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

Observe procedure for REPAIR STAGE 3 .

Read contents of BODY, GENERAL .

STRIP DOWN VEHICLE .

Place vehicle on straightening bench.

Following new body parts are required (refer to CONSUMABLES ):

• (1) Wheel arch, front
• (2) Carrier support, outer wheel arch section

Following CONSUMABLES  are required:

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Material	Quantity
Adhesive K1	1
Blind rivets N1	41
Punch rivets N5	38
EMC screws	2
Cleaning agent R1	1
Cavity sealing wax remover	1
Sealant D1

Removal of front section of engine support with wheel arch: 

Open welded connections in area (1).

Installation note: 

New parts are bonded and riveted in areas (2).

Apply sealant to cavity sealing  . See 41 00... INSTALLING CAVITY SEALING (EXPANDED)  or 41 00... INSTALLING CAVITY SEALING (NOT EXPANDED)  (3).

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Mark severance cut (1) in accordance with dimension a and cut engine support.

Dimension a=130 mm from front edge of bush

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Open welded connections in areas (1).

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Open welded connections in areas (1).

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Open welded connections in area (1).

Installation note: 

If equipment compartment partition wall (2) is damaged, cut along line (3).

Mark severance cut on new part according to severance cut on vehicle + 20 mm material extra and cut.

Bond both parts overlapping and rivet. Depending on accessibility, use punch rivets N4 and blind rivets N3.

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Open welded connections in area (1).

Remove front section of engine support with wheel arch.

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Preparation of new part: 

Mark and cut the severance cut on new part as per the severance cut on the vehicle.

Prepare REINFORCEMENT PLATES  at severance cut.

Open welded connections in areas (1) on both sides.

Open welded connections in area (2).

Detach remainder of reinforcement from engine support.

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Adjust new parts to fit with alignment bracket or universal mount and secure.

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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.

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.

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