Preparing New Part

Further information is available.

• Remove adhesive residue on the bonding surfaces (1) through (3).

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• Seal the hole (1) by MAG weld.

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• Adjust new parts with an alignment bracket or a universal fixture and secure.
• Prepare areas (1) and (2) for structural adhesive bonding of steel on aluminum.
• Transfer the holes to the new part in areas (1) and (2). Drill holes with 0 6.8 mm.

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• Prepare area (1) for structural adhesive bonding of steel on aluminum with blind rivets.
• Transfer the holes to the new part in area (1). Drill the holes with dia. 6.8 mm.

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• Prepare areas (1) and (2) for structural adhesive bonding with blind rivets of aluminum on aluminum.
• Transfer the positions of the holes from the engine mount to the spring support in areas (1). Drill out holes to dia. 6.8 mm.
  NOTE: TECHNICAL INFORMATION 
  For additional information see : 41 00... Transferring hole pattern.
• Transfer the hole patterns from the engine mount to the spring support in areas (2). Drill out holes to dia. 6.8 mm.

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• Prepare area (1) for structural adhesive bonding with blind rivets of aluminum on aluminum.
  NOTE: TECHNICAL INFORMATION 
  For additional information see: 41 00... Transferring hole pattern.
• Transfer the hole pattern of the engine mount to the new part in area (1). Drill out holes to dia. 6.8 mm.

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• Fit in new part.
• Prepare areas (1) for joining by welding.
• Prepare area (2) for structural adhesive bonding with blind rivets of aluminum on steel.
• In the area (2), drill holes to 0 6.8 mm. Select the number and position in line with the self-tapping screws of the standard production.
• Prepare area (3) for structural adhesive bonding with blind rivets of steel on steel.

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  NOTE: TECHNICAL INFORMATION 
  For additional information see: 41 00... Transferring hole pattern.
• Transfer the hole pattern to the new part in area (3). Drill the holes with dia. 6.8 mm.
• Prepare area (1) for structural adhesive bonding with blind rivets of aluminum on steel.
• Transfer the hole positions from the wheelhouse to the spring support in area (1). Drill out holes to dia. 6.8 mm.

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• Prepare area (1) for structural adhesive bonding of steel on aluminum with blind rivets.
• Transfer the hole positions from the engine compartment bulkhead to the spring support in area (1). Drill out holes to dia. 6.8 mm.

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• Prepare area (1) for structural adhesive bonding with blind rivets of aluminum on aluminum.
• Prepare area (2) for structural adhesive bonding of steel on aluminum with blind rivets.
• Set holes Ø 6.8 mm in the areas (1) and (2). Get the number and position of the holes from the standard parts.

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• Prepare the area (1) for the structural adhesive bonding of steel on steel.

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• Prepare areas (1) and (2) for structural adhesive bonding with punch rivets of aluminum on aluminum and of steel on aluminum.

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• Mark and make the separating cut (1) on the new part according to the separating cut (2) on the vehicle with a material allowance of 15 - 20 mm.
• In areas (3), prepare overlapping joining by welding.

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• Fit in new part section.
• Prepare area (1) for structure bonding steel on steel.
• Prepare area (2) for joining by welding.

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• Set a bore Ø 6.8 mm centrally in area of recess (1).
• Set two holes (2) Ø 6.8 mm according to dimension (a).

  Dimension (a) = 70 mm from the component edge

• Transfer holes (3) to the new part and drill with Ø 6.8 mm.
• Adapt the new part in the area of the existing bores (4) for setting blind rivets if applicable.
• Remove new parts and deburr bores.

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• Position holder (1).
• Prepare area (2) for structural adhesive bonding of aluminum on aluminum.
• In the area (2), drill holes to Ø 6.8 mm. Select the number and position in line with the self-tapping screws of the standard production.

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  Replacing the coarse thread bolts and threaded weld bolts, surface steel 

  NOTE: Schematic diagram is for example purposes. Some parts may differ in certain details.
• Take the number and position from the component to be replaced or the installed parts.
• Replace the coarse thread bolt (1) and the threaded weld bolt (2).

  Parts:  Coarse thread bolt (1), threaded weld bolt (2)

• Weld the coarse thread bolt (1) and threaded weld bolt (2) onto the new part.

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  Check ground pins and replace if necessary 

  NOTE: Schematic diagram is for example purposes. Some parts may differ in certain details.
• Check the ground pins (1) for stability and replace if necessary.

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