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

Read contents of BODY, GENERAL .

Follow procedure for REPAIR STAGE 2 .

STRIP DOWN  vehicle.

The following new body parts are required (refer to OVERVIEW OF CONSUMABLES ):

• (1) Outer wheel arch carrier support
• (2) Carrier support, inner wheel arch section
• (3) Holder DSC (right side of vehicle only)

Following CONSUMABLES  are required:

Fig 1: Identifying Outer And Inner Wheel Arch Carrier Support And Holder DSC

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Removing carrier support 

Open welded connections in area (1).

Fig 2: Identifying Engine Support Welded Connections Areas

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Right side of vehicle only:

Open weld joint in area (1).

Fig 3: Identifying Carrier Support Weld Joint Area

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Fig 4: Identifying Carrier Support Severance Cutting Area

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Mark severance cuts in accordance with specified dimensions and cut.

Only sever outer panel  at severance cut (2)!

Dimension a = approx. 40 mm from bore hole Ø 20 mm.

Dimension b = approx. 50 mm from severance cut (1).

Open welded connections in areas (3).

Remove carrier support sections.

New part preparation 

Mark new part in accordance with severance cut on vehicle (1) + 20 mm extra material and cut (2).

Fig 5: Identifying Carrier Support Severance Cutting Dimension

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Mark new part in accordance with severance cut on vehicle and cut (1).

For the severance cut, create a REINFORCEMENT PLATE  (welded) from the trim of the new part.

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

Fig 6: Identifying Reinforcement Plate Severance Cutting Part

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In areas (1) to (3), introduce Ø 6.8 mm bore holes for blind rivets N1.

Fig 7: Identifying Bore Holes For Blind Rivets (N1) Area

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In areas (1) and (2) introduce one Ø 6.8 mm bore hole for blind rivets N1.

Fig 8: Identifying Bore Hole Areas For Blind Rivets N1

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Prepare area of overlap (1) for plug-welding.

Fig 9: Identifying Plug-Welding Area

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Prepare area of reinforcement plate (1) for plug-welding.

Fig 10: Identifying Reinforcement Plate For Plug-Welding

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Right side of vehicle only:

Fit DSC (1) holder.

In areas (2), introduce three bore holes Ø 4.2 mm for blind rivets N3.

Remove new parts and deburr bore holes.

Fig 11: Identifying DSC Holder And Blind Rivets (N3) Area

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Installing carrier support 

Clean all bonding surfaces with cleaning agent R1.

Apply adhesive to bonding surfaces.

Install new parts with add-on parts and rivet with blind rivets.

Plug-weld in area of overlap (1).

At severance cut additionally set 4 metal active gas weld seams each with a length of 1 cm.

Fig 12: Identifying Plug-Welding Area

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Install and weld reinforcement plate in area of severance cut.

Clean bonding surfaces with cleaning agent R1.

Apply adhesive to bonding surfaces, and adjust and fix new part.

In areas (1) and (2), rivet each new part with 9 punch rivets N5.

In area of severance cut, weld new part and reinforcement plate.

Fig 13: Identifying Carrier Support Adhesive Rivet Areas

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After hardening of adhesive, in areas (2) and (3) install one EMC SCREW  in each case.

Fig 14: Identifying Bore Holes For Blind Rivets (N1) Area

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