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

Procedure OBSERVE  repair stage 3!

Read contents of BODY, GENERAL .

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

Spot-weld bonding is used on this vehicle. Observe specific procedure  . See 41 00... BONDING ALUMINUM ON STEEL  or 41 00... OPENING RIVET CONNECTIONS .

Use only approved SPOT-WELDING APPARATUS  for repairs!

Place vehicle on straightening bench.

Following new body parts are required (see ELECTRONIC PARTS CATALOGUE ):

• (1) Engine support
• (2) Engine support, rear
• (3) Wheel arch, front
• (4) Connection, wheel arch/entrance
• (5) Connection, side frame, rear
• (6) Shaped parts, carrier support, wheel arch, front (not shown)
  Fig 1: Identifying Engine Support, Wheel Arch/Entrance, Connection, Side Frame (Rear)

  Courtesy of BMW OF NORTH AMERICA, INC.

Following CONSUMABLES  are required:

Removal of engine support with wheel arch 

Open welded connections in area (1).

Fig 2: Identifying Engine Support Welded Connections In Area (Right Side)

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Open welded connections in area (1).

Fig 3: Identifying Engine Support Welded Connections In Area (Left Side)

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Roughly cut side frame connection along lines (1).

LOOSEN  spot-welded adhesive joints in areas (2).

Open welded connections in areas (3).

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

Open remaining welded connections in areas (1).

Fig 4: Identifying Side Frame Connection From Cavity Sealing

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Open welded connections in area (1).

Remove cavity sealing (2).

Fig 5: Identifying Cavity Sealing And Welded Connections Area

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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 Cutting 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 Wheel Arch With Engine Support

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Open welded connections in area (1).

Remove metal section (2).

Fig 8: Identifying Metal Section And Welded Connections Area

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Mark severance cut (1) and cut.

Open welded connections in area (2).

Fig 9: Identifying Engine Support Welded Connections Area

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View of engine support from front.

Open welded connections in area (1).

Fig 10: Identifying Engine Support (Front) Welded Connections Area

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Open welded connections in area (1).

Remove metal section (2).

Fig 11: Identifying Metal Section And Welded Connections Area

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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 Area

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

Dimension a = 20 mm

Fig 13: Identifying Severance Cutting Dimension

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

Fig 14: Identifying Rear Engine Support With Severance Cut On Vehicle

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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 Cutting 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 Drill Out Rivet Connections In Areas

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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 Wheel Arch With Engine Support

Courtesy of BMW OF NORTH AMERICA, INC.

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  . See 41 00... INSTALLING CAVITY SEALING (EXPANDED)  or 41 00... INSTALLING CAVITY SEALING (NOT EXPANDED)  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.

In case of smoke formation, stop the welding procedure and cool the welded area with compressed air if applicable.

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 Engine Support Weld Parts Area

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

Fig 20: Identifying Engine Support Weld Parts Area

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

Fig 21: Identifying Engine Support Welded Connections Area

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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. 15 mm.

Fig 22: Identifying MAG-Weld Part 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-Weld Part Areas

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