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: Body Front Section Component Location

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Installation position of body front section

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

   Information 

   Loosen connection points on one side only. Do not damage the sheet-metal panel underneath.

   1. 1.1  Drill out spotwelds. > Nr.129 - Spotweld drill bit  > VAS 882 001 - Spot-weld breaker 

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      Bracket for longitudinal member for wheel housing

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.

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      Bracket for longitudinal member for wheel housing

3. Make cuts.

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   Cut on upper longitudinal member

4. Make cut in the cowl panel area. > Length 110 mm 
   Fig 2: Checking Cowl Panel Cutting Dimension

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   Cuts on bulkhead/cowl panel

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   Cuts on longitudinal member/spring strut mount

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

   Information 

   Loosen connection points on one side only. Do not damage the sheet-metal panel underneath.

   1. 6.1  Drill out spotwelds.
   2. 6.2  Remove welded seams in area -A-  .

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      Removing cowl panel

7. Heat bonding areas.
   1. 7.1  Remove cowl panel.

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      Removing cowl panel

8. Drill out spotwelds.

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   Body front section, upper longitudinal member area

9. Drill out rivets.
   1. 9.1  Do not drill out rivets -1-  .

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      Body front section, wheel housing area

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.

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       Body front section, inner bulkhead area

11. Use a drill bit with a diameter of > Diameter 6.5 mm  to drill through rivets.

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    Body front section, bulkhead area

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    Body front section, underbody area

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

    Welded seams will be replaced by bonding during installation.

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    Welded seams on bracket

13. Drill out rivets in footwell.
    1. 13.1  Unscrew and remove fastening screws -1-  .

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       Body front section, footwell area

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       Body front section, footwell area

14. Heat marked bonding areas.

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    Heating bonding areas

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    Heating bonding areas

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    Heating bonding areas

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    Heating bonding areas

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    Heating bonding areas

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    Heating bonding areas

    Information 

    For additional 3D information, see 5095IN BODY FRONT SECTION INFORMATION

15. Remove remaining sections of the body front section.