41 11 091 Replacing Engine Support In Front Of Bulkhead, Left (Hybrid)

Observe procedure of REPAIR STAGE 3 .

Read contents of BODY, GENERAL .

Steel-aluminum composite construction is used on the 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

Following CONSUMABLES  are required:

Fig 1: Identifying Engine Support

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Removal of engine support 

Open welded connections in area (1).

Fig 2: Identifying Engine Support Welded Connections Area

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Drill out rivet connections in areas (1) and (2).

Drill diameter maximum 6.8 mm.

Fig 3: Identifying Drill Out Rivet Connections In Areas

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

Dimension a=140 mm

Fig 4: Identifying Engine Support Severance Cutting Dimension

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Roughly mark severance cuts (1) and cut.

Fig 5: Identifying Aluminum Spring Strut Dome

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Heat ADHESIVE AREAS  with hot air blower and release sheet sections (1) from spring strut dome.

Fig 6: Identifying Sheet Sections From Spring Strut Dome

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Open welded connections in area (1) and remove engine support section (2).

Fig 7: Identifying Engine Support Section Welded Connections Area

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Preparation of new part: 

Mark severance cuts on new parts in accordance with severance cuts on vehicle and cut.

Prepare REINFORCEMENT PLATES  at severance cuts.

Remove adhesive residue in areas (1).

Then FLAME-COAT  bonding surfaces of spring strut dome.

Grind bonding surfaces  on engine support blank accordingly. (Structure bonding)

Adjust new parts and reinforcement plates using alignment bracket or universal mount and secure.

Fig 8: Identifying Aluminum Spring Strut Dome And Adhesive Residue

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In areas (1) and (2), transfer 6.8 mm diameter bore holes for blind rivets to new part on engine support.

Fig 9: Identifying Drill Out Rivet Connections In Areas

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Installing engine support 

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.

Using blind rivets, rivet new parts in the areas where the rivets are fitted with adhesive N2.

Weld new parts identically to the series in the other gap areas.

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

Fig 10: Identifying Engine Support Bulkhead Cross Member

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MAG-weld new part in area (1).

To do so, apply 2 fillet welds at spacing of 15 mm. Length of fillet welds approx. 15 mm.

Fig 11: Identifying MAG-Weld Part Area

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