severance cut (1) in accordance with measurement a and cut.

Measurement a = 63 mm from top edge, lug, radiator bracket.

Carry over holes from new part, drill and screw new part into place.

Fig 2: Radiator Bracket Dimension

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Threaded bolts, short and long

Drive through damaged threaded bolts (1) towards rear.

Insert new threaded bolts (1) and (2) in same position, turn if necessary.

Peen threaded bolts (1) and (2) from front end with 2 mm punch.

NOTE: Cut off threaded bolt (2) before driving through.

Installation:

Grind off 3.5 mm of threaded bolt (2) at head on one side and apply primer coating.

Fig 3: Front End Bolts

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Screw, self-tapping

Grind off torn threaded bolts (1) until flush and apply primer coating.

IMPORTANT: Do not damage aluminum surface.

Drill 5.5 mm dia. holes (2) at distance of approx. 8 mm in a level plane.

Insert self-tapping screw.

Tightening torque 8 Nm.

Fig 4: Grind Off Torn Threaded Bolts

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Helicoil thread insert

Thread repair with Helicoil thread insert can be used on the spring support (1).

Read and comply with tool manufacturers instructions.

Fig 5: Spring Support Of Spring Support

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Helicoil thread insert

Thread repair with Helicoil thread insert can be used on the bulkhead (1).

Read and comply with tool manufacturers instructions.

Fig 6: Bulkhead Of Helicoil Thread

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Helicoil thread insert

Thread repair with Helicoil thread insert can be used on the front engine

carrier bushings (1) and middle engine carrier bushings (2).

Read and comply with tool manufacturers instructions.

Fig 7: Carrier Bushings And Middle Engine Carrier Bushings

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Flange nut with shim

Remove damaged press-in nuts in areas (1).

Fig 8: Shim Nuts

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Drill out hole (1) to 18 mm.

Fit Limbach nut (2) from below; if necessary, secure with sealing compound.

Insert shim (3) in bore.

Install screw (4).

Fig 9: Hole, Shim With Nut And Screw

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