41 11 023 Front Section Of Engine Support To Left Wheel Arch Replacement

WARNING: This page is about a different car, the 2010 BMW 550i, 2009 BMW 550i, and 2008 BMW 550i. However, it is still accessible from the selected car via links, so may be relevant.

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

Observe specific procedure .

Place vehicle on straightening bench.

Following new body parts are required:

Wheel arch, front
Support carrier, bulkhead, outer
Engine carrier, front
Reinforcement bracket, front, spring support
Reinforcement bracket, rear, spring support

The engine carrier is supplied with longer bolts for the E60 and E61. The bolts do not have to be shortened.

Fig 1: Wheel Arch, Support Carrier, Engine Carrier And Reinforcement Bracket

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Open rivet joints in areas (1) to (3).

Installation:

Use 3 rivets (size 13) in area (1).

Use 2 rivets (size 13) in area (4).

Use 3 rivets (size 13) in area (3).

Fig 2: Open Rivet Joints In Areas

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NOTE: Engine carrier has been blanked out for purposes of clarity.

Spot-drill rivets in areas (1) and (2) from protruding rear side or grind and punch through.

Installation:

Use 5 rivets (size 13) in areas (1).

Use 2 rivets (size 13) in areas (1).

Fig 3: Spot-drill rivets in areas (1) and (2) from protruding rear side or grind and punch through

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Spot-drill rivets in area (1) from protruding rear side or grind and punch through.

Fig 4: Spot-Drill Rivets In Area (1)

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Open rivet joints in areas (1) to (3).

Installation:

Use 5 rivets (size 13) in area (1).

Use 4 rivets (size 13) in area (2).

Use 3 rivets (size 13) in area (3).

Use 4 rivets (size 13) in area (4).

Use 7 rivets (size 13) in area (5).

Fig 5: Open Rivet Joints In Areas

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Open rivet joints in areas (1) to (3).

As a rule, part of the punch rivet remains in the rear engine carrier in area (2). Do not drill out remnants. Set blind rivets next to punch rivets.

Open weld joint in area (1).

Installation:

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

Use 5 rivets (size 13) in area (2)

Use 6 rivets (size 13) in area (3).

Install 2 EMC screws in area (1).

Fig 6: Open Rivet Joints In Areas (1) To (3)

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Open rivet joints in area (1) to (3).

Open weld joint in area (4).

Installation:

Use 3 rivets (size 13) in area (1).

Use 6 rivets (size 13) in area (2).

Use 1 rivet (size 13) in area (3).

Install 2 EMC screws in area (2).

Fig 7: Rivet Joint Areas

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Drill out rivet joint in area (1).

Installation:

Use 1 rivet (size 15) in area (1).

Fig 8: Drill Out Rivet Joint

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Cut open engine carrier in area (2) from opposite side and open rivets.

Installation:

Adjust new part to fit with straightening attachment or universal mount.

Drill holes for rivets .

Use 6 rivets (size 13) in areas (1).

For accessibility reasons, rivet retaining brackets in areas (1) to engine carrier first.

Rivets are omitted in area (2).

Fig 9: Cut Engine Carrier In Area (2) From Opposite Side And Open Rivets

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Open rivet joints in areas (1) and (2).

As a rule, part of the punch rivet remains in the units compartment partition wall in areas (1) and (2). Drill out remnants.

Installation:

Carry over bores from units compartment partition wall to new part in area (2).

Use 3 rivets (size 13) in area (1).

Use 2 rivets (size 13) in area (2).

Fig 10: Open Rivet Joints In Areas (1) And (2)

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Open weld joints in areas (1) and (2).

Installation:

If necessary, replace brazed seams with MAG weld seams in area (1).

Use 2 rivets (size 13) in area (3).

Fig 11: Open Weld Joints (1) And (2); Use Rivets In Area (3)

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Open weld joints in areas (1).

Fig 12: Open Weld Joints (1)

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Open weld joints in area (1).

Mark severance cut according to measurement a and cut inside A-pillar.

Measurement a = 47 mm from center of bore.

Fig 13: Open Weld Joints In Area (1)

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NOTE: When replacing right wheel arch:
Measurement a = 65 mm from center of bore.
Measurement b = 20 mm

Fig 14: Measurements "a" And "b"

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

Preparation of new part:

Mark severance cut (1) according to vehicle. Cut outer metal sheet only.

Drill out metal sheet in areas (2).

Installation:

Adjust new part to fit with straightening attachment or universal mount.

Let parts overlap 10 mm at severance cut (1).

Weld new component from inside and outside over entire length (from outside if accessible).

Drill holes for rivets .

Bond all new parts.

Rivet all new parts.

Fig 15: Drill Out Metal Sheet In Area (2)

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Installation:

Use 8 rivets (size 13) in areas (1).

Use 6 rivets (size 13) in areas (2).

Use 4 rivets (size 13) in areas (3).

Fig 16: Use Rivets In Areas (1-3)

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Right side only:

Installation:

Use 2 rivets (size 13) in areas (1).

Fig 17: Use 2 Rivets In Area (1)

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Installation:

Use 2 EMC screws in each case (4 x in total) in areas (1) and (2).

Fig 18: EMC Screws

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Installation:

Seal new component in area (1) with sealing compound.

Fig 19: Seal Component Area

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Installation:

AWD only:

After painting on both sides of car, stick zinc foil (1) to center.

bolting point (2) of front axle carrier.

Fig 20: Bolting Point (2) Of Front Axle Carrier

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