Installing Front End

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 

• 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 front end and check that it fits perfectly.
2. Remove front end.

   Information 

   • Apply adhesive evenly over the entire bonding surface. 
3. Apply adhesive on bonding areas of the body.

   > 5X00IN21 PROCESSING OF BODY WORK STRUCTURAL ADHESIVE PAH.071.781.00

   > Application height 0.5 mm 

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   Bonding areas

   Information 

   • Apply adhesive evenly over the entire bonding surface. 
4. Apply adhesive on bonding areas -A-  of the body.

   > 5X00IN21 PROCESSING OF BODY WORK STRUCTURAL ADHESIVE PAH.071.781.00

   > Application height 0.5 mm 

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Joint areas

   Information 

   • Apply adhesive evenly over the entire bonding surface. 
5. Apply adhesive in areas -A-  on the front end.

   > 5X00IN21 PROCESSING OF BODY WORK STRUCTURAL ADHESIVE PAH.071.781.00

   > Application height 0.5 mm 

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Joint areas

   1. 5.1 Also apply a bead of adhesive all around the bonding surface -A-  .

      > Application depth 3 mm 

6. Rivet in the front end.

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   Blind rivets

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

7. Secure front end.

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   Blind rivets

   1. 7.1 Rivet in the front end.

      -A-  > BLIND RIVET 999.190.229.01 

      -B-  > BLIND RIVET 999.190.227.01 

   2. 7.2 Apply a full steel weld in areas -1-  .
8. Secure front end.

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   Plug-welding

   1. 8.1 Plug-weld front end.
   2. 8.2 Apply a full steel weld in areas -1-  .
9. Apply a full steel weld in areas -1-  .

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   Welded seams

10. Apply a full steel weld to the cross member in area -1-  .

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    Welded seams

11. Plug-weld front end.

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    Spot welds

12. Apply a full steel weld to the front end.

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    Full steel welding

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

    > 5X00IN11 STUD WELDING

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Threaded bolt