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

Observe procedure for REPAIR STAGE 3 .

Read contents of BODY, GENERAL .

Steel-aluminium composite construction is used on the vehicle. Observe specific PROCEDURE .

Spot-weld bonding is used on this vehicle. Observe specific procedure for repairs. See BONDING ALUMINIUM ON STEEL  and OPENING RIVETED CONNECTIONS .

Use only approved SPOT-WELDING APPARATUS  for repairs.

Place vehicle on straightening bench.

The following new body parts are required:

• (1) Engine support
• (2) Engine support, rear
• (3) Wheel arch, front
• (4) Connection, wheel arch/entrance
• (5) Connection, side frame, rear
  Fig 1: Identifying New Body Parts Required

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• (6) Shaped parts, carrier support, wheel arch, front (not shown)

Following CONSUMABLES  are required:

Removal of engine support with wheel arch 

Open welded connections in area (1).

Fig 2: Identifying Welded Connections

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Open welded connections in area (1).

Fig 3: Identifying Welded Connections

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OPEN  spot-welded adhesive joints in areas (1).

Open welded connections in area (2).

Roughly cut side frame connection along lines (3).

Release the side frame connection from the cavity sealing (4) and remove.

Fig 4: Identifying Welded Connections, Cutting Lines, And Cavity Sealing

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Open welded connections in area (1).

Remove cavity bulkhead (2).

Fig 5: Identifying Cavity Bulkhead And Welded Connections

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

Dimension "a" = 140 mm

Fig 6: Identifying Engine Support Severance Cut Dimension

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Drill out  rivet connections in area (1).

Open bonded connections in area (1).

Remove wheel arch (2) with engine support.

Fig 7: Identifying Riveted/Bonded Connections And Wheel Arch

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Open welded connections in area (1).

Remove metal section (2).

Fig 8: Identifying Metal Section And Welded Connections

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Mark severance cut (1) and cut.

Open welded connections in area (2).

Fig 9: Identifying Severance Cut And Welded Connections

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View of engine support from front.

Open welded connections in area (1).

Fig 10: Identifying Welded Connections

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Open welded connections in area (1).

Remove metal section (2).

Fig 11: Identifying Metal Section And Welded Connections

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New part preparation 

Open welded connections in areas (1). Remove metal section (2).

Fig 12: Identifying Metal Section And Welded Connections

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Mark severance cut (1) in accordance with Dimension "a" and cut.

Dimension "a" = 20 mm

Fig 13: Identifying Severance Cut Dimension

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Mark rear engine support in accordance with severance cut on vehicle and cut (1).

Fig 14: Identifying Severance Cut Line

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Mark severance cut (1) in accordance with Dimension "a" and cut.

Dimension "a" = 15 mm

Remove metal section (2).

Fig 15: Identifying Metal Section And Severance Cut Dimension

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Prepare REINFORCEMENT PLATES  at severance cuts.

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

In areas (1) and (2), set 19 6.8 mm diameter bore holes for blind rivets N2.

Arrangement of blind rivets is analogous to the series.

Fig 16: Identifying Areas For Blind Rivet Bore Holes

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In area (1) transfer 6 6.8 mm diameter bore holes for blind rivets N2 on new part.

Remove new parts and deburr bore holes.

Fig 17: Identifying Severance Cut And Welded Connections

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Installation of engine support with wheel arch 

Clean bonding surfaces with cleaning agent R1.

Apply adhesive to bonding surfaces.

Apply sealant to new CAVITY SEALING  of wheel arch carrier support.

Install new parts and reinforcement plates with alignment bracket or universal mount.

Rivet the new parts analogous with the series in the adhesive areas.

Weld the new parts in the remaining joint areas.

Fig 18: Identifying Bulkhead Cross Member

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View from below.

Weld new parts in area (1) same as the series.

Fig 19: Identifying Welding Area

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Weld new parts in area (1) same as the series.

Fig 20: Identifying Welding Area

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Weld new parts in area (1) same as the series.

Fig 21: Identifying Welded Connections

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MAG-weld new part in area (1).

To do so, apply 2 fillet welds at distance of approx. 20 mm. Length of fillet welds approx. 10 mm.

Fig 22: Identifying MAG-Weld Area

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MAG-weld new part in areas (1).

To do so, apply 10 mm long fillet welds at spacing of 15 mm.

Fig 23: Identifying MAG-Welding Areas

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