41 11 071 REPLACING ENGINE MOUNT WITH LEFT WHEEL ARCH IN FRONT OF BULKHEAD REP-REP-RAF6041-4111071 - V.1 (Countryman 2017-2023, except PHEV)
Observe procedure of REPAIR STAGE 3 .
Read contents of BODY, GENERAL .
For stripping and rebuilding operations, refer to surrounding texts on KSD (FRU number 41 11 071).
Spot-weld bonding is used on this vehicle. Observe specific PROCEDURE .
Use only an approved SPOT WELDER for repairs!
Place vehicle on straightening bench.
Following new body parts are required (see Electronic Parts Catalog):
- (1) Carrier support, outer wheel arch section
- (2) Front shock tower
- (3) Engine mount, inner
- Wheel arch carrier support shaped part
Removal
Mark severance cut (1) as pictured and cut.
Open welded connections in areas (2).
LOOSEN spot-welded adhesive joints in area (3).
Remove partial section of carrier support.
Remove adhesive residues in the area (3).
Open welded connections in areas (1).
Open welded connections in areas (1) to (3).
Mark severance cut (1) as pictured and cut.
Open welded connections in areas (2) and (3).
Open welded connection for both outer panels in area (2).
Open welded connections in areas (1) and (2).
LOOSEN spot-welded adhesive joints in area (1).
In areas (2), undo welded connections for both external panels.
Open welded connections in area (1).
Mark severance cut (1) as pictured and cut.
Remove welded connections in areas (2) and (3) and remove engine mount with wheel arch.
Remove welded connection in areas (1) and remove residual section of engine mount (2).
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).
Prepare new parts and vehicle for joining by welding.
Adjust new part for engine mount internal part using alignment bracket or universal fixture. Prepare new part for joining by welding in areas (1).
Adapt new part for spring support using alignment bracket or universal fixture.
Support wheel house (1), Engine mount outer part (2) and mount front axle carrier (3) need in the fields (4) by means of PULL-POINT WELDING PROCESS be welded .
In areas (4) drill 2 x holes Ø 10 mm. Do not spot drill or drill through front axle support stand (3)!
In area (5), prepare new part for joining by welding.
Prepare new parts in areas (1) up to (3) for joints through welding.
Increase size of holes in areas (3) (open welded connections) top 0 10 mm. Transfer holes to new engine mount internal part and drill.
Prepare new parts in areas (1) up to (3) for joints through welding.
The component "front axle support stand" needs to be welded in the areas (1) using the plug welding method.
The positions of the bores (2) can be found on the removed part and transferred to the new part.
Do not drill in or drill through "front axle support stand" component!
In areas (2), set 4 x 0 10 mm bores. In area (3) prepare for joining by welding.
Prepare new parts in areas (1) up to (4) for joining through welding.
In areas (1), prepare new parts for joining by welding.
Prepare new parts in areas (1) and (2) for joining by welding.
(3) = position of the cavity sealing.
Installation
Install new engine mount internal part with alignment bracket or universal fixture and weld into areas (1).
Weld new engine mount internal part in areas (1) and (2).
Install new spring support part with alignment bracket or universal fixture and weld into areas (1) and (2).
Weld new parts in areas (1) and (2).
Weld new parts in areas (1) and (2).
Weld new parts in areas (1) to (4).
Weld new parts in areas (1) to (3).
Weld new parts in areas (1).
Apply sealant to CAVITY SEALING (2). Install cavity sealing.
Apply sealant to cavity sealing (3).
Install new part and weld in the areas (1) and (2).