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Preparing Front Side Member For Installation

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.
Fig 1: Identifying Bracket Installation Position On Side Member
G09420409Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  1. Prepare side member in area of bracket for installation.
    1. 1.1. Grind both sides of the connection flanges of the new part in the marked area -A-  until bare using a rotary brush.
      Fig 2: Identifying Side Member Bracket Installation Area
      G09420410Courtesy of PORSCHE CARS NORTH AMERICA, INC.
      Fig 3: Identifying Side Member Installation Position On Spring Strut Mount
      G09420411Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  2. Prepare side member in area of spring strut mount for installation.
    1. 2.1. Grind both sides of the connection flanges of the new part in the marked areas -B-  until bare using a rotary brush.
    2. 2.2. Drill holes Ø 7 mm in the fastening flanges of the spring strut mount (area -B-  ). Maintain spacing as on the old part.
      Fig 4: Identifying Side Member Spring Strut Mount Installation Area
      G09420412Courtesy of PORSCHE CARS NORTH AMERICA, INC.
      Fig 5: Identifying Side Member Installation Position On Spring Strut Mount
      G09420413Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  3. Prepare side member in area of spring strut mount for installation.
    1. 3.1. Grind both sides of the connection flanges of the new part in the marked areas -C-  until bare using a rotary brush.
      Fig 6: Identifying Frame Head Side Member Installation Area
      G09420414Courtesy of PORSCHE CARS NORTH AMERICA, INC.
      Fig 7: Identifying Frame Head Side Member Installation Area
      G09420415Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  4. Prepare side member in area of frame head for installation.
    1. 4.1. Grind both sides of the connection flanges of the new part in the marked area -D-  until bare using a rotary brush.
      Fig 8: Identifying Firewall Side Member Installation Area
      G09420416Courtesy of PORSCHE CARS NORTH AMERICA, INC.
      Fig 9: Identifying Spring Strut Mount Side Member Area
      G09420417Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  5. Prepare side member in area of spring strut mount for installation.
    1. 5.1. Grind both sides of the connection flanges of the new part in the marked areas -E, F-  until bare using a rotary brush.
    2. 5.2. Drill holes Ø 7 mm in the fastening flange of the spring strut mount (area -F-  ). Maintain spacing as on the old part.
      Fig 10: Identifying Side Member Installation Area On Spring Strut Mount (E And F)
      G09420418Courtesy of PORSCHE CARS NORTH AMERICA, INC.
      Fig 11: Identifying Side Member Installation Area On Firewall
      G09420419Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  6. Prepare side member in area of firewall for installation.
    1. 6.1. Grind both sides of the connection flanges of the new part in the marked areas -G, H-  until bare using a rotary brush.
    2. 6.2. Drill holes Ø 8 mm in the fastening flanges of the side member (area -H-  ). Maintain spacing as on the old part.
      Fig 12: Identifying Side Member Installation Area On Firewall
      G09420420Courtesy of PORSCHE CARS NORTH AMERICA, INC.
      Fig 13: Identifying Side Member Installation Area On Floor Front Section
      G09420421Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  7. Prepare side member in area of floor front section for installation.
    1. 7.1. Grind both sides of the connection flanges of the new part in the marked areas -I-  until bare using a rotary brush.
    2. 7.2. Drill holes Ø 8 mm in the fastening flange of the side member (area -I-  ). Maintain spacing as on the old part.
      Fig 14: Preparing Side Member In Area Of Floor Front Section For Installation
      G09420422Courtesy of PORSCHE CARS NORTH AMERICA, INC.
      Fig 15: Identifying Side Member Installation Area On Floor Front Section
      G09420423Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  8. Prepare side member in area of floor front section for installation.
    1. 8.1. Grind both sides of the connection flanges of the new part in the marked areas -L, K-  until bare using a rotary brush.
    2. 8.2. Drill holes Ø 8 mm in the fastening flanges of the side member (area -L-  ). Maintain spacing as on the old part.
      Fig 16: Preparing Side Member In Area Of Floor Front Section For Installation
      G09420424Courtesy of PORSCHE CARS NORTH AMERICA, INC.
      Fig 17: Identifying Reinforcement Area
      G09420425Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  9. Prepare reinforcement for installation.
    1. 9.1. Cut back the new part to the area -M-  .
      Fig 18: Identifying Reinforcement Installation Area (M)
      G09420426Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 9.2. Grind both sides of the connection flanges of the new part in the marked areas -N-  until bare using a rotary brush.
      Fig 19: Identifying Reinforcement Installation Area (N)
      G09420427Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    3. 9.3. Drill holes Ø 7 mm in the fastening flanges of the reinforcement (area -N-  ). Maintain a distance of approx. 20 mm between the holes.
      Fig 20: Identifying Reinforcement Installation Area (N)
      G09420428Courtesy of PORSCHE CARS NORTH AMERICA, INC.
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