41 11 028 Replacing Left Engine Carrier (Partial Replacement Before Front Axle)

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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.

Place vehicle on straightening bench.

Following new body parts are required:

(1) Partial section, engine carrier
(2) Bracket, diagonal strut
(3) Repair element (not shown)
(4) Screw (not shown)

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Removing carrier support

Mark severance cut (1) in accordance with dimension a and cut. Dimension a=125 mm

IMPORTANT: Clean engine support - measured min. 50 mm from cutting edge - thoroughly with cavity sealing wax remover.

Preparation of new part:

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Mark severance cut (1) in accordance with severance cut on vehicle and cut.

Fig 1: Identifying Severance Cut

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Open welded connections on holder (1) by grinding with a belt grinder from inside. Take off holder (1).

The inner surfaces of the engine support must be smooth. If necessary, surface-grind existing raised areas.

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Adjust new part to fit with set of attachments or universal mount. Drill hole (1) at side. Take dimensions for hole from repair element. Hole diameter 12 mm Remove new parts.

Installing engine support

NOTE: Display without alignment bracket or universal mount.

IMPORTANT: To avoid contact corrosion, do not sand the repair element in the area of the bonding surfaces. Grind bonding surfaces in engine support blank.

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Insert screw (2) in repair element (1). Clean all bonding surfaces with cleaning agent R1. Apply adhesive K1 to repair element.

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Carefully slide repair element (1) into body engine support. Make sure there is sufficient adhesive on the bonding surfaces.

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Push new part onto repair element and secure with alignment bracket or universal mount. Expand repair element with screw (1) until it rests on engine support and adhesive can be seen to emerge.

NOTE: Do not tighten bolt too tightly! Make sure the bonding surfaces are correctly aligned, especially on the engine end.

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In area (1) install 6 blind rivets N2.

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In area (1) install 2 blind rivets N2.

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Adjust holder (1) with diagonal strut to fit. In areas (2) and (3) set four 6.8 mm dia. holes. Remove holder (1) and deburr holes. Clean bonding surfaces (2) and (3) with cleaning agent R1. Apply adhesive K1 to bonding surfaces. Rivet bracket in area (2) with blind rivets N1. In area (3) use blind rivets N2.

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NOTE: Remove screw after adhesive has hardened. Seal separation point and hole with sealant.