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Home >> Porsche >> 2016 >> Cayman GTS, Standard Trans >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> 50 - Body Front -- (981) BOXSTER/CAYMAN >> WM 507955 Replacing Front Side Member (Section) (Except BOXSTER GTS) >> Installing Front Side Member

Installing Front Side Member

  1. Apply adhesive to the body.

    Apply adhesive evenly over the entire bonding surface. → Application depth: 0.5 mm 

    Working with body structural adhesive →  5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE 

    Fig 1: Identifying Front Side Member Bonding Areas
    G10024113Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    Fig 2: Identifying Front Side Member Bonding Areas
    G10024114Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    Fig 3: Identifying Front Side Member Bonding Areas
    G10024115Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  2. Apply adhesive to the side member.

    Apply adhesive evenly over the entire bonding surface. → Application depth: 0.5 mm 

    Fig 4: Identifying Side Member Bonding Areas
    G10024116Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    Fig 5: Identifying Side Member Bonding Areas
    G10024117Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    Fig 6: Identifying Side Member Bonding Areas
    G10024118Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 2.1. Also apply a bead of adhesive to the front edge of the screw flange. → Application depth: 5 mm 
  3. Position sub-part on the side member using the straightening system.
    Fig 7: Installing Front Side Member
    G10024119Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Information 

    • The screws also serve as ground connections  .
    • Remove dirt and primer from the threads of the spare part using a tap  .
    • Remove dirt and primer from the body close to the screw heads. 5X00IN25 MAKING GROUND CONNECTIONS
  4. Screw in countersunk screws → countersunk screw 999.073.549.01 and tighten to the specified tightening torque. → Tightening torque: 15 Nm (11 ftlb.) 
    Fig 8: Identifying Front Side Member Screws
    G10024120Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    Fig 9: Identifying Front Side Member Screws
    G10024121Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  5. Rivet in side member
    1. 5.1. Rivet in the area shown -arrow-  using → BLIND RIVET 999.190.227.01.
      Fig 10: Locating Bottom Bore
      G10024122Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 5.2. Rivet in the area shown -A-  using → BLIND RIVET 999.190.230.01.
      Fig 11: Locating Bottom Bore
      G10024123Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    3. 5.3. Rivet in areas shown -A-  using → BLIND RIVET 999.190.230.01.
      Fig 12: Identifying Side Member Rivet
      G10024124Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    4. 5.4. Rivet in areas shown -B-  using → BLIND RIVET 999.190.229.01.
      Fig 13: Identifying Side Member Rivet
      G10024125Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    5. 5.5. Rivet in areas shown using → BLIND RIVET 999.190.229.01.
      Fig 14: Locating Side Member Rivet
      G10024126Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    6. 5.6. The blind rivet is inserted in the area shown -arrow-  after fitting the wing joining plate. →  505355 REPLACING WING JOINING PLATE  
      Fig 15: Locating Side Member Rivet
      G10024127Courtesy of PORSCHE CARS NORTH AMERICA, INC.