Removing A-Pillar

WARNING: This page is about a different car, the 2010 Porsche Cayenne, 2009 Porsche Cayenne, and 2008 Porsche Cayenne. However, it is still accessible from the selected car via links, so may be relevant.

Information

Separating the side member involves cutting through the complete side member as well as the support attached to the outside.

Fig 1: A-Pillar Component Location
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Front side section
A-pillar reinforcement
Filler plate for upper carrier

Remove outer side member. → Removing Outer Lower Side Member
Remove lower side member reinforcement. → Removing Lower Side Member Reinforcement

Fig 2: Overview Of Side Member (Outside)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Separate filler plate section for upper carrier.
Information
- Only the filler plate can be cut through during the separation process. The rear edge of the filler plate on the A-pillar is used as the rear reference line for taking measurements.
1. 3.1. Cut through filler plate for upper carrier in area -A- using the oscillating body saw. Maintain the dimension -X1- → Cut dimension, old part: 130 mm . Do not damage internal components.
  
  Fig 3: Separating Welded Joints On Filler Plate
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 3.2. Cut the laser-welded joint between the filler plate for the upper carrier and the inner A-pillar using the parting grinder (area -B- ).
3. 3.3. Grind off MIG seams on the A-pillar using a parting grinder (area -C- ).
4. 3.4. Mill off welded joints on the filler plate using the spotweld cutter (areas -A and B- ).
  
  Fig 4: Separating Welded Joints On Filler Plate
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. 3.5. Remove filler plate section for upper carrier.
  
  Fig 5: Overview Of Side Member (Outside)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Separate front side section.
Information
- Only the outer panel can be cut through during the separation process. The upper edge of the rectangular opening on the A-pillar is used as the lower reference line for taking measurements.
1. 4.1. Cut through the front side section in area -A- using the oscillating body saw. Maintain the dimension -X2- → Cut dimension, old part: 170 mm . Do not damage internal components.
  
  Fig 6: Separating Welded Joints On Side Section
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 4.2. Mill off welded joints on the side section using the spotweld cutter (area -B- ).
3. 4.3. Cut the laser-welded joints between the side section and inner A-pillar using the parting grinder (area -C- ).
4. 4.4. Mill off welded joints on the side section using the spotweld cutter (area -A- ).
  
  Fig 7: Heating Up Sealing And Bonding Areas
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. 4.5. Heat up sealing area on the side section uniformly using a hot-air blower (area -B- ).
6. 4.6. Heat up bonding area on the side section uniformly using a hot-air blower (area -C- ).
7. 4.7. Remove front side section.
  
  Fig 8: Overview Of Outer A-Pillar Reinforcement
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Cut off outer A-pillar reinforcement.
1. 5.1. Mill off welded joints on the A-pillar reinforcement using the spotweld cutter (areas -A and B- ).
  
  Fig 9: Separating Welded Joints On A-Pillar Reinforcement
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 5.2. Cut the laser-welded joints between the A-pillar reinforcement and inner A-pillar using the parting grinder (areas -C, D and E- ).
  
  Fig 10: Overview Of Side Member (Inside)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Cut off inner A-pillar reinforcement.
1. 6.1. Grind off MIG seams on the inner A-pillar using a parting grinder (area -A- ).
  
  Fig 11: Separating Welded Joints On Inner A-Pillar
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 12: Overview Of Outer A-Pillar Reinforcement
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Release A-pillar reinforcement.
1. 7.1. Heat up sealing area on the outer A-pillar reinforcement uniformly using a hot-air blower (area -A- ).
  
  Fig 13: Heating Up Sealing Areas
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 7.2. Heat up the seal on the A-pillar reinforcement uniformly starting from the inside of the vehicle using a hot-air blower (area -B- ).
Remove A-pillar reinforcement and seal.