41 11 516 Eft Support Carrier Replacement

WARNING: This page is about a different car, the 2010 BMW 535xi, 2009 BMW 535xi, and 2008 BMW 535xi. However, it is still accessible from the selected car via links, so may be relevant.

Read contents of BODY, GENERAL .

The reduced-weight aluminium front end structure (GRAV) is used on this vehicle.

Observe relevant procedures in BODY, GENERAL .

Place vehicle on straightening bench.

NOTE: Damaged support carriers without cracks, sharp-edged damage or holes can be straightened. After repair work, check support carrier again for cracks.
Observe frame alignment control dimensions!

Following new body parts are required :

Support carrier partial section

Fig 1: Support Carrier Partial Section

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Open riveted joints in areas (1).

Open EMC weld seam in area (1).

Installation:

Carry over hole pattern from engine carrier to engine mounting in area (1).

Fig 2: Riveted Joints Areas

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Installation:

Use 2 EMC screws in areas (1).

Use 2 EMC screws in areas (3).

If an engine carrier partial replacement has been carried out, 2 EMC screws must be used in areas (2).

Fig 3: EMC Screws Areas

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NOTE: View from above

Mark severance cut in accordance with measurements a and b and cut support carrier at top.

Measurement a = 77 mm from recess

Measurement b = 215 mm from center of bore

Fig 4: Severance Cut Mark In Accordance With Measurements A And B And Cut Support Carrier At Top

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NOTE: View from below

Mark severance cut in accordance with measurement a and cut support carrier at bottom.

Measurement a = 57 mm parallel to edge of spring support at front

Fig 5: Severance Cut Mark In Accordance With Measurement A And Cut Support Carrier At Bottom

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Installation:

Carry over bores from engine carrier to new part in areas (1).

Adapt new part with straightening attachment or universal mount in area (2).

Drill through new part and engine carrier together.

Use 4 rivets (size 13) in areas (1).

IMPORTANT: If a partial replacement has already been carried out on the engine carrier, rivets (size 15) must be used in areas (1).

Fig 6: Rivets Areas

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Installation:

Drill out rivets with 4 mm dia.

Drill holes for 6 rivets in area (1).

Drill holes for 5 rivets in area (2).

Drill through all holes through both parts together.

Coat all contact faces with adhesive.

Join parts and rivet.

Fig 7: Rivets Area

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Installation:

Use 2 EMC screws after bonding new parts in areas (1).

Fig 8: EMC Screws Areas

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Installation:

Left side only:

Rivet down blind rivet nut 41 32 8 257 508 in bore (1).

Fig 9: Bore

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Installation:

Right side only:

Rivet down blind rivet nut 41 12 8 223 082 in bore (1).

Fig 10: Bore

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Installation:

Seal cutting line and rivets with sprayable body sealing compound .

Spray gun required for body sealing compound .

Different riveting-down elements, depending on the equipment specification, must be mounted on the new component.

Required tools are featured on the Workshop Equipment Planning CD (WEP).