Installing A-Pillar Reinforcement

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. 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.

   Bonding area

2. Apply adhesive to bonding area -A -  of the A-pillar reinforcement.

   > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

   >Application depth 0.5 mm 

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Bonding area

   1. 2.1 Also apply a bead of adhesive all around the bonding surface.

      >Application depth 3 mm 

3. Apply body foam filler all the way around the bulkhead part -1-  in the marked area and clip bulkhead part into the body.

   > 5X00IN22 WORKING WITH BODY FOAM FILLER

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Body foam filler

4. Apply body foam filler all the way around the bulkhead part -1-  in the marked area and clip bulkhead part into A-pillar reinforcement.

   > 5X00IN22 WORKING WITH BODY FOAM FILLER

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Body foam filler

5. Install A-pillar reinforcement.
6. Secure A-pillar reinforcement.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Blind rivets

   1. 6.1 Rivet in A-pillar reinforcement in area -A -  .

      >BLIND RIVET 999.190.229.01 

   2. 6.2 Resistance spot-weld the A-pillar reinforcement in area -B -  .
7. Secure A-pillar reinforcement.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Blind rivets

   1. 7.1 Resistance spot-weld the A-pillar reinforcement in area -B -  .
   2. 7.2 Plug-weld the A-pillar reinforcement in area -A -  .
8. Screw in and tighten self-tapping screws -1-  .

   > 5X00IN24 SETTING SELF-TAPPING SCREWS

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Self-tapping screws

9. Secure A-pillar reinforcement.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Joints

   1. 9.1 Rivet in A-pillar reinforcement.

      >BLIND RIVET 999.190.229.01 

   2. 9.2 Screw in and tighten self-tapping screws -1-  .

      > 5X00IN24 SETTING SELF-TAPPING SCREWS

10. Screw in and tighten self-tapping screws.

    > 5X00IN24 SETTING SELF-TAPPING SCREWS

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Self-tapping screws

11. Apply a full steel weld to the A-pillar reinforcement.

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Welded seams

12. Screw in self-tapping screws on the outer side member until the adhesive has hardened.

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Self-tapping screws on outer side member

13. Check that the marked area is flat and that the outer side member can lie flat. Grind them level if necessary.

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Level contact surface