Removing Side Member

Fig 1: Outer Side Member Component Location

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Installation position of side member

1. Remove A-pillar section.
   1. 1.1  Cut A-pillar section to dimension -A-  at the marked area -X-  .

      > Dimension - A - 120 mm 

      Information 

      Loosen connection points on one side only. Do not damage the sheet-metal panel underneath.

   2. 1.2  Drill out spotwelds. > Nr.129 - Spotweld drill bit  > VAS 882 001 - Spot-weld remover 
   3. 1.3  Heat bonding areas. > V.A.G 1416 - Hot-Air Blower 
   4. 1.4  Remove A-pillar section. Make sure that the section of the A-pillar does not lose its shape so that it can be re-used.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Removing A-pillar section

2. Remove outer side panel section.

   Information 

   Loosen connection points on one side only. Do not damage the sheet-metal panel underneath.

   1. 2.1  Make cuts. > V.A.G 1561B - Electric cutter  > VAS 6780 - Body saw 
   2. 2.2  Cut outer side panel section to dimension -A-  at the marked area -X-  .

      > Dimension - A - 45 mm 

   3. 2.3  Cut outer side panel section to dimension -B-  at the marked area -X-  .

      > Dimension - B - 30 mm 

   Fig 2: Checking Outer Side Panel Section Cutting Dimension

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Removing side panel section

3. Drill out spotwelds. > Nr.129 - Spotweld drill bit  > VAS 882 001 - Spot-weld remover 
   1. 3.1  Heat bonding areas -A-  and -B-  . > V.A.G 1416 - Hot-Air Blower 
   2. 3.2  Heat bonding area marked in yellow. > V.A.G 1416 - Hot-Air Blower 
   3. 3.3  Remove outer side panel section.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Removing side panel section

4. Remove connecting piece of rear side member. The rear connecting piece is installed on the new part. 

   Information 

   Loosen connection points on one side only. Do not damage the sheet-metal panel underneath.

   1. 4.1  Drill out spotwelds. > Nr.129 - Spotweld drill bit  > VAS 882 001 - Spot-weld remover 

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Rear side member connecting piece

5. heat bonding areas marked in yellow. > V.A.G 1416 - Hot-Air Blower 
   1. 5.1  Remove connecting piece of side member.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Bonding areas on connecting piece

6. Remove inner side panel section.
   1. 6.1  Cut inner side panel section to dimension -A-  and -B-  at the marked area -X-  .

      > Dimension - A - 77 mm 

      > Dimension - B - 70 mm 

      Information 

      Loosen connection points on one side only. Do not damage the sheet-metal panel underneath.

   2. 6.2  Drill out spotwelds. > Nr.129 - Spotweld drill bit  > VAS 882 001 - Spot-weld remover 
   Fig 3: Checking Inner Side Panel Section Cutting Dimension

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Removing inner side panel section

7. Heat bonding areas marked in yellow. > V.A.G 1416 - Hot-Air Blower 
   1. 7.1  Remove inner side panel section.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Removing inner side panel section

8. Remove lower B-pillar section.
   1. 8.1  Cut lower B-pillar section to dimension -A, B, C, D-  at the marked areas -X-  .

      > Dimension - A - 150 mm 

      > Dimension - B - 30 mm 

      > Dimension - C - 90 mm 

      > Dimension - D - 40 mm 

      Fig 4: Checking Lower B-Pillar Section Cutting Dimension

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Lower B-pillar section

      Information 

      Loosen connection points on one side only. Do not damage the sheet-metal panel underneath.

   2. 8.2  Drill out spotwelds. > Nr.129 - Spotweld drill bit  > VAS 882 001 - Spot-weld remover 

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Removing lower B-pillar section

   3. 8.3  Cut welded seam in area -D-  .
   4. 8.4  Heat bonding areas marked in yellow. > V.A.G 1416 - Hot-Air Blower 

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Bonding areas on lower B-pillar section

   5. 8.5  Remove lower B-pillar section.
9. Drill out spotwelds. > Nr.129 - Spotweld drill bit  > VAS 882 001 - Spot-weld remover 

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Spotwelds on side member

10. Drill through area -A-  with > Diameter 6. mm carefully. 

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Spotwelds on side member

11. Heat bonding areas marked in yellow. > V.A.G 1416 - Hot-Air Blower 

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Heating adhesive

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Heating adhesive & removing side member

12. The remaining side member reinforcements must be removed.

    The side member reinforcements are installed on the new part.

13. Remove front side member closing panel.

    The front closing panel is installed on the new part.

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Front side member closing panel