Installing Front Side Members

WARNING: This page is about a different car, the 2010 Porsche Cayenne, 2009 Porsche Cayenne, and 2008 Porsche Cayenne. However, it is still accessible from the selected car via links, so may be relevant.

Fit side member to the body.
1. 1.1. Place the side member against the body and fasten to the straightening set.
  Information
  - To fit the side member, the frame head (impact absorber mount) and the top side member support must be secured to the straightening attachments.
2. 1.2. Install frame head and support for top side member.
  
  Fig 1: Identifying Floor Front Section Side Member Welded Joint Area
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Weld in side member in area of floor front section.
1. 2.1. Plug-weld the side member in area -S- under shielding gas.
2. 2.2. Weld the side member in area -T- with interrupted full weld under shielding gas.
  
  Fig 2: Identifying Welded Joints In Area Of Web Plate
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 3: Identifying Floor Front Section Side Member Welded Joint Area
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Weld in side member in area of floor front section.
1. 3.1. Plug-weld the side member in area -I- under shielding gas.
  
  Fig 4: Identifying Welded Joints For Floor Inner Section
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 5: Identifying Spring Strut Mount Side Member Welded Joint Area
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Weld in side member in area of spring strut mount.
1. 4.1. Plug-weld the spring strut mount in area -A- under shielding gas.
2. 4.2. Weld the spring strut mount in area -B, C- with interrupted full weld under shielding gas.
3. 4.3. Resistance spot-weld the spring strut mount in area -D- .
  
  Fig 6: Identifying Welded Joints For Spring Strut Mount
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 7: Identifying Lower Side Member Welded Joint Area
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Weld in side member in area of lower side member.
1. 5.1. Plug-weld the side member in area -K- under shielding gas.
  
  Fig 8: Identifying Welded Conection At Lower Side Member Front Section
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 9: Identifying Lower Side Member Welded Joint Area
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Weld in side member in area of lower side member.
1. 6.1. Plug-weld the side member in area -L- under shielding gas.
  
  Fig 10: Identifying Welded Conection At Lower Side Member Inner Section
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 11: Identifying Welded Joints At Firewall
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Weld in side member in area of firewall.
1. 7.1. Plug-weld the side member in area -J- under shielding gas.
  
  Fig 12: Identifying Welded Joints At Firewall Lower Section
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 13: Identifying Firewall Side Member Welded Joint Area
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Weld in side member in area of firewall.
1. 8.1. Plug-weld the side member in area -P- and -U- under shielding gas.
  
  Fig 14: Identifying Welded Joints At Firewall
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 15: Identifying Welded Joints At Top Of Side Member
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 8.2. Weld the side member in area -Q- with interrupted full weld under shielding gas.
  
  Fig 16: Identifying Welded Joints At Firewall
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 17: Identifying Floor Lower Section Side Member Welded Joint Area
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Weld in side member in area of floor lower section.
1. 9.1. Plug-weld the side member in area -V- under shielding gas.
  
  Fig 18: Identifying Welded Joints At Bottom Of Side Member (V)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 9.2. Weld the side member in area -W- with interrupted full weld under shielding gas.
  
  Fig 19: Identifying Welded Joints At Bottom Of Side Member (W)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 20: Identifying Firewall Side Member Welded Joint Area
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Weld in side member in area of firewall.
1. 10.1. Plug-weld the side member in area -Y-, -Y- and -Y- under shielding gas.
  
  Fig 21: Identifying Welded Joints At Firewall
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 22: Identifying Welded Joints At Firewall Lower Section
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 23: Identifying Welded Joints At Bottom Of Side Member
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 10.2. Weld the side member in area -Z- and -Z- with interrupted full weld under shielding gas.
  
  Fig 24: Identifying Welded Joints At Firewall
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 25: Identifying Welded Joints At Bottom Of Side Member
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 26: Identifying Firewall Spring Strut Mount Welded Joint Area
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Weld in spring strut mount in area of firewall.
1. 11.1. Plug-weld the spring strut mount in area -H, G- under shielding gas.
  
  Fig 27: Identifying Welded Joints For Spring Strut Mount
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 28: Identifying Spring Strut Mount Welded Joint Area
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Weld in reinforcement for spring strut mount.
1. 12.1. Plug-weld the reinforcement in area -F- under shielding gas.
  
  Fig 29: Identifying Welded Joints For Spring Strut Mount
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 30: Identifying Inner Floor Welded Joint Area
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Weld in reinforcement at floor inner section.
1. 13.1. Grinding the spot welds flat in area -S- .
  
  Fig 31: Identifying Welded Joints In Area Of Web Plate
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 13.2. Evacuate accessible cavities.
3. 13.3. Prime the welds -T- .
  
  Fig 32: Identifying Welded Joints In Area Of Web Plate
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. 13.4. Position the reinforcement and plug-weld in area -R- under shielding gas.
  
  Fig 33: Identifying Welded Joints For Floor Inner Section
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install support and top side member.
1. 14.1. Replace side member for wheel housing upper section.
Install frame head (impact absorber mount).
1. 15.1. Replacing frame head (impact absorber mount)