41 11 023 Replacing Front Section Of Engine Support To Left Wheel Arch: Notes

Read contents of, see BODY, GENERAL .

The reduced-weight aluminum front end structure (GRAV) is used on this vehicle.

Observe specific procedure. See 4100... BONDING ALUMINUM ON ALUMINUM ; 4100... MATERIALS SCIENCE ; 4100... EMC SCREWS ; 4100... STRAIGHTENING ALUMINUM PARTS or 4100... GRINDING ALUMINUM PARTS .

Place vehicle on straightening bench.

Following new body parts are required (refer to EPC):

(1) Wheel arch, front
(2) Support carrier, bulkhead, outer
(3) Engine carrier, front
(4) Reinforcement bracket, front, spring support
(5) Reinforcement bracket, rear, spring support

The engine carrier is supplied with longer bolts for the E60 and E61. The bolts do not have to be shortened.

Fig 1: Wheel Arch, Support Carrier, Engine Carrier And Reinforcement Bracket

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Open rivet joints in areas (1) to (3).

Installation:

Use 3 rivets (size 13) in area (1).

Use 2 rivets (size 13) in area (4).

Use 3 rivets (size 13) in area (3).

Fig 2: Rivets Joint On Area

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NOTE: Engine carrier has been blanked out for purposes of clarity.

Spot-drill rivets in areas (1) and (2) from protruding rear side or grind and punch through.

Installation:

Use 5 rivets (size 13) in areas (1).

Use 2 rivets (size 13) in areas (1).

Fig 3: Rear Side Rivets

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Spot-drill rivets in area (1) from protruding rear side or grind and punch through.

Fig 4: Rear Side Rivet

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Open rivet joints in areas (1) to (3).

Installation:

Use 5 rivets (size 13) in area (1).

Use 4 rivets (size 13) in area (2).

Use 3 rivets (size 13) in area (3).

Use 4 rivets (size 13) in area (4).

Use 7 rivets (size 13) in area (5).

Fig 5: Rivets On Area

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Open rivet joints in areas (1) to (3).

As a rule, part of the punch rivet remains in the rear engine carrier in area (2). Do not drill out remnants. Set blind rivets next to punch rivets.

Open weld joint in area (1).

Installation:

Use 4 rivets (size 13) in area (1).

Use 5 rivets (size 13) in area (2)

Use 6 rivets (size 13) in area (3).

Install 2, see EMC SCREWS in area (1).

Fig 6: Rivets On Area

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Open rivet joints in area (1) to (3).

Open weld joint in area (4).

Installation:

Use 3 rivets (size 13) in area (1).

Use 6 rivets (size 13) in area (2).

Use 1 rivet (size 13) in area (3).

Install 2, see EMC SCREWS in area (2).

Fig 7: Rivets On Area

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Drill out rivet joint in area (1).

Installation:

Use 1 rivet (size 15) in area (1).

Fig 8: Rivets Joint On Area

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Cut open engine carrier in area (2) from opposite side and open rivets.

Installation:

Adjust new part to fit with straightening attachment or universal mount.

Drill holes for, see RIVETS .

Use 6 rivets (size 13) in areas (1).

For accessibility reasons, rivet retaining brackets in areas (1) to engine carrier first.

Rivets are omitted in area (2).

Fig 9: Engine Carrier And Rivets On Area

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Open rivet joints in areas (1) and (2).

As a rule, part of the punch rivet remains in the units compartment partition wall in areas (1) and (2). Drill out remnants.

Installation:

Carry over bores from units compartment partition wall to new part in area (2).

Use 3 rivets (size 13) in area (1).

Use 2 rivets (size 13) in area (2).

Fig 10: Rivets Joint On Area

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Open weld joints in areas (1) and (2).

Installation:

If necessary, replace brazed seams with MAG weld seams in area (1).

Use 2 rivets (size 13) in area (3).

Fig 11: MAG Weld Seams And Rivets On Area

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Open weld joints in areas (1).

Fig 12: Weld Joints On Areas

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Open weld joints in area (1).

Mark severance cut according to measurement a and cut inside A-pillar.

Measurement a = 47 mm from center of bore.

Fig 13: Weld Joints Area Dimension

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NOTE: When replacing right wheel arch:

Measurement a = 65 mm from center of bore.

Measurement b = 20 mm

Fig 14: Wheel Arch Dimension

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Different riveting-down elements, depending on the equipment specification, must be mounted on the new component.