Removing D-Pillar Reinforcement

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

All straightening work on the body in the connection area of the sheetmetal parts to be replaced must be completed before the damaged parts are removed .

Fig 1: D-Pillar Reinforcement Component Location

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

D-pillar, outer
D-pillar reinforcement, top
D-pillar, inner
D-pillar gusset plate
Seal
D-pillar reinforcement, bottom
End piece

Remove end plate. → Removing End Plate
Remove rear side section. → Removing Rear Side Panel

Fig 2: Overview Of D-Pillar - Inside
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Cut off D-pillar gusset plate.
1. 3.1. Mill off welded joints on the D-pillar gusset plate using the spotweld cutter (areas -A- ).
  
  Fig 3: Separating Welded Joints On Left D-Pillar Gusset Plate
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 3.2. Grind off MIG seams on the D-pillar gusset plate using a parting grinder (areas -B- ).
Remove D-pillar gusset plate.

Fig 4: Overview Of D-Pillar - Inside
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Cut off D-pillar on rear side member.
1. 5.1. Grind off MIG seams on the rear side member using a parting grinder (area -A- ).
  
  Fig 5: Separating Welded Joints On Side Member
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 6: Overview Of D-Pillar - Inside
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Cut off inner D-pillar.
1. 6.1. Mill off welded joints on the inner D-pillar using the spotweld cutter (areas -A and B- ).
  
  Fig 7: Separating Welded Joints On Inner D-Pillar
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 8: Overview Of D-Pillar - Outside
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Cut off outer D-pillar.
1. 7.1. Grind off welded joints on the outer D-pillar using a parting grinder (area -A- ).
  
  Fig 9: Separating Welded Joints On Outer D-Pillar
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 7.2. Mill off welded joints on the outer D-pillar using the spotweld cutter (area -B- ).
3. 7.3. Drill off welded joints on the outer D-pillar using a drill (area -C- ). This will bore through all panel thicknesses.
  
  Fig 10: Overview Of D-Pillar - Outside
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Cut off outer D-pillar.
1. 8.1. Mill off welded joints on the C-pillar reinforcement using the spotweld cutter (areas -A, B and C- ).
  
  Fig 11: Separating Welded Joints On Outer D-Pillar
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 12: Overview Of D-Pillar - Outside
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Cut off D-pillar at the rear wheel housing.
1. 9.1. Mill off welded joints on the rear wheel housing using the spotweld cutter (areas -A and B- ).
  
  Fig 13: Separating Welded Joints On Rear Wheel Housing
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 14: Overview Of D-Pillar - Inside
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Cut off D-pillar at the lock carrier.
1. 10.1. Grind off MIG seams on the lock carrier using a parting grinder (area -A- ).
  
  Fig 15: Separating Welded Joints On Lock Carrier
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 16: Overview Of D-Pillar - Outside
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Cut off D-pillar at the side member.
1. 11.1. Mill off welded joints on the rear side member using the spotweld cutter (area -A- ).
  
  Fig 17: Separating Welded Joints On Side Member
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Remove outer and inner D-pillar with reinforcements.