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Home >> Porsche >> 2016 >> Boxster Spyder >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> 51 - Body Center, Roof, Frame - BOXSTER & CAYMAN >> WM 514555 Replacing Outer Side Member >> Removing Side Member

Removing Side Member

Fig 1: Side Member Component Location
G10029161Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  1. Remove A-pillar section.
    1. 1.1. Cut A-pillar section to dimension -A-  at the marked area -X-  .

      → Dimension - A -: 120 mm 

      Information 

      Drill out the connection point on one side only. Do not damage the plate underneath.

    2. 1.2. Drill out spotwelds. Spotweld drill bit Nr.129 Pneumatic spotweld remover, Vario Drill WS 90 WE 1139 
    3. 1.3. Heat bonding areas. Hot-air blower, Leister-Electron/V.A.G. 1416 WE 1119 
    4. 1.4. Remove A-pillar section. Make sure that the section of the A-pillar does not lose its shape so that it can be re-used  .
      G10029162Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  2. Remove outer side panel section.

    Information 

    Drill out the connection point on one side only. Do not damage the plate underneath.

    1. 2.1. Make cuts. Special electric cutter - fine WE 1137 Pneumatic body saw PS 1 WE 1138 
    2. 2.2. Cut outer side panel section to dimension -A-  at the marked area -X-  .

      → Dimension - A -: 45 mm 

    3. 2.3. Cut outer side panel section to dimension -B-  at the marked area -X-  .

      → Dimension - B -: 30 mm 

      G10029163Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Information 

      Drill out the connection point on one side only. Do not damage the plate underneath.

  3. Drill out spotwelds. Spotweld drill bit Nr.129 Pneumatic spotweld remover, Vario Drill WS 90 WE 1139 
    1. 3.1. Heat bonding areas -A-  and -B-  . Hot-air blower, Leister-Electron/V.A.G. 1416 WE 1119 
    2. 3.2. Heat bonding area marked in yellow. Hot-air blower, Leister-Electron/V.A.G. 1416 WE 1119 
    3. 3.3. Remove outer side panel section.
      G10029164Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  4. Remove connecting piece of rear side member. The rear connecting piece is installed on the new part  .

    Information 

    Drill out the connection point on one side only. Do not damage the plate underneath.

    1. 4.1. Drill out spotwelds. Spotweld drill bit Nr.129 Pneumatic spotweld remover, Vario Drill WS 90 WE 1139 
      G10029165Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  5. Heat bonding areas marked in yellow. Hot-air blower, Leister-Electron/V.A.G. 1416 WE 1119 
    1. 5.1. Remove connecting piece of side member.
      G10029166Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  6. Remove inner side panel section.
    1. 6.1. Cut inner side panel section to dimension -A-  and -B-  at the marked area -X-  .

      → Dimension - A -: 77 mm 

      → Dimension - B -: 70 mm 

      Information 

      Drill out the connection point on one side only. Do not damage the plate underneath.

    2. 6.2. Drill out spotwelds. Spotweld drill bit Nr.129 Pneumatic spotweld remover, Vario Drill WS 90 WE 1139 
      G10029167Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  7. Heat bonding areas marked in yellow. Hot-air blower, Leister-Electron/V.A.G. 1416 WE 1119 
    1. 7.1. Remove inner side panel section.
      G10029168Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  8. Remove lower B-pillar section.
    1. 8.1. Cut lower B-pillar section to dimension -A, B, C, D-  at the marked areas -X-  .

      → Dimension - A -: 150 mm 

      → Dimension - B -: 30 mm 

      → Dimension - C -: 90 mm 

      → Dimension - D -: 40 mm 

      G10029169Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Information 

      Drill out the connection point on one side only. Do not damage the plate underneath.

    2. 8.2. Drill out spotwelds. Spotweld drill bit Nr.129 Pneumatic spotweld remover, Vario Drill WS 90 WE 1139 
      G10029170Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    3. 8.3. Cut welded seam in area -D-  .
    4. 8.4. Heat bonding areas marked in yellow. Hot-air blower, Leister-Electron/V.A.G. 1416 WE 1119 
      G10029171Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    5. 8.5. Remove lower B-pillar section.

      Information 

      Drill out the connection point on one side only. Do not damage the plate underneath.

  9. Drill out spotwelds. Spotweld drill bit Nr.129 Pneumatic spotweld remover, Vario Drill WS 90 WE 1139 
    G10029172Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  10. Drill through area -A-  with → Diameter: 6. mm  carefully.
    G10029173Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  11. Heat bonding areas marked in yellow. Hot-air blower, Leister-Electron/V.A.G. 1416 WE 1119 
    G10029174Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    G10029175Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  12. The remaining side member reinforcements must be removed.

    The side member reinforcements are installed on the new part.

  13. Remove front side member closing panel.

    The front closing panel is installed on the new part.

    G10029176Courtesy of PORSCHE CARS NORTH AMERICA, INC.
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