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. Refer to WM 6X00IN GAP DIMENSIONS .
   1. 1.1. Apply foam filler to the body in area -A-  . Refer to WM 5X00IN WORKING WITH BODY STRUCTURAL FOAM (2010 - 14) , WM 5X00IN WORKING WITH BODY STRUCTURAL FOAM (2014 -) .

      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. Refer to WM 5X00IN WORKING WITH BODY STRUCTURAL ADHESIVE 000.043.206.30 , WM 5X00IN WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00 .. Application depth: 3.0 mm 

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Applying adhesive 

2. Plug-weld area -A-  using inert gas.
   1. 2.1. Resistance spot-weld area -B-  .

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   Installing front side member 

3. Apply adhesive to the areas marked in yellow. Refer to WM 5X00IN WORKING WITH BODY STRUCTURAL ADHESIVE 000.043.206.30 , WM 5X00IN WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00 .. → Application depth: 3.0 mm 

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Applying adhesive 

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

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   Installing front side member 

5. Rivet in front side member. → BLIND RIVET 999.190.227.01

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   Installing front side member 

6. Plug-weld reinforcement using inert gas.

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   Installing reinforcement 

7. Apply adhesive to the areas marked in orange. Refer to WM 5X00IN WORKING WITH BODY STRUCTURAL ADHESIVE 000.043.206.30 , WM 5X00IN WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00 .. Application depth: 3.0 mm 

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Applying adhesive 

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

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Installing mounting 

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.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Installing front wheel housing extension