41 11 091 Replacing Left Engine Support In Front Of Bulkhead

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Observe procedure of REPAIR STAGE 3 .

Read contents of BODY, GENERAL .

Steel-aluminium composite construction is used on the vehicle.

Observe specific procedure for repairs. See BONDING ALUMINIUM ON STEEL and OPENING RIVETED CONNECTIONS .

Use only approved SPOT-WELDING APPARATUS .

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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Material	Quantity
Adhesive K1	1
Blind rivet N2	19
Cleaning agent R1	1
Cavity sealing wax remover	1
Sealant D1

Removal of engine support

Open welded connections in area (1).

Fig 2: Identifying Welded Connections

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

IMPORTANT: Do not damage aluminium spring strut dome.
Drill diameter maximum 6.8 mm.

Fig 3: Identifying Rivet Connections

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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 Severance Cut Dimension

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Roughly mark severance cuts (1) and cut.

IMPORTANT: Do not damage aluminium spring strut dome (2).

Fig 5: Identifying Severance Cut Areas And Spring Strut Dome

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

IMPORTANT: Do not damage aluminium spring strut dome (2).

Fig 6: Identifying Sheet Sections And 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 Weld Connections

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Preparation of new part:

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).

IMPORTANT: Do not damage aluminium spring strut dome (2).

Fig 8: Identifying Spring Strut Dome And Adhesive Locations

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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.

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

Fig 9: Identifying Rivet Connections

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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.

NOTE: The bulkhead cross member (1) is filled with low-flammable cavity foam.
In case of smoke formation, stop the welding procedure and cool the welded area with compressed air if applicable.

Fig 10: Identifying Bulkhead Cross Member

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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 11: Identifying MAG-Weld Area

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