Removing Body Front Section

Information 

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

Information 

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Body front section, wheel housing area

• Do not drill out rivets -1  - (> Body front section, wheel housing area).

Information 

• Welded seams will be replaced by bonding during installation.

Fig 1: Body Front Section Component Location

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Installation position of body front section

1. Drill out spotwelds and remove supporting plate for longitudinal member for wheel housing > Bracket for longitudinal member for wheel housing.  > Nr. 129 - Spotweld drill  bit > VAS 882 001 - Spot-weld remover  > Bracket for longitudinal member for wheel housing 

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   Bracket for longitudinal member for wheel housing

2. Heat bonding areas of supporting plate for longitudinal member for wheel housing and remove supporting plate for longitudinal member for wheel housing > Bracket for longitudinal  member for wheel housing. 

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   Bracket for longitudinal member for wheel housing

3. Make cuts > Cut on upper longitudinal member.

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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  - (> Removing cowl panel).

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      Removing cowl panel

7. Heat bonding areas and remove cowl panel > Removing cowl panel.

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   Removing cowl panel

8. Drill out spotwelds > Body front section, upper longitudinal member area.

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   Body front section, upper longitudinal member area

9. Drill out rivets > Body front section, wheel housing area.

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   Body front section, wheel housing area

10. Cut welded seams in area -A-  (>; Body front section, inner bulkhead area).
    1. 10.1  Drill through rivets. > Diameter 6.5 mm 
    2. 10.2  Drill out rivets in area -B-  and drill through the reinforcement behind them. > Diameter 7.2 mm 

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       Body front section, inner bulkhead area

11. Drill through rivets.

    > Body front section, bulkhead area

    > Body front section, underbody area

    > Diameter 6.5 mm 

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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.

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    Welded seams on bracket

13. Drill out rivets in footwell.
14. Unscrew fastening screws -1-  .

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    Body front section, footwell area

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    Body front section, footwell area

15. Heat marked bonding areas.

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    Heating up bonding areas

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    Heating up bonding areas

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    Heating up bonding areas

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    Heating up bonding areas

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    Heating up bonding areas

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    Heating up bonding areas

16. Remove remaining sections of the body front section.