41 11 015 Replacing Engine Support With Wheel Arch, Left

41 11 015 Replacing engine support with wheel arch, left







Observe procedures of repair stages 3.
Read contents of Body, General.
For stripping and rigging operations, refer to texts on KSD CD (FR number 41 11 015).
The steel-aluminium mixed construction is used on the vehicle.
Observe specific procedure.
Place vehicle on straightening bench.

Following new body parts are required (refer to Electronic Parts Catalogue):







- (1) Engine support
- (2) Engine support, rear
- (3) Wheel arch, front
- (4) Connection, wheel arch/entrance
- (5) Connection, side frame, rear
- (6) Shaped parts, carrier support, wheel arch, front (not shown)







Open weld joints in area (1).







Open weld joints in area (1).







Open weld joints in areas (1).
Open spot-weld bonded joints in areas (2).
Roughly cut side frame connection along lines (3).

Remove side frame connection.

Installation note:
MAG-weld new part in areas (3).

To do so, apply 10 mm long fillet welds at spacing of 15 mm.







Open weld joints in area (1).

Installation note:
Replace cavity acoustic baffles (2).







Mark severance cut (1) in accordance with measurement a and cut engine support.

Measurement a=140 mm

Installation note:
Weld in reinforcement plate at severance cut.







Drill out rivet connections in area (1).
Open adhesive bonds in area (1).
Remove wheel arch (2) with engine support.

Installation note:
Use 6 N2 rivets in area (1).
Glue new part with adhesive K1.







Open weld joints in area (1).
Remove metal section (2).







Mark severance cut (1) and cut.

IMPORTANT: Cut outer panel only.

Open weld joints in area (2).







View of engine support from front.
Open weld joints in area (1).







Open weld joints in area (1).
Remove part section (2).

Preparation of new part:







Open weld joints in areas (1). Remove metal section (2).

Preparation of new part:







Mark severance cut (1) in accordance with measurement a and cut.

Measurement a = 20 mm

Preparation of new part:







Mark rear engine support in accordance with severance cut on vehicle and cut (1).







Installation note:
Mark severance cut (1) in accordance with measurement a and cut.

Measurement a=15 mm

Remove metal section (2).







IMPORTANT: To avoid contact corrosion, do not grind the new wheel arch part in the area of the adhesive surfaces.

Grind bonding surfaces on body blank.
Clean bonding surfaces with cleaning agent R1.

Installation note:
Adjust new parts to fit with alignment bracket or universal mounting.







Drill new rivet holes in areas (1) and (2).

Deburr holes.
Use 19 N2 rivets.
Glue new part with adhesive K1.

View from below.







Installation note:
Weld new components in area (1) additionally.







Installation note:
Weld new components in area (1) additionally.







Installation note:
Weld new component in area (1) additionally.







Installation note:
MAG-weld new component in area (1) additionally.

To do so, apply 2 fillet welds at spacing of approx. 20 mm. Length of fillet welds approx. 10 mm.