41 11 023 Front Engine Support To Left Wheel Arch Section Replacement
Observe procedure for repair stage 3 .
Read contents of Body, General .
Remove or cover those vehicle components in the repair area which are susceptible to heat or dust.
Strip down vehicle.
Place vehicle on straightening bench.
Following new body parts are required:
- Wheel arch, front
- Support carrier, wheel arch, outer
Following consumables are required:
| Material | Quantity |
|---|---|
| Adhesive K1 | 1 |
| Blind rivets N1 | 41 |
| Punch rivets N5 | 39 |
| EMC screws | 2 |
| Cleaning agent R1 | 1 |
| Cavity sealing wax remover | 1 |
| Sealant D1 |
Removal of front section of engine support with wheel arch:
Mark severance cut (1) in front of holder (2) and cut (holder (2) remains on vehicle).
Open welded connections in area (3).
Installation note:
Mark severance cut (1) in on new part and cut. Take off holder (2).
Apply sealant to cavity sealing (4). See (expanded) or (not expanded) .
Mark severance cut (1) in accordance with dimension a and cut engine support.
Dimension a=130 mm from front edge of bush
Open welded connections in areas (1).
Open welded connections in areas (1).
Open welded connections in area (1).
Installation note:
If equipment compartment partition wall (2) is damaged, cut along line (3).
Mark severance cut on new part according to severance cut on vehicle + 20 mm material extra and cut.
Bond both parts overlapping and rivet. Depending on accessibility, use punch rivets N4 and blind rivets N3.
Open welded connections in area (1).
Remove front section of engine support with wheel arch.
Preparation of new part:
Mark and cut the severance cut on new part as per the severance cut on the vehicle.
Prepare reinforcement plates at severance cut.
Open welded connections in areas (1) on both sides.
Open welded connections in area (2).
Detach remainder of reinforcement from engine support.
Open welded connections in areas (1).
Take off holder.
Adjust new parts to fit with alignment bracket or universal mount and secure.
In area (1) set ten 6.8 mm dia. bore holes for blind rivets N1.
Installation note:
In area (2) 2 N5 punch rivets are used later.
In areas (1) and (2) set 6.8 mm dia. bore holes for blind rivets N1:
- Area (1): 3 bore holes
- Area (2): 2 bore holes
In area (1) set seven 6.8 mm dia. bore holes for blind rivets N1.
Installation note:
In area (2) 1 N5 punch rivet is used later.
In areas (1) to (4) set 6.8 mm dia. bore holes for blind rivets N1:
Open welded connections in area (1).
- Area (1): 5 bore holes
- Area (2): 2 bore holes
- Area (3): 1 bore hole
- Area (4): 9 bore holes
Installation note:
After adhesive has hardened install 2 EMC screws in areas (1) and (4).
Set two 6.8 mm dia. holes for blind rivets N1 in area (1).
Remove all new parts and deburr holes.
Structure bonding!
Observe preparation of bonding surfaces.
Installation of engine support with wheel arch
Clean bonding surfaces with cleaning agent R1.
Apply adhesive K1 to bonding surfaces.
Install new parts and reinforcement plates with alignment bracket or universal mount.
Rivet new parts with blind rivets.
Three-sheet-metal combination in area (1)!
In area (1) rivet new part on both sides offset with 4 punch rivets N5.
Use 14 punch rivets N5 in area (2).
Use 18 punch rivets N5 in area (3).
In area (1) rivet new part with blind rivets N1.
Use 2 punch rivets N5 in area (2).
In area of severance cut, weld new part of engine support and reinforcement plates.
Vehicles with spring strut dome plate insert:
Different plate inserts are fitted, depending on the model.
- Version (A) riveted
- Version (B) screwed
Riveted version:
If damaged, the plate inserts must always be replaced with screwed versions on both sides of the vehicle.
Glued version:
Adhesive/contact surfaces of plate insert must be free of sealant, top coat and underbody protection.
Do not grind off primer.
Use adhesive gun 41 3 102 in conjunction with adhesive K3.
Apply K3 adhesive in areas (1). Do not apply any adhesive in area (2).
Secure plate insert with 3 screws and nuts for 2 hours at min. 20 °C.