41 11 095 Engine Support In Front Of Left Wheel Arch Replacement: Notes

Follow procedure for REPAIR STAGE 3 .

Read contents of BODY, GENERAL .

STRIP DOWN VEHICLE .

Use only APPROVED SPOT-WELDING APPARATUS for repairs.

Place vehicle on straightening bench.

The following new body parts are required:

(1) Engine support, outer
(2) Engine support, inner

Fig 1: Identifying Engine Supports
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Removal

Mark severance cut in accordance with Dimension "a" and cut.

IMPORTANT: Offset severance cuts.
Cut outer metal panel only.

Dimension "a" = approx. 63 mm before center point of 9 x 9 mm dia. hole.

Severance cut path is carried out through 7 mm diameter hole.

Open welded connections in areas (1).

Fig 2: Identifying Cutting Dimension And Welded Connections

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View of inside:

Mark severance cut in accordance with Dimension "a" and cut.

IMPORTANT: Cut outer metal panel only.

Dimension "a" = approx. 5 mm from component edge of reinforcement plate.

Remove section of engine support.

Fig 3: Identifying Cutting Dimension

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New part preparation

Open welded connections (1) and remove component (2) which is not required.

Mark severance cuts on new parts according to severance cuts on vehicle and sever.

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

Fig 4: Locating Welded Connections And Component

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Adjust engine support outer section (1) to alignment bracket or universal fixture and fix in position.

Adjust REINFORCEMENT PLATE (2) for engine support outer section (1) according to schematic diagram.

Remove engine support outer section.

Fig 5: Identifying Engine Support Outer Section And Reinforcement Plate

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IMPORTANT: Reinforcement plate must be adjusted in area of axle support (3).

Different procedure: Reinforcement plate is welded from inside during installation.

Bore hole for welding the reinforcement plate from outside are therefore not required.

Alignment bracket not shown for purposes of clarity.

Adjust engine support inner section (1) to alignment bracket or universal fixture and fix in position.

Adjust REINFORCEMENT PLATE (2) for engine support inner section (1) according to schematic diagram.

IMPORTANT: Reinforcement plate (2) must be adjusted in area of axle support (3).

Fig 6: Adjusting Reinforcement Plate In Area Of Axle Support

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Reinforcement plate is welded from inside to outside during installation.

Bore hole for welding the reinforcement plate from outside are therefore only required in the front area.

See Fig 7 below.

Alignment bracket and carrier support not shown for purposes of clarity.

In areas (2), set bore holes for plug welding.

Remove engine support inner section (1).

Fig 7: Identifying Locations For Setting Bore Holes

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Installation

Install the reinforcement plate (1) for the engine support inner section and weld to the axle support.

For this purpose, in areas (2) set MAG weld seams with a length of 10 - 15 mm.

NOTE: Alignment bracket and engine support inner section not shown for purposes of clarity.

Fig 8: Identifying Reinforcement Plate And Areas For Setting MAG Weld Seams

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Install engine support outer section (1) and reinforcement plate (2) with alignment bracket or universal fixture and weld.

For this purpose, in areas (3) set MAG weld seams with a length of 10 - 15 mm.

NOTE: Alignment bracket not shown for purposes of clarity.

Fig 9: Identifying Engine Support Outer Section, Reinforcement Plate, And Areas For Setting MAG Weld Seams

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Install engine support inner section with alignment bracket or universal fixture and weld in areas (1) and (2).

NOTE: Alignment bracket not shown for purposes of clarity.

Fig 10: Identifying Areas For Welding

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In areas (1) weld new part.

Fig 11: Identifying Areas For Welding New Part

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Weld new part in area (1).

Fig 12: Identifying Welded Joint

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