Installing Body Front Section

Information 

• Some of the repair illustrations show only one side of the vehicle or a similar component. 
• Naturally, some steps also have to be performed on the opposite side of the vehicle as well. 

Information 

• Apply adhesive evenly over the entire bonding surface. 

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. Fit body front section and check that it fits perfectly.
2. Apply adhesive on bonding areas of the body.

   > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

   >Application depth 0, 5 mm 

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Bonding areas

3. Apply adhesive on bonding areas -A-  of the body.

   > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

   >Application depth 0, 5 mm 

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Joint areas

4. Apply adhesive on bonding area -A-  of the body.

   > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

   >Application depth 0.5 mm 

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Joint areas

5. Apply adhesive on bonding area -A-  of the body.

   > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

   >Application depth 0.5 mm 

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Joint areas

6. Apply adhesive on bonding areas of the body.

   > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

   >Application depth 0, 5 mm 

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Bonding areas

7. Apply adhesive in areas -A-  on the body front section.

   > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

   >Application depth 0.5 mm 

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Joint areas

   1. 7.1 Also apply a bead of adhesive all around the bonding surface -A-  .

      >Application depth 3 mm 

8. Apply adhesive in area -A-  on the body front section.

   > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

   >Application depth 0.5 mm 

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Joint areas

   1. 8.1 Also apply a bead of adhesive all around the bonding surface -A-  .

      >Application depth 3 mm 

9. Apply adhesive in areas -A-  on the body front section.

   > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

   >Application depth 0.5 mm 

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Joint areas

   1. 9.1 Also apply a bead of adhesive all around the bonding surface -A-  .

      >Application depth 3 mm 

10. Apply adhesive on body front section.

    > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

    >Application depth 0.5 mm 

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Bonding areas

    1. 10.1 Also apply a bead of adhesive all around the bonding surface.

       >Application depth 3 mm 

11. Rivet in body front section.

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Blind rivets

    BLIND RIVETS SPECIFICATION 

    A	>BLIND RIVET 999.190.229.01
    B	>BLIND RIVET 999.190.227.01
    C	>BLIND RIVET 999.190.230.01

12. Secure body front section.

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Blind rivets

    1. 12.1 Rivet in body front section.

       -A-  >BLIND RIVET 999.190.229.01 

       -B-  >BLIND RIVET 999.190.227.01 

    2. 12.2. Apply a full steel weld in areas -1-  .
13. Secure body front section.

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Plug-welding

    1. 13.1 Plug-weld body front section.
    2. 13.2. Apply a full steel weld in areas -1-  .
14. Secure body front section.

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Blind rivets

    1. 14.1 Rivet in body front section.

       -A-  >BLIND RIVET 999.190.229.01 

    2. 14.2. Apply a steel plug-weld in areas -B-  .
    3. 14.3. Screw in self-tapping screws -1-  .

       > 5X00IN24 SETTING SELF-TAPPING SCREWS

15. Secure body front section.

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Blind rivets

    1. 15.1 Rivet in body front section.

       >BLIND RIVET 999.190.229.01 

    2. 15.2. Screw in self-tapping screws -1-  .

       > 5X00IN24 SETTING SELF-TAPPING SCREWS

16. Secure body front section.

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Plug-welding

    1. 16.1 Apply a steel plug-weld in areas -A-  .
    2. 16.2. Rivet in body front section.

       -B-  >BLIND RIVET 999.190.229.01 

17. Apply a full steel weld to the body front section.

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Full steel welding

18. Fit new threaded bolt -1-  >WELDING BOLT 999.516.032.01.

    > 5X00IN11 STUD WELDING

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Threaded bolt