41 11 043 Replacing Front Section Of Left Engine Support

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) Engine carrier, front
(2) Support carrier, bulkhead, outer
(3) Reinforcement bracket, front, spring support
(4) Reinforcement bracket, rear, spring support
(5) Extension, engine carrier

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 For Front, Rear Support

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT: Use the mouthpiece (steel or plastic) with 10 mm inside diameter in the following work step to extract the rivets in areas (1) and (2). Using the plastic mouthpiece with 14 mm inside diameter will result in damage to the wheel arch!

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

Open, see EMC WELD SEAM in area (3).

Installation:

Use 8 rivets (size 13) in areas (1).

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

Use 4 rivets (size 13) in areas (3).

Fig 2: Rivet Joints With Rivets And EMC Weld Seam

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

Use 2, see EMC SCREWS in each case (4 x in total) in areas (1) and (2).

Fig 3: EMC Screws On Area

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: Right side only:

Open rivet joints in areas (1).

Installation:

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

Fig 4: Rivet Joints With Rivets On Area

Courtesy of BMW OF NORTH AMERICA, INC.

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 area (2).

Fig 5: Rear Side Rivets

Courtesy of BMW OF NORTH AMERICA, INC.

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

Installation:

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

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

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

Fig 6: Rivet Joints With Rivets On Area

Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 7: Rear Side Spot-Drill Rivets

Courtesy of BMW OF NORTH AMERICA, INC.

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 8: Rivet Joints With Rivets On Area

Courtesy of BMW OF NORTH AMERICA, INC.

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

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 9: Weld Joint And Rivets On Area

Courtesy of BMW OF NORTH AMERICA, INC.

Open rivet joints in area (1).

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).

Drill holes for, see RIVETS .

Fig 10: EMC Screws And Rivets On Area

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

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

Fig 11: Rivet On Area

Courtesy of BMW OF NORTH AMERICA, INC.

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

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 (3).

Installation:

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

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

Use 7 rivets (size 13) in area (2).

Apply as much adhesive in area (2) that the adhesive emerges from the flange during riveting.

Fig 12: Rivet, Weld Joint And Rear Engine Carrier On Areas

Courtesy of BMW OF NORTH AMERICA, INC.

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

Installation:

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

Set rivets from inside.

Fig 13: Rivet On Area

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

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

For reasons of accessibility, bond and rivet retaining brackets in areas (1) to engine carrier first after adjusting to fit.

Bond in area (2) only.

Fig 14: Rivets And Bond On Area

Courtesy of BMW OF NORTH AMERICA, INC.

Preparation of new part:

Shorten new part in area (1) to a length of 50 mm by 7 mm.

Measurement a=35 mm

Fig 15: New Part Area Dimension

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

Bend open bulkhead support carrier (2) slightly in area (1).

Adjust all new parts to fit with straightening attachment or universal mount. Drill holes for, see RIVETS .

Bond engine carrier first and then rivet.

Slide engine carrier extension in direction of arrow underneath bulkhead support carrier (2).

see BOND new part.

see RIVET new part.

Align bulkhead support carrier (2) in area (1) until flush.

Fig 16: Locating Bulkhead Support Carrier On Area

Courtesy of BMW OF NORTH AMERICA, INC.

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

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

Installation:

AWD only:

After painting on both sides of car, stick zinc foil (1) to center bolting point (2) of front axle carrier.

Fig 17: Zinc Foil And Centre Bolting Point Of Front Axle Carrier

Courtesy of BMW OF NORTH AMERICA, INC.