41 11 043 Replacing Front Section Of Left Engine Support

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Read contents of BODY, GENERAL .

The reduced-weight aluminum front end structure (GRAV) is used on this vehicle.

Observe specific procedure.

Place vehicle on straightening bench.

Following new body parts are required :

Engine carrier, front
Support carrier, bulkhead, outer
Reinforcement bracket, front, spring support
Reinforcement bracket, rear, spring support
Extension, engine carrier

The engine carrier is supplied with longer bolts for the E60 and E61. The bolts do not have to be shortened.

Fig 1: Identifying Support Carrier, Bulkhead, Outer And Engine Carrier, Front

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IMPORTANT: Use the mouthpiece (steel or plastic) with 10 mm inside diameter in the following work step to extract the rivets in areas (1) and (2). Using the plastic mouthpiece with 14 mm inside diameter will result in damage to the wheel arch!

Open rivet joints in areas (1) to (3).

Open EMC WELD SEAM in area (3).

Installation:

Use 8 rivets (size 13) in areas (1).

Use 6 rivets (size 13) in areas (2).

Use 4 rivets (size 13) in areas (3).

Fig 2: Identifying Rivet Joints Areas

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Installation:

Use 2 EMC SCREWS in each case (4 x in total) in areas (1) and (2).

Fig 3: Identifying EMC Screws Areas

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NOTE: Right side only:
Open rivet joints in areas (1).

Installation:

Use 2 rivets (size 13) in areas (1).

Fig 4: Identifying Rivet Joints Areas

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NOTE: Engine carrier has been blanked out for purposes of clarity.

Spot-drill rivets in areas (1) and (2) from protruding rear side or grind and punch through.

Installation:

Use 5 rivets (size 13) in areas (1).

Use 2 rivets (size 13) in area (2).

Fig 5: Identifying Spot-Drill Rivets Areas From Protruding Rear Side Or Grind

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Open rivet joints in areas (1) to (3).

Installation:

Use 3 rivets (size 13) in area (1).

Use 4 rivets (size 13) in area (2).

Use 3 rivets (size 13) in area (3).

Fig 6: Identifying Rivet Joints Areas

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Spot-drill rivets in area (1) from protruding rear side or grind and punch through.

Fig 7: Identifying Spot-Drill Rivets Area From Protruding Rear Side Or Grind

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Open rivet joints in areas (1) to (3).

Installation:

Use 5 rivets (size 13) in area (1).

Use 4 rivets (size 13) in area (2).

Use 3 rivets (size 13) in area (3).

Use 4 rivets (size 13) in area (4).

Use 7 rivets (size 13) in area (5).

Fig 8: Identifying Rivet Joints Areas

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Open rivet joints in areas (1) and (2).

As a rule, part of the punch rivet remains in the rear engine carrier in area (2). Do not drill out remnants. Set blind rivets next to punch rivets.

Open weld joint in area (1).

Installation:

Use 4 rivets (size 13) in area (1).

Use 5 rivets (size 13) in area (2).

Use 6 rivets (size 13) in area (3).

Install 2 EMC SCREWS in area (1).

Fig 9: Identifying Weld Joint Area

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Open rivet joints in area (1).

Installation:

Use 3 rivets (size 13) in area (1).

Use 6 rivets (size 13) in area (2).

Use 1 rivet (size 13) in area (3).

Install 2 EMC SCREWS in area (2).

Drill holes for rivets.

Fig 10: Identifying Rivet Joints Area

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Installation:

Use 1 rivet (size 15) in area (1).

Fig 11: Identifying Rivet Joints Area

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Open rivet joints in areas (1) and (2).

As a rule, part of the punch rivet remains in the rear engine carrier in area (2). Do not drill out remnants. Set blind rivets next to punch rivets.

Open weld joint in area (3).

Installation:

Use 2 rivets (size 13) in area (1).

Install 2 EMC SCREWS in area (1).

Use 7 rivets (size 13) in area (2).

Apply as much adhesive in area (2) that the adhesive emerges from the flange during riveting.

Fig 12: Identifying Rivet Joints Areas

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Spot-drill rivets in area (1) from protruding rear side or grind and punch through.

Installation:

Use 2 rivets (size 13) in area (1).

Set rivets from inside.

Fig 13: Identifying Spot-Drill Rivets Area From Protruding Rear Side Or Grind

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Installation:

Use 6 rivets (size 13) in areas (1).

For reasons of accessibility, bond and rivet retaining brackets in areas (1) to engine carrier first after adjusting to fit.

Bond in area (2) only.

Fig 14: Identifying Rivets Areas

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Preparation of new part:

Shorten new part in area (1) to a length of 50 mm by 7 mm.

Measurement a=35 mm

Fig 15: Identifying New Part Area

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Installation:

Bend open bulkhead support carrier (2) slightly in area (1).

Adjust all new parts to fit with straightening attachment or universal mount. Drill holes for rivets.

Bond engine carrier first and then rivet.

Slide engine carrier extension in direction of arrow underneath bulkhead support carrier (2).

Bond new part.

Rivet new part.

Align bulkhead support carrier (2) in area (1) until flush.

Use 2 rivets (size 13) in area (1).

Install 2 EMC SCREWS in area (1).

Fig 16: Identifying Bulkhead Support Carrier And Area

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Installation:

AWD only:

After painting on both sides of car, stick zinc foil (1) to center bolting point (2) of front axle carrier.

Fig 17: Identifying Zinc Foil And Centre Bolting Point Of Front Axle Carrier

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