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

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Observe procedure for REPAIR STAGE 3 .

Read contents of BODY, GENERAL .

Spot-weld bonding is used on this vehicle.

Observe specific PROCEDURE .

Use only an approved SPOT-WELDING APPARATUS for repairs!

Place vehicle on straightening bench.

The following new body parts are required:

Fig 1: Vehicle Body Parts

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(1) Carrier support, outer wheel arch section
(2) Wheel arch inner section support member
(3) Carrier support bulkhead
(4) Front spring strut dome
(3) Engine support, inner
Wheel arch carrier support shaped part

Removal

Fig 2: Severance Cut Mark And Spot-Welded Adhesive Joints Area

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Mark severance cut (1) as pictured and cut.

Open WELDED CONNECTIONS in areas (2).

Release SPOT-WELDED ADHESIVE JOINTS in area (3) and remove partial carrier support section.

Fig 3: Severance Cut Mark And Welded Connections Areas

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Mark severance cuts (1) and (2) and cut according to schematic diagram.

Release WELDED CONNECTIONS and remove partial inner carrier support part section.

NOTE: New part is installed with overlap in area of severance cut (2).

Fig 4: Severance Cut Marks And Welded Connections Area

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Mark severance cut (1) as pictured and cut.

Fig 5: Severance Cut Mark

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Open WELDED CONNECTIONS in area (1).

Open WELDED CONNECTIONS in areas (1) and (2).

3 panels are welded in area (2). Open WELDED CONNECTION for both outer panels.

Fig 6: Welded Area And Welded Connections

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Open welded connections in area (1)

Fig 7: Welded Connections Area

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Mark severance cut (1) as pictured and cut.

Remove WELDED CONNECTIONS in areas (2) and (3) and remove engine support with wheel arch.

NOTE: Three panels are welded in areas (3). Open WELDED CONNECTION for both outer panels.

Fig 8: Severance Cut Mark And Welded Connections Areas

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Remove WELDED CONNECTION in areas (1) and remove residual section of engine support (2).

Fig 9: Engine Support Residual Section And Welded Connection Areas

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New part preparation

Mark severance cut (1) in accordance with severance cut on vehicle and cut. Cut through both panels in area (2). In the area (2) the width of the severance cut must be approximately 5 mm, so that both panels can be welded to the body.

Mark severance cut (3) in accordance with severance cut on vehicle and approx. 5 mm extra material and cut. (4) = Severance cut on vehicle.

Remove metal section (5).

Fig 10: Metal Section Severance Cut Marks

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Prepare new parts and vehicle for joining by welding.

Adjust new part for engine support internal part using alignment bracket or universal fixture.

Prepare new part for joining by welding in areas (1).

Fig 11: Welding Areas

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Adapt new part for spring support using alignment bracket or universal fixture.

NOTE: Inner part of engine support new part is hidden for a better overview.

Wheel arch support (1), engine support outer part (2) and front axle support fixture (3) must be welded in areas (4) using PLUG WELDING method.

In areas (4) drill 2 x holes Ø 10 mm. Do not spot-drill or drill through front axle support fixture (3)!

In area (5), prepare new part for joining by welding.

Fig 12: Wheel Arch Support, Engine Support Outer Part And Front Axle Support Fixture

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Prepare new parts in areas (1) for joints through welding.

NOTE: All 3 panels must be welded to each other in areas (3).

Increase size of holes in areas (3) (open WELDED CONNECTIONS ) top Ø 10 mm. Transfer holes to new engine support internal part and drill.

NOTE: The "front axle support fixture" is located in the areas (1). See Fig 11 and Fig 12.

The "front axle support fixture" component must be welded in the areas (1) using PLUG WELDING method.

The positions of the bore holes (2) can be found on the removed part and transferred to the new part.

Do not drill in or drill through "front axle support fixture" component!

In areas (2), set 4 x Ø 10 mm bore holes. Prepare the new part for joining by welding in this (3)

Fig 13: Bore Holes And Welding Areas

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In area (1), prepare new part for joining by welding.

Fig 14: Severance Cut Mark

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Produce REINFORCEMENT PLATE (1) for severance cut (2) and adjust.

Adjust bulkhead (3).

In areas (4), prepare new parts for joining by welding.

Mark severance cut on carrier support inner section according to severance cut on vehicle +20 mm material extra and cut.

Fig 15: Severance Cut And Welding Areas

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Adjust new part and prepare in areas (1) and (2) for joining by welding.

NOTE: Follow procedure for replacement of SPOT-WELDED ADHESIVE JOINTS in area (2).

Remove adhesive residues in the area (2).

Fig 16: Weld-Joint Areas And Spot-Welded Adhesive Joints

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Adjust new part and prepare in areas (1) and (2) for joining by welding.

Remove new parts and deburr bore holes.

NOTE: Follow procedure for replacement of SPOT-WELDED ADHESIVE JOINTS in area (2).

(3) = position of the CAVITY SEALING .

Fig 17: Cavity Sealing Position And Weld-Joint Areas

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Installation

Install new engine support internal part with alignment bracket or universal fixture and weld into areas (1).

Fig 18: Welding Areas

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Weld new engine support internal part in areas (1) and (2).

Fig 19: Welding Areas

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Install new spring support part with alignment bracket or universal fixture and weld into areas (1) and (2).

Fig 20: Welding Areas

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Weld new parts in areas (1) and (2).

Fig 21: Welding Areas

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Weld new parts in areas (1) and (2).

Fig 22: Welding Areas

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Fig 23: Severance Cut Mark

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Weld new part in area (1).

Fig 24: Severance Cut And Welding Areas

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Install reinforcement plate (1) and weld with severance cut (2). Weld new part and bulkhead (3) in the areas (4).

Install new part and weld in the areas (1) and (2).

Fig 25: Weld-Joint Areas And Spot-Welded Adhesive Joints

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Apply sealant to cavity sealing (3). Install cavity sealing.

Fig 26: Cavity Sealing Position And Weld-Joint Areas

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Install new part, weld in areas (1) and (2).