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

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

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 Wheel Housing Longitudinal Member Bracket

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
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 Wheel Housing Longitudinal Member Bracket

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Make cuts.
   Fig 4: Identifying Upper Longitudinal Member Cut

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Make cut in the cowl panel area. → Length: 110 mm 
   Fig 5: Identifying Bulkhead/Cowl Panel Cuts

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   Fig 6: Identifying Longitudinal Member/Spring Strut Mount Cuts

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
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: Removing Cowl Panel

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
7. Heat bonding areas.
   1. 7.1. Remove cowl panel.
      Fig 8: Removing Cowl Panel

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
8. Drill out spotwelds.
   Fig 9: Identifying Body Front Section - Upper Longitudinal Member Area

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
9. Drill out rivets.
   1. 9.1. Do not drill out rivets -1-  .
      Fig 10: Identifying Body Front Section Rivets - Wheel Housing Area

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
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 Body Front Section - Inner Bulkhead Area

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
11. Use a drill bit with a diameter of → Diameter: 6.5 mm  to drill through rivets.
    Fig 12: Identifying Body Front Section - Bulkhead Area

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    Fig 13: Identifying Body Front Section - Underbody Area

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
12. Cut welded seams -1-  on the bracket.

    Welded seams will be replaced by bonding during installation.

    Fig 14: Identifying Bracket Welded Seams

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
13. Drill out rivets in footwell.
    1. 13.1. Unscrew and remove fastening screws -1-  .
       Fig 15: Identifying Body Front Section - Footwell Area

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
       Fig 16: Identifying Body Front Section - Footwell Area

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
14. Heat marked bonding areas.
    Fig 17: Identifying Body Front Section Bonding Areas

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    Fig 18: Identifying Body Front Section Bonding Areas

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    Fig 19: Identifying Body Front Section Bonding Areas

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    Fig 20: Identifying Body Front Section Bonding Areas

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    Fig 21: Identifying Body Front Section Bonding Areas

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    Fig 22: Identifying Body Front Section Bonding Areas

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
15. Remove remaining sections of the body front section.