Fitting Outer Lower Side Member And Preparing 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 Fitting Outer Lower Side Member

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Produce repair part.
1. 1.1. Cut off the connection areas to the pillar on the new lower side member. Ensure that the repair part in the area of the cut overlaps by -W- → Overlap: 50 mm over the remaining piece of the vehicle. The overlap on the wheel arch is automatically defined when the cut is made.
  
  Fig 2: Identifying Pillar Connection Areas Dimension
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 3: Identifying Pillar Connection Areas Dimension
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Adapt the lower side member to the body.
1. 2.1. Fix the lower side member to the body with tensioning clamps. To fit, install the front and rear doors and adjust the contours and gap dimensions between the doors and lower side member according to the adjustment values. → GAP DIMENSIONS
Fit lower side member joints.
1. 3.1. Use a body saw to cut the two sheetmetal plates -T- in the area of the overlap between the lower side member and pillars. Do not damage the internal components.
  
  Fig 4: Identifying Overlap Between Lower Side Member And Pillars
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Remove lower side member.
1. 4.1. Remove lower side member and remaining pieces from the pillars.
Clean welding and sealing areas.
1. 5.1. Grind both sides of the connection flange of the lower side member in the marked areas -A-, -B, C, D, E, I, J-, -F-, -G, H- and -K- until bare using a rotary brush.
  
  Fig 5: Identifying Grind Area On Connection Flange Of Lower Side Member
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 6: Identifying Grind Area On Connection Flange Of Lower Side Member
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 7: Identifying Grind Area On Connection Flange Of Lower Side Member Dimension
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 8: Identifying Grind Area On Connection Flange Of Lower Side Member Dimension
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 9: Identifying Grind Area On Connection Flange Of Lower Side Member Dimension
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Drilling holes for plug welding using inert gas
1. 6.1. On the lower side member, drill holes with a diameter of 7 mm (→ Fig 10) or use a hole punch (areas -I, J- ). Maintain spacing as on the old part.
  
  Fig 10: Identifying Drilling Holes Area For Plug Welding Using Inert Gas
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 11: Identifying Lower Side Member And Drill Holes Punch (Areas -I, J-)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.