Preparing Connection Areas Of Body For 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.

Fit 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 (new part) to the frame head and secure top side member support.
2. 1.2. Fix outer side member (new part) to the inner side member (new part).
3. 1.3. Mark the cut on the body in the area where the inner side member and outer side member overlap (new part to old part).
4. 1.4. Remove inner and outer side members (new parts).
  
  Fig 1: Overview Of Remaining Pieces Of Side Member
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Remove remaining pieces of side member on the body.
Information
- Thick body panels (> 1.5 mm) must not be butt-welded without a welding gap.
- Always allow a welding gap of s = approx. 1x material strength when fitting new parts.
1. 2.1. Cut through the inner side member (old part) in area -A- using a parting grinder. Use a 1 mm cutting disc for high-strength steel Nr.129-1 for cutting. Maintain the welding gap of → Welding gap: 2 mm. Do not damage internal components.
  
  Fig 2: Identifying Inner Side Member Cutting Position
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Information
  - Thick body panels (> 1.5 mm) must not be butt-welded without a welding gap.
  - Always allow a welding gap of s = approx. 1x material strength when fitting new parts.
2. 2.2. Cut through the outer side member (old part) in area -A- using a parting grinder. Use a 1 mm cutting disc for high-strength steel Nr.129-1 for cutting. Maintain the welding gap of → Welding gap: 2 mm. Do not damage internal components.
  
  Fig 3: Identifying Outer Side Member Cutting Position
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 2.3. Mill off welded joints on the bottom of the outer side member using the spotweld cutter (area -A- ).
  
  Fig 4: Separating Welded Joints On Remaining Pieces Of Side Member
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. 2.4. Grind off inert gas-welded seam on the top of the outer side member using a parting grinder (area -B- ).
5. 2.5. Remove remaining pieces of the front side member -1 and 2- .
  
  Fig 5: Identifying Remaining Pieces Of Side Member
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 6: Overview Of Side-Member Connecting Flanges
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Clean welding and sealing areas.
1. 3.1. Clean undersealing, adhesive residue and paint from the marked areas of the body connecting flanges using a hot-air gun and rotary brush. Grind the connecting flanges until bare.
  
  Fig 7: Identifying Side-Member Connecting Flanges
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Coat spot-weld flange areas with zinc powder paint.
1. 4.1. Coat all spot-weld flange areas with zinc powder paint.