41 11 516 Replacing Front Left or Right Support Carrier (Partial Replacement, Front Side Panel Removed)

41 11 516 Replacing Front Left Or Right Support Carrier (Partial Replacement, Front Side Panel Removed)

Read contents of Body, General.
Strip down vehicle.

NOTE: Observe new procedure for bonding and riveting (repair stage 2).

Following new body parts are required (refer to Electronic Parts Catalogue - EPC):
- (1) Support carrier, wheel arch, front,
- (2) Carrier support, wheel arch, inner
- (3) Bracket, diagonal strut, carrier support

Following consumables are required:

Removing carrier support

View from below.
Mark severance cut (1) in accordance with specified measurements and cut.
Measurement a = 80 mm
Measurement b = 50 mm

IMPORTANT: Cut outer metal sheet only.

Open weld joints in areas (2).

Roughly mark severance cut (1) and cut.
Remove carrier support section (2).
Open weld joints in area (3) from below.

Preparation of new part:

Open weld joints in area (1).
Mark severance cut (2) in accordance with severance cut on vehicle + 20 mm extra material and cut.

Offer up new parts with attachments and fix in place.
Set four 6.8 mm dia. holes for blind rivets N1 in area (1).

View from below.
Diagonal strut must be fitted in order to adjust holder (1) to fit.
In areas (2) set eight 6.8 mm dia. holes for blind rivets N1.
Remove new parts again and deburr holes.

IMPORTANT: Do not grind new part and body in area of bonding surfaces.

Installing carrier support

Clean all bonding surfaces on vehicle and on new part with cleaning agent R1.
Apply adhesive K5a to bonding surfaces.
Attach new part and attachments and rivet with blind rivets (1).

Clean all bonding surfaces on vehicle and on new part with cleaning agent R1.
Apply adhesive K5a to bonding surfaces.
Mount new part and rivet with blind rivets (1).

In area (1) rivet new parts with 12 punch rivets N5.

Seal adhesive areas and blind rivets in accordance with right side of vehicle with sealant.