41 11 205 Completely replacing left carrier support

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Read contents of BODY, GENERAL .

Follow procedure for REPAIR STAGE 3 .

Spot-weld bonding is used on this vehicle.

Observe specific PROCEDURE .

Use only approved SPOT-WELDING APPARATUS for repairs.

The following new body parts are required:

(1) Outer wheel arch carrier support
(2) Carrier support, inner wheel arch section
(3) Carrier support bulkhead
Support bracket shaped part

Fig 1: Inner/Outer Wheel Arch Carrier Supports And Bulkhead Carrier Support

Courtesy of BMW OF NORTH AMERICA, INC.

Removal:

Open WELDED CONNECTIONS in areas (1).

Open SPOT-WELDED ADHESIVE JOINTS in area (2).

Release and remove carrier support outer section from cavity sealing (3).

Fig 2: Cavity Sealing Position And Weld-Joint Areas

Courtesy of BMW OF NORTH AMERICA, INC.

Mark severance cut (1) as pictured and cut.

Open WELDED CONNECTIONS in areas (2).

Undo SPOT-WELDED ADHESIVE JOINTS in areas (3) and remove carrier support inner section.

Fig 3: Carrier Support Inner Section Spot-Welded Adhesive Joints Areas, Welded Connections Areas, And Severance Cut Mark

Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 4: Bulkhead Welded Connections Areas

Courtesy of BMW OF NORTH AMERICA, INC.

Preparation of new part:

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

Fig 5: Bulkhead Welded Connections Areas

Courtesy of BMW OF NORTH AMERICA, INC.

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

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).

Fig 6: Weld-Joint Areas And Spot-Welded Adhesive Joints

Courtesy of BMW OF NORTH AMERICA, INC.

Install new part in areas (1) and (2), prepare 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 cavity sealing.

Fig 7: Cavity Sealing Position And Weld-Joint Areas

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

Install bulkhead (2) and weld in areas (1).

Fig 8: Bulkhead Welded Connections Areas

Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 9: Weld-Joint Areas And Spot-Welded Adhesive Joints

Courtesy of BMW OF NORTH AMERICA, INC.

Apply sealant to CAVITY SEALING (3).

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

Fig 10: Cavity Sealing Position And Weld-Joint Areas

Courtesy of BMW OF NORTH AMERICA, INC.