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Home >> Porsche >> 2022 >> 718 Boxster Base, Standard Trans >> Repair and Diagnosis >> External Pages >> Different car >> Section 2 (50 - Body Front) >> WM, 509555 Replacing Body Front Section >> Installing Body Front Section

Installing Body Front Section

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IMPORTANT:
  • 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. Install body front section and check that it fits perfectly. Check gap dimensions.

    5X00IN DIAGRAM - BODY GAP DIMENSIONS

  2. Apply adhesive. > Application depth 3.0 mm 

    Working with body structural adhesive

    5X00IN WORKING WITH BODY STRUCTURAL ADHESIVE

    G14269606Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Preparing body front section

  3. Rivet in body front section in upper longitudinal member area. > BLIND RIVET 999.190.229.01 
    G14269607Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Upper longitudinal member area

  4. Rivet in body front section in wheel housing area. > BLIND RIVET 999.190.229.01 
    G14269608Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Body front section, wheel housing area

  5. Weld and rivet in body front section in inner bulkhead area.
    1. 5.1  Apply a full weld to the body front section area - A-  using inert gas.
    2. 5.2  Rivet in body front section area -B-  > BLIND RIVET 999.190.229.01 
      G14269609Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Body front section, inner bulkhead area

  6. Rivet in body front section in the bulkhead area. > BLIND RIVET 999.190.229.01 
    G14269610Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Body front section, bulkhead area

  7. Rivet in body front section in the underbody area. > BLIND RIVET 999.190.230.01 
    G14269611Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Body front section, underbody area

    1. 7.1  Do not use rivets at the position shown.

      Once installation is complete, use a ground connection at this position.

  8. Rivet in body front section in the footwell area. > BLIND RIVET 999.190.230.01 
    G14269612Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Body front section, footwell area

  9. Rivet in body front section in the footwell area. > BLIND RIVET 999.190.229.01 
    1. 9.1  Screw in (self-tapping) fastening screws -1-  > TORX SCREW 999.073.541.01 
    G14269613Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Body front section, footwell are a

  10. Install cowl panel.
  11. Apply adhesive. > Application depth 3.0 mm 

    Working with body structural adhesive

    5X00IN WORKING WITH BODY STRUCTURAL ADHESIVE

    1. 11.1  Fit and secure the cowl panel.

      Check gap dimensions.

      5X00IN DIAGRAM - BODY GAP DIMENSIONS

      G14269614Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Installing cowl panel

  12. Apply foam filler to area

    5X00IN22 WORKING WITH BODY FOAM FILLER - SECTION ON "INSTALLING"

    Make sure that all openings and gaps are closed off with the foam filler.

    G14269615Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Preparing connection areas on cowl panel

  13. Resistance spot-weld the cowl panel.
    1. 13.1  Apply a full weld to area -A -  using inert gas.
      G14269616Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Installing cowl panel

  14. Prepare connection areas on bracket for longitudinal member for wheel housing.
    G14269617Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Connection areas on bracket for longitudinal member for wheel housing

  15. Straighten sealing surface and connection areas of the body.
  16. De-burr connection areas and prepare for welding.
  17. Prepare marked areas for welding and bonding.
  18. Fit bracket for longitudinal member for wheel housing.
    1. 18.1  For better positioning of the bore holes, fit the wing holder -2-  .
    2. 18.2  Drill holes for rivets in the marked areas -1-  using a drill bit with > Diameter 6.6 mm  Drill bit diameter of 6.6 mm.
      G14269618Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Drilling holes

  19. Apply adhesive. > Application depth 3.0 mm 

    Working with body structural adhesive

    5X00IN WORKING WITH BODY STRUCTURAL ADHESIVE

    1. 19.1  Fit and secure supporting plate for longitudinal member for wheel housing.
      G14269619Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Applying adhesive

  20. Rivet in bracket for longitudinal member for wheel housing in area -B-  > BLIND RIVET 999.190.230.01 
    1. 20.1  Resistance spot-weld bracket for longitudinal member for wheel housing in area -A -  .
      G14269620Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Supporting plate

  21. Make ground connections using a through bolt.

    Making ground connections 

    1. 21.1  Make a ground connection -1-  on both sides of the vehicle.

      Check screw-in direction.

      G14269621Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Making ground connection

    2. 21.2  Between the two rivets -2 and 3-  , make a ground connection

      Check screw-in direction.

      G14269622Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Making ground connection

      Countersunk screw > COUNTERSUNK SCREW 999.073.549.01 

      Hexagon nut > HEXAGON NUT 900.377.003.01 

    3. 21.3  Tighten threaded joint to the specified torque. > Tightening torque 15 N.m (11 ft.lb) 
    4. 21.4  Seal threaded joint.
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