Preparing FLOORPAN For Installation

Information 

• Before final assembly, make sure you fully understand all the work steps involved and carry out a trial assembly without applying adhesive. 
• The bonding process can only be carried out reliably when a smooth and swift sequence of operations is guaranteed. 
• Do not begin bonding work until all materials and tools necessary for later repair work are available. 

Information 

• The floorpan and seat cross member are fitted in and secured together. 
• Holes for rivets are drilled through both components. 

1. Fit in floorpan together with the seat cross member and secure them to the body.
   1. 1.1. Drill holes for rivets -A, B and C-  through the existing holes using a drill bit with a diameter of → Diameter: 6.6 mm  .

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2. Fit in and secure the connection cross member.
   1. 2.1. Drill holes for rivets -A-  through the existing holes using a drill bit with a diameter of → Diameter: 6.6 mm  .
   2. 2.2. Prepare connection cross member for bonding and riveting.

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3. Fit in and secure mounting plate for roll-over bar.
   1. 3.1. Install roll-over bar -3-  for fitting in and securing the mounting plate -1-  → INSTALLING ROLL-OVER BAR .
   2. 3.2. Drill holes for rivets through the existing holes using a drill bit with a diameter of → Diameter: 6.6 mm  .

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   3. 3.3. Mark holes for the lower Z mounting plate -1-  .

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   4. 3.4. Remove roll-over bar. → 697219 REMOVING AND INSTALLING ROLL-OVER BAR .
   5. 3.5. Drill holes for nuts for the lower Z mounting plate -1-  using a drill bit with a diameter of → Diameter: 10 mm  .
   6. 3.6. Drill holes for rivets for the lower Z mounting plate -1-  using a drill bit with a diameter of → Diameter: 6.6 mm  .
4. Cut new lower firewall -arrows-  .
   1. 4.1. Use old lower firewall as a template and position it in area -1-  .
   2. 4.2. Cut lower firewall section with an overlap of 1 cm in area -2-  .

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5. Fit in lower firewall section and secure it to the body. Check gap dimensions. → WM 5X00IN GAP DIMENSIONS (EXCEPT CARRERA "EDITION", CARRERA CABRIOLET "EDITION", CARRERA 4 "EDITION", TARGA 4, TARGA 4S, TARGA 4 GTS, CARRERA 4 CABRIOLET "EDITION") - section on "Preparing".
   1. 5.1. In area -A, B and C-  , drill holes for rivets using a drill bit with a diameter of → Diameter: 6.6 mm  .

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   2. 5.2. Remove firewall section again.
6. Prepare the marked connection areas on the floorpan for bonding, riveting and welding.

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7. Prepare connection areas of lower firewall section.

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8. Prepare connection areas of mounting plate for roll-over bar on the inside.

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9. Prepare connection areas of Z mounting plate for roll-over bar at the bottom.

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