Installing Body Front Section

Information 

• Before final assembly, make sure you fully understand all the work steps involved and carry out a trial assembly without applying adhesive.
• Bonding 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.

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Body front section, underbody area

• Do not use rivets at the position shown -inset-  . Once installation is complete, use a ground connection at this position -inset-  .

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

1. Install body front section and check that it fits perfectly.

   WM, 5X00IN41 GAP DIMENSIONS .

2. Apply adhesive > Preparing body front section. > Application depth 3.0 mm 

   WM, 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00 ..

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   Preparing body front section

3. Rivet in body front section in the upper longitudinal member area using > BLIND RIVET 999.190.229.01  (> Upper longitudinal member area).

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   Upper longitudinal member area

4. Rivet in body front section in the wheel housing area using > BLIND RIVET 999.190.229.01  (> Body front section, wheel housing area).

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   Body front section, wheel housing area

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 the body front section area -B-  using > BLIND RIVET 999.190.229.01  (> Body front section, inner bulkhead area).

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   Body front section, inner bulkhead area

6. Rivet in body front section in the bulkhead area using > BLIND RIVET 999.190.229.01  (> Body front section, bulkhead area).

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   Body front section, bulkhead area

7. Rivet in body front section in the underbody area using > BLIND RIVET 999.190.230.01  (> Body front section, underbody area).

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   Body front section, underbody area

8. Rivet in body front section in the footwell area using > BLIND RIVET 999.190.230.01  (> Body front section, footwell area).

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   Body front section, footwell area

9. Rivet in body front section in the footwell area using > BLIND RIVET 999.190.229.01  (> Body front section, footwell area).
10. Screw in (self-tapping) screws -1-  . > TORX SCREW 999.073.541.01 

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    Body front section, footwell area

11. Install cowl panel.
12. Apply adhesive.

    WM, 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00 ..

    > Application depth 3.0 mm

    > Installing cowl panel

13. Fit in and secure the cowl panel > Installing cowl panel.

    WM, 5X00IN41 GAP DIMENSIONS .

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    Installing cowl panel

14. Apply foam filler to area -1-  .

    WM, 5X00IN20 WORKING WITH BODY STRUCTURAL FOAM .

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    Preparing connection areas on cowl panel

15. Resistance spot-weld the cowl panel >Installing cowl panel.
16. Apply a full weld to area -A-  using inert gas.

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    Installing cowl panel

17. Prepare connection areas on bracket for longitudinal member for wheel housing > Connection areas on bracket for longitudinal member for wheel housing.

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    Connection areas on bracket for longitudinal member for wheel housing

18. Align the sealing surface and connections with the body.
19. De-burr connection points and prepare them for welding.
20. Prepare the marked areas for welding and bonding.
21. Fit bracket for longitudinal member for wheel housing.
    1. 21.1  For better positioning of the bore holes, fit the wing holder -2-  .
    2. 21.2  Drill holes for rivets in the marked areas -1-  .

       > Diameter 6.6 mm 

       > Drilling holes

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    Drilling holes

22. Apply adhesive and fit in and secure supporting plate for longitudinal member for wheel housing > Apply adhesive.

    WM, 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00 ..

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    > Application depth 3.0 mm

23. Rivet in bracket for longitudinal member for wheel housing in area -B-  using >BLIND RIVET 999.190.230.01  (> Installing supporting plate for longitudinal member for wheel housing).
24. Resistance spot-weld bracket for longitudinal member for wheel housing in area -A-  (> Installing supporting plate for longitudinal member for wheel housing).

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    Installing supporting plate for longitudinal member for wheel housing

25. Make ground connections using a through bolt.

    WM, 5X00IN25 MAKING GROUND CONNECTIONS .

    Information 

    • Check screw-in direction.
    1. 25.1  Make a ground connection -1-  on both sides of the vehicle.

       Making ground connection

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       Information 

       • Check screw-in direction.
    2. 25.2  Between the two rivets -2 and 3-  , make a ground connection -1-  .

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       Making ground connection

       Countersunk screw > COUNTERSUNK SCREW 999.073.549.01 

       Hexagon nut > HEXAGON NUT 900.377.003.01 

    3. 25.3  Tighten threaded joint. > Tightening torque 15 Nm (11 lb.ft)
    4. 25.4  Seal threaded joint.