41 11 015 Replacing Left Engine Carrier With Wheel Arch

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Read contents of BODY, GENERAL .

The steel-aluminium mixed construction is used on the vehicle.

Observe specific procedure , see 41 00... Bonding aluminum on steel and 41 00... Riveting aluminum parts .

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, see 41 00... Workshop equipment .

Place vehicle on straightening bench.

Following new body parts are required:

(1) Wheel arch, front
(2) Engine carrier
(3) Support, wheel arch
(4) Reinforcement, support carrier

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

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Open weld joints in area (1).

Fig 2: Identifying Weld Joint Areas

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Mark severance cut in accordance with measurement a and cut support carrier.

Measurement a=50 mm before 20 mm dia. bore

Open weld joints in area (1).

Installation:

Weld in reinforcement plate at severance cut.

Fig 3: Identifying Weld Joint Areas

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Open weld joints in area (1).

Fig 4: Identifying Weld Joint Areas

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

Measurement a=50 mm before 20 mm dia. bore

Open weld joints in area (2).

Installation:

Weld in reinforcement plate at severance cut, see 41 00... Welding in reinforcement plate (steel plate) .

Open weld joints in area (1).

Fig 5: Identifying Weld Joint Areas And Cut Mark Area

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Fig 6: Identifying Weld Joint Areas

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Drill out riveted joints in area (2).

Open adhesive joints in areas (2) and (3), see 41 00... Opening bonded connections .

Installation:

Use 19 rivets (size 815) in area (1).

Use 4 rivets (size 815) in area (2).

Glue new component with adhesive K1 , see 41 00... Bonding aluminum on steel

Fig 7: Identifying Rivets Area And Adhesive Joints Area

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IMPORTANT: To avoid contact corrosion, do not grind the new part in the area of the adhesive surfaces , see 41 00... Overview of consumables (Electronic Parts Catalogue - EPC) .

Clean adhesive areas with isopropanol, acetone or spirit.

Preparation of new part:

Mark engine carrier in accordance with severance cut on vehicle and cut.

IMPORTANT: Cut outer metal sheet only.
Do not cut through reinforcement (1).

Cut weld joints on both sides in areas (2).

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

Fig 8: Identifying Weld Joint Areas And Reinforcement