Installing Rear Side Member (Section)

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To fit the rear side member, the frame head (impact absorber mount) must be secured to the straightening set.

Fit rear side member to the body.
1. 1.1. Secure the frame head of the rear side member to the straightening set.
2. 1.2. Fix rear side member to the body using tensioning clamps.
Weld in rear side member on the inside and at the bottom.
1. 2.1. Use an inert-gas arc welder to weld the side member to the inside and underside of the carrier in areas -A- .
  
  Fig 1: Identifying Welded Joints On Inside And Underside Of Side Member
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Weld in rear side member on the outside.
1. 3.1. Apply a full weld to secure the side member in area -A- to the outside of the carrier using inert gas.
  
  Fig 2: Identifying Welded Joints On Outside Of Side Member
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 3.2. Resistance spot-weld the side member in area -B- .
Information

Never grind MIG seams on load-bearing body parts. However, a partial flat-grind may be required for subsequent installation of body parts.
The MIG seam on the upper side member flange must be ground down in order to accommodate the floor section.
1. 4.1. Grind down MIG seam in areas -A and B- .
  
  Fig 3: Grinding Down MIG Seam On Upper Side Member
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Weld in rear side member at the bottom of the D-pillar.
1. 5.1. Weld side member in area -A- using inert gas.
  
  Fig 4: Identifying Welded Joints On Rear Side Member
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Apply adhesive.

Fig 5: Applying Adhesive To Rear Side Member
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 6.1. Evenly apply structural adhesive to the marked areas -A and B- .
Fit the floor section on the body and weld it in.
1. 7.1. Fix the floor section to the body with tensioning clamps.
2. 7.2. Resistance spot-weld the floor section in areas -A and B- .
  
  Fig 6: Identifying Welded Joints On Floor Section
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 7.3. Plug-weld the floor section in area -A- using inert gas.
  
  Fig 7: Identifying Plug-Weld On Floor Section
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fill rear side member with foam.
1. 8.1. Fill the rear side member with foam from behind through the opening on the frame head -arrow- close to the seal -A- . → WM 5X00IN PROCESSING BODY FOAM FILLER (CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE (3.0))
  
  Fig 8: Filling Rear Side Member With Foam
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install spare-wheel well and side floor section. → 532455 REPLACING REAR TRUNK FLOOR PANEL - section on "Installing"