41 11 201 Replacing The Carrier Support Before The Wheel Arch On The Left

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Read contents of BODY, GENERAL .

Follow procedures for REPAIR STAGE 2 .

STRIP DOWN vehicle.

The following new body parts are required:

(1) Carrier support, outer wheel arch section
(2) Wheel arch inner section support member
(3) Carrier support end plate

The following consumables are required:

Fig 1: Identifying Carrier Support, Support Member, And Carrier Support End Plate

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Material	Quantity
Adhesive K1	1
Punch rivets N5	33
Sealant D1
Cleaning agent R1	1

Removing carrier support

Open welded connections in areas (1).

Fig 2: Locating Welded Connections

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Open welded connections in area (1).

Fig 3: Identifying Welded Joint

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Mark severance cut (1) in accordance with dimension and detach carrier support.

Dimension "a" = approx. 35 mm from 15 mm diameter hole.

Fig 4: Identifying Carrier Support Severance Cut Dimension

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Detach welded connections (1) and remove holder (2).

Fig 5: Identifying Holder And Welded Connections

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Mark severance cut in accordance with dimension and cut.

IMPORTANT: Cut outer metal panel only.

Dimension "a" = approx. 55 mm from previous separation cut.

Open weld joints in areas (1) and remove metal panel section.

Fig 6: Identifying Welded Joints And Cutting Line Dimension

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New part preparation

Mark severance cut (1) on inside part of carrier support in accordance with severance cut on vehicle and cut.

Release welded connections (2) for holder.

Mark severance cut on outside part of carrier support in accordance with severance cut on vehicle and disconnect.

Fig 7: Identifying Cutting Line And Welded Connections

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Adjust new parts with add-on parts to fit and secure.

Prepare REINFORCEMENT PLATES (welded) at severance cuts (1).

Prepare new parts in engine support area (2) for plug-welding.

NOTE: In areas (3), the new components are joined using the adhesive riveting method.

Fig 8: Identifying Severance Cuts, Plug-Welding Area, And Adhesive Bonding-Riveting Area

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In area (1), prepare new part and engine support for plug-welding.

NOTE: In areas (2), the new parts are joined using the adhesive riveting method.

Fig 9: Identifying Plug-Welding Area And Bonding-Riveting Area

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IMPORTANT: Structure bonding.
Observe PREPARATION OF BONDING SURFACES .

Installing carrier support

Install new part (carrier support for inner wheel arch section) and reinforcement plate and weld in place.

Install reinforcement plate in area of severance cut (1) and weld in place.

Clean all bonding surfaces with cleaning agent R1.

Apply adhesive to bonding surfaces, fit new component (outside part of carrier support) and fasten.

In areas (2) and (3), rivet new part with punch rivets N5.

Fig 10: Identifying Severance Cut And Areas For Punch Rivets

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Area	Number
2	11
3	10

Weld new part and reinforcement plate in the area of severance cut (1).

IMPORTANT: Risk of damage to adhesive area.
Avoid applying excessive heat to the neighboring adhesive areas.

NOTE: Do not seal new parts in the adhesive rivet areas (2) and (3). (visible area)

Apply adhesive to bonding surfaces, fit new part carrier support end plate and secure.

In areas (2), rivet new part with 12 punch rivets N5.

Weld new part in area (1).

IMPORTANT: Risk of damage to adhesive area.
Avoid applying excessive heat to the neighboring adhesive areas.

Fig 11: Identifying Plug-Welding Area And Bonding-Riveting Area

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NOTE: Do not seal new parts in the area of the adhesive riveting. (visible area)

Remove excess adhesive.

Do not use any cleaning agents containing solvents.