Installing Outer Side Member (When Replacing Side Member Reinforcement)

Information 

If the side member reinforcement was replaced (

> 514955 REPLACING SIDE MEMBER REINFORCEMENT 

), the outer side member must be prepared and installed differently.

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. Tack on sheetmetal insert used as welding backing strip on the body.

   > 5X00IN10 WELDING ALUMINIUM

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Sheetmetal insert

2. Apply adhesive on bonding areas of the body.

   > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

   >Application depth 0.5 mm 

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   Bonding areas

3. Apply adhesive on marked areas -A-  .

   > 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. 3.1 Also apply a bead of adhesive all around the bonding surface.

      >Application depth 3 mm 

4. Secure outer side member.

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   Outer side member

   1. 4.1 Screw in self-tapping screws.

      > 5X00IN24 SETTING SELF-TAPPING SCREWS

   2. 4.2 Rivet in outer side member. >BLIND RIVET 999.190.227.01 
5. Apply full aluminum weld to outer side member.

   > 5X00IN10 WELDING ALUMINIUM

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   Separation points

6. Bend over folded edges in the front door aperture using >VAS 6635 - crimping pliers set, 4-piece  .

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   Front door aperture folded edges

7. Bend over folded edges in the rear door aperture using >VAS 6635 - crimping pliers set, 4-piece  .

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   Rear door aperture folded edges

8. Bend over folded edge in rear wheel housing using >VAS 6635 - crimping pliers set, 4-piece  .

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   Folded edge in wheel housing