Installing Front Side Member

Information 

• Before final assembly, make sure you fully understand all the work steps involved and carry out a trial assembly without applying adhesive. 
• The bonding process can only be carried out reliably when a smooth and swift sequence of operations is guaranteed. 
• Do not begin bonding work until all materials and tools necessary for later repair work are available. 

1. Install front side member and check that it fits perfectly. Check gap dimensions. → 5X00IN DIAGRAM - BODY GAP DIMENSIONS
   1. 1.1. Apply foam filler to the body in area -A-  . → 5X00IN22 WORKING WITH BODY FOAM FILLER

      Make sure that all openings and gaps between the body and C-pillar reinforcement are closed off with the sealing compound.

   2. 1.2. Apply adhesive to the areas marked in yellow. → 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE→ Application depth: 3.0 mm 
      Fig 1: Applying Adhesive

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. Plug-weld area -A-  using inert gas.
   1. 2.1. Resistance spot-weld area -B-  .
      Fig 2: Installing Front Side Member

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Apply adhesive to the areas marked in yellow. → 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE→ Application depth: 3.0 mm 
   Fig 3: Applying Adhesive

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Spot-weld front side member using inert gas and set blind rivets.
   1. 4.1. Rivet in front side member in the marked areas -B-  . → BLIND RIVET 999.190.227.01
      Fig 4: Installing Front Side Member

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. Rivet in front side member. → BLIND RIVET 999.190.227.01
   Fig 5: Installing Front Side Member

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
6. Plug-weld reinforcement using inert gas.
   Fig 6: Installing Reinforcement

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7. Apply adhesive to the areas marked in orange. → 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE→ Application depth: 3.0 mm 
   Fig 7: Applying Adhesive

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
8. Spot-weld the mounting using inert gas and set blind rivets.
   1. 8.1. Resistance spot-weld area -A-  .
   2. 8.2. Rivet in the mounting in area -B-  . → BLIND RIVET 999.190.229.01
      Fig 8: Installing Rivet Mounting Area

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
9. Plug-weld front wheel housing extension using inert gas.
   1. 9.1. Resistance spot-weld area -A-  .
   2. 9.2. Apply a full weld to the area -arrows-  using inert gas.
      Fig 9: Installing Front Wheel Housing Extension

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.