41 11 205 Completely replacing the 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 WELDER for repairs.

The following new body parts are required:

Outer wheel arch carrier support
Carrier support, inner wheel arch section
Carrier support bulkhead
Support bracket shaped part (not shown)

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

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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 And New Part Welding Areas

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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

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Open welded connections in areas (1) and remove bulkhead (2).

Fig 4: Bulkhead Welded Connections Areas

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Preparation of new part:

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

Fig 5: Bulkhead Welded Connections Areas

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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

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

Remove new parts and deburr bores.

NOTE: Follow procedure for replacement of spot-welded adhesive joints in area (2).

(3) Position of cavity sealing.

Fig 7: Cavity Sealing And New Part Welding Areas

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Installation:

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

Fig 8: Bulkhead Welded Connections Areas

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

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

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Apply sealant to CAVITY SEALING (3).

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

Fig 10: Cavity Sealing And New Part Welding Areas

Courtesy of BMW OF NORTH AMERICA, INC.