Installing Side Member

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.

WARNING: Body repairs not carried out properly

Unintentional triggering of airbag and seat-belt pretensioner
Risk of damage to control units for airbag and seat-belt pretensioner units

→ Only apply MIG welds on the side member using the welders authorized.

→ Do not butt-weld thick body panels (more than → Length: +1.5 mm thick) without a welding gap during MIG welding.

→ To achieve the required welding quality, maintain the specified welding gap.

→ Do not grind down the welded seams.

Fig 1: Identifying Installation Position Of Front Side Member (Section)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Inner front side member (section)
Outer front side member (section)

Secure side member to the body.
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.
1. 1.1. Fix inner side member to the frame head and secure top side member support.
2. 1.2. Fix inner side member to the body using tensioning clamps.
3. 1.3. Fix outer side member to inner side member using tensioning clamps.
  
  Fig 2: Overview Of Side Member (Inside)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Weld in the inner side member.
1. 2.1. Weld inner side member in area -A- using inert gas.
  
  Fig 3: Identifying Welding In Inner Side Member (A)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 4: Overview Of Side Member (Outside)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Weld in outer side member and inner side member.
1. 3.1. Weld outer side member in areas -A, B, C and D- using inert gas. The inert gas-welded seams -C and D- are applied in addition to the standard welded joints.
  
  Fig 5: Identifying Inert Gas Welding Outer Side Member
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 3.2. Resistance spot weld the outer side member in areas -A, B, C and D- .
  
  Fig 6: Identifying Resistance Spot Welding Outer Side Member
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 3.3. Plug-weld the outer side member in areas -A and B- using inert gas.
  
  Fig 7: Identifying Plug-Welding Outer Side Member
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install support for top side member. → Installing Side Member For Wheel Housing Upper Section
Install frame head (impact absorber mount). → Installing Frame Head (Impact Absorber Mount)