Removing Body Front End

Information 

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

1. Loosen front end section.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Punch rivets

   1. 1.1 Remove punch rivets -A-  using > VAS 852 001 - body dent removal unit, aluminium  and > VAS 6790 - compact booster  .

      > 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

   2. 1.2 Drill out spotwelds -B-  using > VAS 882 001 - spot-weld breaker  .
2. Loosen front end section.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Spot welds

   1. 2.1 Drill out spotwelds using > VAS 882 001 - spot-weld breaker  .
   2. 2.2 Grind down welded seams -1-  .
3. Drill out spotwelds from the outside using > VAS 882 001 - weld-spot remover  .

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Spot welds

4. Remove threaded bolt -1-  .

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Threaded bolt

5. Loosen front end section.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Welded seams

   1. 5.1 Drill out spotwelds using > VAS 882 001 - spot-weld breaker  .
   2. 5.2 Separate welded seams -1-  .
6. Separate welded seams.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Welded seams

7. Make a rough cut through the cross member at the marked areas.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Rough cuts

8. Drill out spotwelds using > VAS 882 001 - spot-weld breaker  .

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Spot welds

9. Grind down welded seams.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Welded seams

10. Heat bonding areas using > V.A.G 1416 - hot-air blower  .

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Bonding areas

11. Heat bonding areas using > V.A.G 1416 - hot-air blower  .

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Bonding areas

12. Heat bonding area using > V.A.G 1416 - hot-air blower  .

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Bonding area

13. Remove front end section.
14. Remove remaining pieces of cross member -1-  from supports -2-  on the body.

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Welded seams

    1. 14.1 Grind down welded seams -3-  .
    2. 14.2 Remove remaining pieces -1-  .