41 11 091 Replacing Left Engine Support In Front Of Bulkhead

Observe procedures for REPAIR STAGE 3 .

Read contents of BODY, GENERAL .

Steel-aluminium composite construction is used on the vehicle.

Observe specific procedure. See OPENING ADHESIVE BONDS , BONDING ALUMINIUM ON STEEL , and OPENING RIVETED JOINTS .

Use only approved SPOT-WELDING APPARATUS  for repairs.

Place vehicle on straightening bench.

The following new body parts are required:

• (1) Engine support
• (2) Engine support, rear

Following CONSUMABLES  are required:

Fig 1: Identifying Engine Supports

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Removal of engine support 

Open welded connections in area (1).

Fig 2: Identifying Engine Support Welded Connections Area

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Drill out rivet connections in areas (1) and (2).

Drill diameter max. 6.8 mm.

Fig 3: Identifying Rivet Holes Drill Areas

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

Dimension a=140 mm

Fig 4: Identifying Engine Support Cutting Position

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Roughly mark severance cuts (1) and cut.

Fig 5: Identifying Aluminium Spring Strut Dome And Severance Cut Marks

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Heat ADHESIVE AREAS  with hot air blower and release sheet sections (1) from spring strut dome.

Fig 6: Identifying Sheet Sections And Aluminium Spring Strut Dome

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Open welded connections in area (1) and remove engine support section (2).

Fig 7: Identifying Engine Support Section And Welded Connection Area

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New part preparation 

Mark severance cuts on new parts in accordance with severance cuts on vehicle and cut.

Prepare REINFORCEMENT PLATES  at severance cuts.

Remove adhesive residue in areas (1).

Then FLAME-COAT  bonding surfaces of spring strut dome.

Grind bonding surfaces  on engine support blank accordingly. (Structure bonding)

Adjust new parts and reinforcement plates using alignment bracket or universal mount and secure

Fig 8: Identifying Aluminium Spring Strut Dome And Adhesive Residue Areas

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In areas (1) and (2), transfer bore holes Ø 6.8 mm for blind rivets to new part on engine support.

Fig 9: Identifying Rivet Holes Drill Areas

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Installing engine support 

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.

Using blind rivets, rivet new parts in the areas where the rivets are fitted with adhesive N2.

Weld new parts identically to the series in the other gap areas.

MAG-weld new part in area (1).

To do so, apply 2 fillet welds at spacing of 15 mm. Length of fillet welds approx. 15 mm.

Fig 10: Identifying MAG Welded Area

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