41 11 071 Replacing Engine Support With Front Left Wheel Arch In Front Of Bulkhead

Follow procedures for REPAIR STAGE 3 .

Read contents of BODY, GENERAL .

Spot-weld bonding is used on this vehicle. Observe specific PROCEDURE .

Use only an approved SPOT-WELDING APPARATUS  for repairs.

Place vehicle on straightening bench.

The following new body parts are required:

• (1) Wheel arch, front
• (2) Extension, wheel arch carrier support
• (3) Shaped part, wheel arch carrier support (not shown)
  Fig 1: Identifying Front Wheel Arch And Carrier Support Extension

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The following consumables are required.

Removal: 

Mark severance cut (1) at component edge and cut.

Mark severance cut (2) as pictured and cut.

LOOSEN  spot-welded adhesive joints in area (3).

Open welded connections in area (4).

Release metal section from cavity sealing (5) and remove.

Remove cavity sealing (5).

Fig 2: Identifying Cutting Lines, Welded Connections, Spot-Welded Adhesive Joints, And Cavity Sealing

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Open welded connections in area (1).

Fig 3: Identifying Area Of Welded Connections

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Open welded connections in area (1).

Fig 4: Identifying Area Of Welded Connections

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Open welded connections in areas (1) and (2).

Fig 5: Locating Welded Connections

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Open welded connections in area (1).

Fig 6: Identifying Area Of Welded Connections

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Open welded connections in area (1).

Fig 7: Identifying Area Of Welded Connections

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Mark severance cut (1) roughly as pictured and cut engine support.

Open welded connections in area (2) and remove engine support (3) with wheel arch.

Fig 8: Identifying Engine Support, Cutting Line, And Welded Connections

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Open welded connections in areas (1) by grinding and remove residual section of engine support (2).

Fig 9: Locating Welded Connections And Residual Section Of Engine Support

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Preparation of new part: 

Mark and disconnect severance cut on the new part according to the severance cut on the vehicle + 20 mm added material (1).

Fig 10: Identifying Severance Cutting Area

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Release welded connections and remove non-required components (1) from new part.

Fig 11: Identifying Non-Required Components

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Mark severance cut in accordance with dimension and cut.

Measurement "a" = approx. 145 mm from component edge.

Cut outer metal panel only.

Open welded connections in area (1).

Remove metal section (2).

Fig 12: Identifying Cutting Dimension, Metal Section, And Welded Connections

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Prepare REINFORCEMENT PLATE  at severance cut.

Adjust new parts to fit with alignment bracket or universal mounting. 

Adjust extension, wheel arch carrier support new part to fit and secure.

In areas (1) and (2), make Ø 6.8 mm bore holes for blind rivet.

In area (3), make 4x Ø 4.2 mm bore holes for blind rivet N3.

Remove new parts and deburr bore holes.

Fig 13: Identifying Locations For Creating Blind Rivet Bore Holes

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Installation: 

Install new part with alignment bracket or universal mount and secure.

Weld new part in area (1).

Fig 14: Identifying Area Of Welded Connections

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Weld new part in the areas (1) and (2).

Fig 15: Identifying Areas For Welding New Part

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Install sheet metal section (1) and reinforcement plate and weld in areas (2) and (3).

Fig 16: Identifying Sheet Metal Section And Areas For Welding

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Weld new part in area (1).

Fig 17: Identifying Area Of Welded Connections

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Weld new part in the areas (1) and (2).

Fig 18: Identifying Areas For Welding New Part

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Weld new part in area (1).

Fig 19: Identifying Area For Welding New Part

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Installation: 

Clean bonding surfaces with cleaning agent R1.

Apply adhesive to bonding surfaces.

Apply sealant to CAVITY SEALING .

Install extension, wheel arch carrier support.

In areas (1) and (2), rivet new part with blind rivets N7.

In area (3) rivet new part with blind rivets N3.

In areas (4) and (5), rivet new part with punch rivets N5.

Fig 20: Identifying Areas For Riveting New Part

Courtesy of BMW OF NORTH AMERICA, INC.