41 11 015 Replacing Engine Support With Wheel Arch, Left

Observe procedures of REPAIR STAGES 3 .

Read contents of BODY, GENERAL .

Steel-aluminium composite construction is used on the vehicle. Observe specific PROCEDURE .

Spot-weld bonding is used on this vehicle.

Observe specific PROCEDURE .

Use only approved SPOT-WELDING APPARATUS  for repairs.

Place vehicle on straightening bench.

Following new body parts are required (see BMW ELECTRONIC PARTS CATALOGUE ):

Fig 1: Identifying Engine Support, Connection And Wheel Arch

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• (1) Engine support
• (2) Engine support, rear
• (3) Wheel arch, front
• (4) Connection, wheel arch/entrance
• (5) Connection, side frame, rear
• (6) Shaped parts, carrier support, wheel arch, front (not shown)

Following CONSUMABLES  are required:

Removal of engine support with wheel arch 

Open welded connections in area (1).

Fig 2: Identifying Welded Connections Area

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Open welded connections in area (1).

Fig 3: Identifying Welded Connections Area

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Open welded connections in areas (1).

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

Roughly cut side frame connection along lines (3).

Release the side frame connection from the cavity sealing and remove.

Fig 4: Identifying Spot-Welded Adhesive Joints And Welded Connections Areas

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Open welded connections in area (1).

Remove cavity sealing (2).

Fig 5: Identifying Cavity Sealing And Welded Connections Area

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

Dimension a = 140 mm

Fig 6: Identifying Severance Cut Dimension

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Drill out  rivet connections in area (1).

Open bonded connections in area (1).

Remove wheel arch (2) with engine support.

Fig 7: Identifying Rivet Connections And Bonded Connections Area

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Open welded connections in area (1).

Remove metal section (2).

Fig 8: Identifying Metal Section And Welded Connections Area

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Mark severance cut (1) and cut.

Open welded connections in area (2).

Fig 9: Identifying Severance Cut And Welded Connections Area

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View of engine support from front.

Open welded connections in area (1).

Fig 10: Identifying Welded Connections Area

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Open welded connections in area (1).

Remove part section (2).

Fig 11: Identifying Welded Connections Area And Part Section

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New part preparation 

Open welded connections in areas (1).

Remove metal section (2).

Fig 12: Identifying Metal Section And Welded Connections Areas

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

Dimension a = 20 mm

Fig 13: Identifying Severance Cut Dimension

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

Fig 14: Identifying Rear Engine Support Mark

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

Dimension a = 15 mm

Remove metal section (2).

Fig 15: Identifying Severance Cut Dimension

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Prepare REINFORCEMENT PLATES  at severance cuts.

Adjust new parts to fit with alignment bracket or universal mount and secure.

In areas (1) and (2), set 19 6.8 mm diameter bore holes for blind rivets N2.

Arrangement of blind rivets is analogous to the series.

Fig 16: Identifying Bonding Surfaces On Body Blank

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In area (1) transfer 6 6.8 mm diameter bore holes for blind rivets N2 on new part.

Remove new parts and deburr bore holes.

Fig 17: Identifying Bore Holes For Blind Rivets

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Installation of engine support with wheel arch 

Clean bonding surfaces with cleaning agent R1.

Apply adhesive to bonding surfaces.

Apply sealant to new cavity sealing of wheel arch carrier support. See INSTALLING CAVITY SEALING (EXPANDED)  and INSTALLING CAVITY SEALING (NOT EXPANDED) .

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

Rivet the new parts analogous with the series in the adhesive areas.

Weld the new parts in the remaining joint areas.

Fig 18: Identifying Bulkhead Cross Member

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View from below.

Weld new parts in area (1) same as the series.

Fig 19: Identifying Weld Parts Area

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Weld new parts in area (1) same as the series.

Fig 20: Identifying Weld Area

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Weld new parts in area (1) same as the series.

Fig 21: Identifying Weld Parts Area

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MAG-weld new part in area (1).

To do so, apply 2 fillet welds at distance of approx. 20 mm. Length of fillet welds approx. 15 mm.

Fig 22: Identifying MAG-Weld Part Area

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MAG-weld new part in areas (1).

To do so, apply 10 mm long fillet welds at spacing of 15 mm.

Fig 23: Identifying MAG-Weld Areas

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