41 11 516 Replacing Front Left Or Right Support Carrier (Partial Replacement, Front Side Panel Removed)

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

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

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) Support carrier, wheel arch, outer

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Mark severance cut (1) through 20 mm dia. hole and cut carrier support.

Measurement a = 240 mm from edge of rectangular hole.

Open welded connections in areas (1).

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Open weld joints in area (1).

Remove carrier support section.

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Preparation of new part: 

Make severance cut on new part in accordance with severance cut on vehicle. Adjust new parts with add-on parts to fit and secure. Set two 6.8 mm dia. bore holes for blind rivets N1 in area (1).

For the severance cut, create a reinforcement plate from the trim of the new part. In area of reinforcement plate (1) set six 4.3 mm dia. bore holes for blind rivets N3. Remove new part again and deburr bore holes.

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Installing carrier support 

Clean all bonding surfaces (1) on vehicle and on new part with cleaning agent R1. Apply adhesive K5a to bonding surfaces.

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Install new part with add-on parts and rivet.

In area (2) rivet new part with 2 punch rivets N5. Use 6 punch rivets N5 in area (3). In area of reinforcement plate (4) use 6 blind rivets N3.

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In area (1) rivet new part with 2 blind rivets N1.

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