Replacing Engine Support With Left Wheel Arch In Front Of Bulkhead

Observe procedure of REPAIR STAGE 3 .

Read contents of BODY, GENERAL .

For stripping and rebuilding operations, refer to surrounding texts on KSD (flat rate unit number 41 11 071).

Spot-weld bonding is used on this vehicle. Observe specific PROCEDURE .

Use only an approved SPOT-WELDING APPARATUS  for repairs!

Place vehicle on straightening bench.

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

• (1) Wheel arch, front
• (2) Extension, wheel arch carrier support
• (3) Shaped part, wheel arch carrier support (not shown)

Following CONSUMABLES  are required.

Material	Quantity
Adhesive K1	1
Blind rivet N7	9
Blind rivet N3	5
Punch rivet N5	12
Sealant D1
Cleaning agent R1	1

Removal 

Mark severance cut (1) at component edge and cut.

Mark severance cut (2) as pictured and cut.

LOOSEN  spot-welded adhesive joints in area (3).

Open welded connections in area (4).

Release metal section from cavity sealing (5) and remove.

Remove cavity sealing (5).

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Open welded connections in area (1).

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Open welded connections in area (1).

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Open welded connections in areas (1) and (2).

Open welded connections in area (1).

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Open welded connections in area (1).

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Mark severance cut (1) roughly as pictured and cut engine support.

Open welded connections in area (2) and remove engine support (3) with wheel arch.

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Open welded connections in areas (1) by grinding and remove residual section of engine support (2).

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New part preparation 

Mark and disconnect severance cut on the new part according to the severance cut on the vehicle + 20 mm added material (1).

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Release welded connections and remove non-required components (1) from new part.

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Mark severance cut in accordance with dimension and cut.

Measurement a = approx. 145 mm from component edge.

Cut outer metal panel only.

Open welded connections in area (1).

Remove metal section (2).

Prepare REINFORCEMENT PLATE  at severance cut.

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

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Adjust extension, wheel arch carrier support new

part to fit and secure.

In areas (1) and (2), set 0 6.8 mm bore holes for blind rivet.

Area	Number
1	3
2	5

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In area (3), set 4 0 4.2 mm bore holes for blind rivet N3.

Remove new parts and deburr bore holes.

Attention! 

Structure bonding!

OBSERVE  preparation of bonding surfaces.

Installation 

Install new part with alignment bracket or universal mount and secure.

Weld new part in area (1).

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Weld new part in the areas (1) and (2).

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Install sheet metal section (1) and reinforcement plate and weld in areas (2) and (3).

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Weld new part in area (1).

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Weld new part in the areas (1) and (2).

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Weld new part in area (1).

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Installation 

Clean bonding surfaces with cleaning agent R1.

Apply adhesive to bonding surfaces.

Apply sealant to CAVITY SEALING .

Install extension, wheel arch carrier support.

In areas (1) and (2), rivet new part with blind rivets N7.

In area (3) rivet new part with blind rivets N3.

In areas (4) and (5), rivet new part with punch rivets N5.

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Area	Number
4	6
5	5