41 11 071 Replacing engine support with left wheel arch in front of bulkhead

Read contents of SAFETY INFORMATION and BODY, GENERAL .

Observe procedure of REPAIR STAGE 3 .

Remove or cover those vehicle components in the repair area which are susceptible to heat or dust.

Spot-weld bonding is used on this vehicle. Observe specific PROCEDURE .

Use only approved SPOT-WELDING APPARATUS for repairs.

Place vehicle on straightening bench.

The following new body parts are required:

(1) Carrier support, wheel arch, outer
(2) Wheel arch, front
(3) Engine support, rear

Fig 1: Identifying Front Wheel Arch And Rear Engine Support

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Removal of engine support with wheel arch

Open welded connections in areas (1).

OPEN spot-welded adhesive joints in area (2).

Remove the carrier support for wheel arch.

Fig 2: Identifying Carrier Support Welded Connection Areas

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Mark severance cut in accordance with dimension and cut.

Dimension "a" = 20 mm from A-pillar component.

Open welded connections in areas (1).

Installation note:

Weld on new part, overlapping severance cut connection face.

Fig 3: Identifying A-Pillar Component Dimension

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Open welded connections in areas (1).

Fig 4: Identifying Welded Connection Areas

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Open welded connections in area (1).

Fig 5: Identifying Welded Connection Area

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

Dimension "a" = approx. 135 mm from center of 10 mm dia. hole.

Mark severance cut (2) as pictured and cut.

Remove section (3).

Fig 6: Identifying Engine Support Section And Severance Cuts

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Open welded connections in areas (1).

Mark severance cut (2) on engine support as pictured and cut.

Fig 7: Identifying Severance Cut Mark On Engine Support

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Outer side of engine support.

Mark severance cut (1) as pictured and cut.

Open welded connections in area (2).

Remove engine support with wheel arch.

Fig 8: Identifying Engine Support Welded Connection Area

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New part preparation

Grind a V-shaped groove (1) into engine support.

NOTE: In area (1), all 3 panels and the reinforcement plate must be properly MAG welded to each other.

Fig 9: Identifying Panels And Reinforcement Plate Welded Connection Area

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Mark severance cut on new wheel arch part in accordance with severance cut on vehicle +20 mm extra material and cut (1).

NOTE: New part is installed with overlap in area of severance cut (1).

Fig 10: Identifying Severance Cut On Wheel Arch Part

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Mark severance cut (1) in accordance with vehicle and cut.

Remove metal section (2).

Fig 11: Identifying Metal Section

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Mark severance cut (1) on new engine support part in accordance with severance cut on vehicle and cut (1).

Release welded connection (2) and take off engine support section.

Fig 12: Identifying Engine Support Section Welded Connection Area

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Grind a V-shaped groove (2) into the engine support section (1).

Determine the correct position of the groove by fitting the section into the new wheel arch part.

Prepare REINFORCEMENT PLATES at severance cuts.

Adjust new parts to fit with alignment bracket or universal mounting.

Fig 13: Identifying V-Shaped Groove Into Engine Support Section

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Installation of engine support with wheel arch

Install new parts and reinforcement plates with alignment bracket or universal mount and weld.

NOTE: Only weld new parts in area (1) after installation of engine support section (2).

Additionally weld new parts in area (1) using plug welding method.

NOTE: In area (1), all 3 panels and the reinforcement plate must be properly MAG welded to each other.

Fig 14: Identifying Engine Support Section Welded Connection Area

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Additionally weld new parts in area (1) using plug welding method.

Fig 15: Identifying Engine Support Section Plug Welded Connection Area

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In area (1) drill 1 Ø 6.8 mm hole for blind rivet.

IMPORTANT: Risk of damage.

Do not drill through add-on parts in passenger compartment behind panel.

Rivet new engine support part in area (1) with BLIND RIVET N1 .

Fig 16: Identifying Engine Support Part Riveting Area

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