Preparing Front Panel For Installation

Information 

• Some of the repair illustrations show only one side of the vehicle. 
• Naturally, some steps also have to be performed on the opposite side of the vehicle as well. 

Information 

Remove component carefully.

The removed part must be re-used during installation.

Information 

The rivet positions -1-  will also be used for the wing joining plate during installation.

Fig 1: Identifying Cross Member Rivet Positions

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1. Loosen upper cross member.
   1. 1.1. Drill through punch rivets -1 and 2-  .
      Fig 2: Identifying Cross Member Rivets Position

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   2. 1.2. Heat bonding areas.
      Fig 3: Identifying Cross Member Heat Bonding Areas

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   3. 1.3. Remove cross member.
2. Fit front panel and secure it to the body.
   1. 2.1. Position front panel.
      1. 2.1.1. Bend sheetmetal flange in slightly on one side.
         Fig 4: Bending Sheetmetal Flange

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      2. 2.1.2. Insert front panel.
         Fig 5: Inserting Front Panel

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   2. 2.2. Drill bores for the rivets through the existing holes. → Diameter: 6.5 mm 
3. Drill new holes in the areas shown. → Diameter: 6.5 mm 
   Fig 6: Identifying Drilling Holes Areas

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   Fig 7: Locating Drilling Holes (1 Of 4)

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   Fig 8: Locating Drilling Holes (2 Of 4)

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   Fig 9: Locating Drilling Holes (3 Of 4)

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   Fig 10: Locating Drilling Holes (4 Of 4)

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4. Fit upper cross member.
   1. 4.1. On the cross member, drill new holes through the existing holes on the body.
      Fig 11: Identifying Front Panel Drilling Holes

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5. Countersink the bores shown for installing countersunk rivets. Countersink Nr.202 
   Fig 12: Identifying Front Panel Counterbores

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6. Remove cross member and front panel.
7. De-burr the bores.
8. Prepare connection areas for bonding. → WM 5X00IN WORKING WITH BODY STRUCTURAL ADHESIVE (EXCEPT CARRERA "EDITION", CARRERA CABRIOLET "EDITION", CARRERA 4 "EDITION", CARRERA 4 CABRIOLET "EDITION")
   Fig 13: Preparing Connection Areas For Bonding (1 Of 3)

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   Fig 14: Preparing Connection Areas For Bonding (2 Of 3)

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   Fig 15: Preparing Connection Areas For Bonding (3 Of 3)

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   Fig 16: Preparing Connection Areas On Cross Member For Bonding

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