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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 509555 Replacing Body Front Section (Except BOXSTER GTS) >> Installing Body Front Section

Installing Body Front Section

  1. Install body front section and check that it fits perfectly. Check gap dimensions. →  5X00IN DIAGRAM - BODY GAP DIMENSIONS 

    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  .
  2. Apply adhesive. → Application depth: 3.0 mm 

    Working with body structural adhesive →  5X00IN WORKING WITH BODY STRUCTURAL ADHESIVE 

    Fig 1: Identifying Body Front Section
    G10024167Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  3. Rivet in body front section in upper longitudinal member area. → BLIND RIVET 999.190.229.01
    Fig 2: Identifying Upper Longitudinal Member Area
    G10024168Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  4. Rivet in body front section in wheel housing area. → BLIND RIVET 999.190.229.01
    Fig 3: Identifying Body Front Section - Wheel Housing Area
    G10024169Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  5. Weld and rivet in body front section in inner bulkhead area.
    1. 5.1. Apply a full weld to the body front section area -A-  using inert gas.
    2. 5.2. Rivet in body front section area -B-  . → BLIND RIVET 999.190.229.01
      Fig 4: Identifying Body Front Section - Inner Bulkhead Area
      G10024170Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  6. Rivet in body front section in the bulkhead area. → BLIND RIVET 999.190.229.01
    Fig 5: Identifying Body Front Section - Bulkhead Area
    G10024171Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  7. Rivet in body front section in the underbody area. → BLIND RIVET 999.190.230.01
    Fig 6: Identifying Body Front Section - Underbody Area
    G10024172Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 7.1. Do not use rivets at the position shown.

      Once installation is complete, use a ground connection at this position.

  8. Rivet in body front section in the footwell area. → BLIND RIVET 999.190.230.01
    Fig 7: Identifying Body Front Section - Footwell Area
    G10024173Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  9. Rivet in body front section in the footwell area. → BLIND RIVET 999.190.229.01
    1. 9.1. Screw in (self-tapping) fastening screws -1-  . → TORX SCREW 999.073.541.01
      Fig 8: Identifying Body Front Section - Footwell Area
      G10024174Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  10. Install cowl panel.

    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  .
  11. Apply adhesive. → Application depth: 3.0 mm 

    Working with body structural adhesive →  5X00IN WORKING WITH BODY STRUCTURAL ADHESIVE 

    1. 11.1. Fit and secure the cowl panel.

      Check gap dimensions. →  5X00IN DIAGRAM - BODY GAP DIMENSIONS 

      Fig 9: Identifying Front Cowl Panel
      G10024175Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  12. Apply foam filler to area -1-  . → 5X00IN22 WORKING WITH BODY FOAM FILLER

    Make sure that all openings and gaps are closed off with the foam filler.

    Fig 10: Identifying Cowl Panel Connection Areas
    G10024176Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  13. Resistance spot-weld the cowl panel.
    1. 13.1. Apply a full weld to area -A-  using inert gas.
      Fig 11: Identifying Cowl Panel
      G10024177Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  14. Prepare connection areas on bracket for longitudinal member for wheel housing.
    Fig 12: Identifying Wheel Housing Longitudinal Member Bracket Connection Areas
    G10024178Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  15. Straighten sealing surface and connection areas of the body.
  16. De-burr connection areas and prepare for welding.

    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  .
  17. Prepare marked areas for welding and bonding.
  18. Fit bracket for longitudinal member for wheel housing.
    1. 18.1. For better positioning of the bore holes, fit the wing holder -2-  .
    2. 18.2. Drill holes for rivets in the marked areas -1-  using a drill bit with → Diameter: 6.6 mm  Drill bit diameter of 6.6 mm.
      Fig 13: Identifying Body Front Section Holes
      G10024179Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      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  .
  19. Apply adhesive. → Application depth: 3.0 mm 

    Working with body structural adhesive →  5X00IN WORKING WITH BODY STRUCTURAL ADHESIVE 

    1. 19.1. Fit and secure supporting plate for longitudinal member for wheel housing.
      Fig 14: Identifying Adhesive Applying Area
      G10024180Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  20. Rivet in bracket for longitudinal member for wheel housing in area -B-  . → BLIND RIVET 999.190.230.01
    1. 20.1. Resistance spot-weld bracket for longitudinal member for wheel housing in area -A-  .
      Fig 15: Installing Wheel Housing Longitudinal Member Supporting Plate
      G10024181Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  21. Make ground connections using a through bolt. → Making ground connections 
    1. 21.1. Make a ground connection -1-  on both sides of the vehicle.

      Check screw-in direction.

    2. 21.2. Between the two rivets -2 and 3-  , make a ground connection -1-  .
      Fig 16: Identifying Body Front Section Ground Connection
      G10024182Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Check screw-in direction.

      Countersunk screw → COUNTERSUNK SCREW 999.073.549.01

      Hexagon nut → HEXAGON NUT 900.377.003.01

      Fig 17: Identifying Ground Connection And Rivets
      G10024183Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    3. 21.3. Tighten threaded joint to the specified torque. → Tightening torque: 15 Nm (11 ftlb.) 
    4. 21.4. Seal threaded joint.
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