The front panel contains quite a few sensors -- a PIR motion detector for locating warm objects (such as people), a headlight, an infrared proximity detector, and a third microphone. It also contains gearing and a small DC motor for rotating the PIR sensor unit. To remove it, several electrical connectors must be unplugged from the main board and threaded towards the front. If the rear body panel has been removed, as in the previous part, these connectors will be within easy reach.

This part is shown in pages 4 and 11 of the Assembly Diagram.

Remove Front Panel. Disconnect the following from the main board: J5 (bottom right - motor and encoder for the PIR Unit), J16 (left side, near chip A - headlamp and infrared sensor), J7 (top right - front microphone), and J9 (midway up on right - PIR sensor). Unscrew the 4 allen screws (3/16" hex wrench) securing the front panel and pull it free, threading the electrical connectors and cables through the body until they are completely removed. The figure at right shows the location of J5. The locations of J16, J7, and J9 are shown below:

Inside View of Front Panel. Here's the inside of the front panel right after it's been removed.

Remove Headlamp and Infrared Proximity Sensor. If you want, you can also dismantle the front panel itself. The headlamp bulb, reflector, and lens lift right out once the gray plastic retaining piece is removed. To remove the infrared proximity detector, unscrew the phillips screws holding it in, then use a screwdriver to carefully pry out the small PCB board with the proximity detector from its slot.

Close-up of the infrared proximity detector:

Remove PIR Unit. Unscrew the 4 phillips screws securing the PIR unit to the front panel. These screws are glued in to hold them despite vibrations, so they're very tight.

Close-Up of PIR Unit's Encoder. There are two sets of spacings on the encoder wheel. The gaps to the right in this picture are close together, while those to the left are fairly far apart. The region of the encoder wheel with tight gap spacing should be centered under the interrupter beam when the PIR unit is facing straight forward.

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