Removing Body Front Section

Information 

Only make cuts in the top plate. Make sure not to damage the plate underneath when doing this.

Fig 1: Identifying Body Front Section Position

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1. Remove supporting plate for longitudinal member for wheel housing.

   Information 

   Drill out the connection point on one side only. Do not damage the plate underneath.

   1. 1.1. Drill out spotwelds. Spotweld drill bit Nr.129 Pneumatic spotweld remover, Vario Drill WS 90 WE 1139 
      Fig 2: Identifying Bracket For Longitudinal Member For Wheel Housing

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2. Heat bonding areas on supporting plate for longitudinal member for wheel housing.
   1. 2.1. Remove supporting plate for longitudinal member for wheel housing.
      Fig 3: Identifying Bracket For Longitudinal Member For Wheel Housing

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3. Make cuts.
   Fig 4: Identifying Cutting Dimension On Upper Longitudinal Member

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4. Make cut in the cowl panel area. → Length: 110 mm 
   Fig 5: Identifying Cutting Dimension On Bulkhead/Cowl Panel

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   Fig 6: Identifying Cutting Dimension On Longitudinal Member/Spring Strut Mount

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5. Remove body front section.
6. Remove cowl panel.

   Information 

   Drill out the connection point on one side only. Do not damage the plate underneath.

   1. 6.1. Drill out spotwelds.
   2. 6.2. Remove welded seams in area -A-  .
      Fig 7: Identifying Cowl Panel Welded Seams Area

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7. Heat bonding areas.
   1. 7.1. Remove cowl panel.
      Fig 8: Identifying Cowl Panel Bonding Areas

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8. Drill out spotwelds.
   Fig 9: Identifying Upper Longitudinal Member Spotwelds Area - Body Front Section

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9. Drill out rivets.
   1. 9.1. Do not drill out rivets -1-  .
      Fig 10: Identifying Wheel Housing Rivets Area - Body Front Section

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10. Cut welded seams in area -A-  .
    1. 10.1. Use a drill bit with a diameter of → Diameter: 6.5 mm  to drill through rivets.
    2. 10.2. Drill out rivets in area -B-  using a drill bit with a diameter of → Diameter: 7.2 mm  and drill through the reinforcement behind it.
       Fig 11: Identifying Inner Bulkhead Rivets Area - Body Front Section

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11. Use a drill bit with a diameter of → Diameter: 6.5 mm  to drill through rivets.
    Fig 12: Identifying Bulkhead Area - Body Front Section

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    Fig 13: Identifying Underbody Area - Body Front Section

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12. Cut welded seams -1-  on the bracket.

    Welded seams will be replaced by bonding during installation.

    Fig 14: Identifying Bracket Welded Seams Areas

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13. Drill out rivets in footwell.
    1. 13.1. Unscrew and remove fastening screws -1-  .
       Fig 15: Identifying Footwell Area - Body Front Section (1 Of 2)

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       Fig 16: Identifying Footwell Area - Body Front Section (2 Of 2)

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14. Heat marked bonding areas.
    Fig 17: Identifying Footwell Bonding Areas (1 Of 6)

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    Fig 18: Identifying Footwell Bonding Areas (2 Of 6)

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    Fig 19: Identifying Footwell Bonding Areas (3 Of 6)

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    Fig 20: Identifying Footwell Bonding Areas (4 Of 6)

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    Fig 21: Identifying Footwell Bonding Areas (5 Of 6)

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    Fig 22: Identifying Footwell Bonding Areas (6 Of 6)

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15. Remove remaining sections of the body front section.