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

Read contents of Body, General  . Refer to 41 0 Contents Of Body, General .

Remove or cover those vehicle components in the repair area which are susceptible to heat or dust.

Use only approved spot-welding apparatus  for repairs. Refer to 41 00... Workshop Equipment .

Place vehicle on straightening bench.

Following new body parts are required (refer to ELECTRONIC PARTS CATALOGUE ETK ):

• (1) Wheel arch, front
• (2) Support carrier, wheel arch, outer

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Open weld joints in area (1).

Installation: 

Weld new components in areas (2) additionally.

Apply window glass adhesive to cavity acoustic baffle  (3). Refer to 41 00... Installing A Cavity Acoustic Baffle (Expanded)  and/or 41 00... Installing A Cavity Acoustic Baffle (Not Expanded) .

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

Measurement a = 130 mm from front edge of sleeve

Installation: 

Weld in reinforcing panels  at all severance cuts. Refer to 41 00... Welding In Reinforcement Plate (Steel Plate) .

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Open weld joints in areas (1).

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Open weld joints in areas (1).

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Open weld joints in area (1).

Installation: 

If equipment 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.

Join both parts by spot-welding.

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Open weld joints in area (1).

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Preparation of new part: 

Mark new part in accordance with severance cut on car and cut.

Open weld joints in areas (1) on both sides.

Open weld joints in area (2).

Detach remainder of reinforcement from engine carrier.

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Installation: 

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

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In area (1) set ten 6.8 mm dia. bore holes for blind rivets N1

Installation note:  In area (2) 2 N5 punch rivets are used later.

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In areas (1) and (2) set 6.8 mm dia. bore holes for blind rivets N1: Area (1): 3 bore holes Area (2): 2 bore holes.

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In area (1) set seven 6.8 mm dia. bore holes for blind rivets N1. Installation note: In area (2) 1 N5 punch rivet is used later.

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In areas (1) to (4) set 6.8 mm dia. bore holes for blind rivets N1: Area (1): 5 bore holes Area (2): 3 bore holes Area (3): 1 bore hole Area (4): 8 bore holes

Installation note:  After adhesive has hardened install 2 EMC screws in areas (1) and (4).

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Set two 6.8 mm dia. holes for blind rivets N1 in area (1). Remove all new parts and deburr holes.

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Installation of engine support with wheel arch 

Clean bonding surfaces with cleaning agent R1. Apply adhesive K1 to bonding surfaces. Install new parts and reinforcement plates with alignment bracket or universal mount. Rivet new parts with blind rivets.

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Use 14 punch rivets N5 in area (2). Use 17 punch rivets N5 in area (3).

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In area (1) rivet new part with blind rivets N1. Use 2 punch rivets N5 in area (2). In area of severance cut, weld new part of engine support and reinforcement plates

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Riveted version: If damaged, the plate inserts must always be replaced with screwed versions on both sides of the vehicle.