41 11 205 Left Carrier Support Complete Replacement: Notes

When replacing the right carrier support, follow the special procedure concerning the vehicle identification number. (order new body part with vehicle identification number if necessary)

Read contents of BODY, GENERAL .

Follow procedure for REPAIR STAGE 2 .

STRIP DOWN vehicle.

The following new body parts are required:

(1) Carrier support, outer wheel arch section
(2) Wheel arch inner section support member
(3) Carrier support end plate

The following CONSUMABLES are required:

Fig 1: Carrier Support, Support Member, And Carrier Support End Plate

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Material	Quantity
Adhesive K1	1
Blind rivet N1	4
Blind rivet N7	5
Punch rivets N5	56
Sealant D1	1
Cleaning agent R1	1

Removal:

Open welded connections in areas (1).

Fig 2: Locating Welded Connections

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Open weld joint in area (1).

Fig 3: Identifying Welded Joint

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Mark severance cut (1) as pictured and cut off carrier support.

Open weld connections in area (2) and remove outer part of carrier support.

Fig 4: Identifying Cutting Line And Welded Connections

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NOTE: Concealed welding spots.

In areas (1), undo welded connections for both external panels.

Fig 5: Identifying Welded Connections

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Release welded connections in area (1) and remove sheet section (2).

Fig 6: Identifying Sheet Section And Welded Connections

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Preparation of new part:

Release welded connections and take off components (1) and (2) that are not required.

Fig 7: Identifying Components

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Adjust new parts with add-on parts to fit and secure.

Areas (1) and (2): join using bond-and-rivet method.

In area (1), drill a 6.8 mm dia. bore hole for blind rivet N1.

Fig 8: Identifying Bonding-And-Riveting Areas

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Areas (1) and (2): join using bond-and-rivet method.

In areas (1) and (2), set 8 6.8 mm diameter bore holes for blind rivets.

Prepare areas (3) for joints by welding.

Fig 9: Identifying Bonding-Riveting And Welding Areas

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Areas (1) to (3): join using bond-and-rivet method. (punch rivets)

Fig 10: Identifying Bonding-And-Riveting Areas

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In area (1), prepare new part/engine support for plug-welding.

Area (2): join using bond-and-rivet method.

Remove new parts.

Fig 11: Identifying Plug-Welding Area And Bonding-Riveting Area

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Attention.

Structure bonding: observe PREPARATION OF BONDING SURFACES .

Installation:

Clean all bonding surfaces with cleaning agent R1.

Apply adhesive to bonding surfaces.

Install and secure inside part of carrier support (new part) with add-on parts.

In area (1), rivet new part with blind rivet N1.

In area (2) rivet new part with 4 punch rivets N5.

Fig 12: Identifying Bonding-And-Riveting Areas

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In areas (1) weld new part.

Fig 13: Locating Welded Connections

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Install and secure outside part of carrier support (new part).

In areas (1) and (2), rivet new part with blind rivets.

Area	Remarks
1	N1
2	N7

Fig 14: Identifying Welding Areas And Riveting Areas

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In areas (3) weld new part.

Attention.

Risk of damage.

Avoid excessive application of heat to adjacent adhesive areas.

In areas (1) to (3), rivet new part with punch rivets N5.

Area	Number
1	22
2	15
3	3

NOTE: Do not seal new parts in adhesive rivet areas (1) and (2). (Field of view)

Fig 15: Bonding-And-Riveting Areas

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Install and secure carrier support end plate.

In areas (2), rivet new part with 12 punch rivets N5.

Weld new part in area (1).

Attention.

Risk of damage to adhesive area.

Avoid applying excessive heat to the neighboring adhesive areas.

Fig 16: Identifying Plug-Welding Area And Bonding-Riveting Area

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NOTE: Do not seal new parts in the area of the adhesive riveting. (Field of view)

Remove excess adhesive.

Do not use any cleaning agents containing solvents.