41 11 023 Front Engine Support To Left Wheel Arch Section Replacement

WARNING: This page is about a different car, the 2010 BMW 535xi, 2009 BMW 535xi, and 2008 BMW 535xi. However, it is still accessible from the selected car via links, so may be relevant.

Read contents of BODY, GENERAL .

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

Observe relevant procedures in BODY, GENERAL .

Place vehicle on straightening bench.

Following new body parts are required :

Wheel arch, front
Support carrier, bulkhead, outer
Engine carrier, front
Reinforcement bracket, front, spring support
Reinforcement bracket, rear, spring support

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

Fig 1: Support Carrier, Bulkhead, Outer And Wheel Arch, Front

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

Installation:

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

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

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

Fig 2: 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 areas (1).

Fig 3: Spot-Drill Rivets Areas

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

Fig 4: Spot-Drill Rivets Area

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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 5: Rivet Joints Areas

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

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 6: Weld Joint Area

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

Open weld joint in area (4).

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).

Fig 7: Rivet Joints In Area

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Drill out rivet joint in area (1).

Installation:

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

Fig 8: Rivet Joint Area

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Cut open engine carrier in area (2) from opposite side and open rivets.

Installation:

Adjust new part to fit with straightening attachment or universal mount.

Drill holes for rivets.

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

For accessibility reasons, rivet retaining brackets in areas (1) to engine carrier first.

Rivets are omitted in area (2).

Fig 9: Engine Carrier Area

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

As a rule, part of the punch rivet remains in the units compartment partition wall in areas (1) and (2). Drill out remnants.

Installation:

Carry over bores from units compartment partition wall to new part in area (2).

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

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

Fig 10: Rivet Joints Areas

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

Installation:

If necessary, replace brazed seams with MAG weld seams in area (1).

Use 2 rivets (size 13) in area (3).

Fig 11: Weld Joints Areas

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Open weld joints in areas (1).

Fig 12: Weld Joints Areas

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Open weld joints in area (1).

Mark severance cut according to measurement a and cut inside A-pillar.

Measurement a = 47 mm from center of bore.

Fig 13: Weld Joints Area

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NOTE: When replacing right wheel arch:
Measurement a = 65 mm from center of bore.
Measurement b = 20 mm

Fig 14: Cut Mark From Bore

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Different riveting-down elements, depending on the equipment specification, must be mounted on the new component.

Required tools are featured on the Workshop Equipment Planning CD (WEP).

Preparation of new part:

Mark severance cut (1) according to vehicle. Cut outer metal sheet only.

Drill out metal sheet in areas (2).

Installation:

Adjust new part to fit with straightening attachment or universal mount.

Let parts overlap 10 mm at severance cut (1).

Weld new component from inside and outside over entire length (from outside if accessible).

Drill holes for rivets.

Bond all new parts.

Rivet all new parts.

Fig 15: Metal Sheet Drill Areas

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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 16: Rivets Areas

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Right side only:

Installation:

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

Fig 17: Rivets Areas

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Installation:

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

Fig 18: Rivets Areas

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Installation:

Seal new component in area (1) with sealing compound.

Fig 19: Sealing New Component In Area With Sealing Compound

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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 20: Zinc Foil And Centre Bolting Point Of Front Axle Carrier

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