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

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Observe procedure of REPAIR STAGE 3 .

Read contents of BODY, GENERAL .

Spot-weld bonding is used on this vehicle. Observe specific procedure . See 41 00... SPOT-WELD BONDING STEEL COMPONENTS or 41 00... OPENING BONDED CONNECTIONS .

Use only approved SPOT-WELDING APPARATUS for repairs.

Place vehicle on straightening bench.

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

(1) Wheel arch, front
(2) Outer wheel arch carrier support
(3) Carrier support end plate
(4) A-pillar bulkhead
(5) Shaped part, wheel arch carrier support (not shown)

Fig 1: Identifying Wheel Arch (Front), Outer Wheel Arch Carrier Support, Carrier Support End Plate And A-Pillar Bulkhead
Courtesy of BMW OF NORTH AMERICA, INC.

Removal of engine support with wheel arch

Mark severance cut (1) roughly as pictured and cut.

Open spot-welded adhesive joints in area (2)

Open welded connections in area (3).

Release metal section from cavity sealing (4) and remove.

NOTE: Separating cut (1) is only required for removal.

Fig 2: Identifying Metal Section From Cavity Sealing And Spot-Welded Adhesive Joints Area

Courtesy of BMW OF NORTH AMERICA, INC.

Mark severance cut (1) as pictured and cut.

IMPORTANT: Cut outer metal panel only.

Open welded connections in areas (2).

Remove carrier support end plate metal section (3).

Fig 3: Identifying Carrier Support End Plate Metal Section

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Mark severance cut (1) as pictured and cut.

Fig 4: Identifying Engine Support Severance Cutting Mark

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Open welded connections in area (1).

Fig 5: Identifying Engine Support Welded Connections Area

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Open weld joint in area (1).

Fig 6: Identifying Engine Support Weld Joint Area

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

Dimension a = 110 mm from engine support edge.

Open welded connections in area (1).

Remove partial section (2.

Fig 7: Identifying Engine Support Welded Connections Areas

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Fig 8: Identifying Bulkhead Cross Member Welded Connections Areas

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Mark and cut severance cut (1) at a distance of approx. 25 mm to bulkhead cross member (2).

Open welded connections in areas (3).

Remove engine support with wheel arch.

NOTE: New part is installed with overlap in area of severance cut (1).

New part preparation

Release the applicable welded connections and remove metal sections that are not needed from the new wheel arch.

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

Open welded connections in areas (2).

Remove metal section (3).

NOTE: The metal section (3) is needed to close the engine support.

Fig 9: Identifying Metal Section Welded Connections Areas

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Perform severance cut (1) according to illustration.

Carry out severance cut (2) in accordance with severance cut on vehicle + 15 mm extra material.

Mark further severance cuts in accordance with vehicle and cut.

Prepare REINFORCEMENT PLATES at severance cuts.

Adjust new parts to fit with alignment bracket or universal mounting.

Fig 10: Identifying Reinforcement Plates Severance Cutting Area

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Adjust the new A-pillar bulkhead (1) in the area of the reinforcement plate (2).

(The new A-pillar bulkhead is set onto the reinforcement plate)

Fig 11: Identifying A-Pillar Bulkhead Area Of Reinforcement Plate

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Installation of engine support with wheel arch

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

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

Weld the new part to the body in the areas (1) and (2)!

Fig 12: Identifying Engine Support With Wheel Arch Weld Part Area

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: The bulkhead cross member (1) is filled with low-flammable cavity foam.

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

(2) Bulkhead
(3) Engine support

Fig 13: Identifying Bulkhead Cross Member Filled With Low-Flammable Cavity Foam
Courtesy of BMW OF NORTH AMERICA, INC.

Weld new components in area (1) additionally.

Fig 14: Identifying Engine Support With Wheel Arch Weld Components Area

Courtesy of BMW OF NORTH AMERICA, INC.