Installing Outer Side Member

WARNING: This page is about a different car, the 2021 Porsche Cayenne, 2020 Porsche Cayenne, and 2019 Porsche Cayenne. However, it is still accessible from the selected car via links, so may be relevant.

IMPORTANT:

Apply adhesive evenly over the entire bonding surface.

IMPORTANT:

Before final assembly, make sure you fully understand all the work steps involved and carry out a trial assembly without applying adhesive.
Bonding 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.

Tack on sheetmetal insert > Sheetmetal insert wsed as a welding backing strip on the body.
5X00IN10 WELDING ALUMINIUM

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Sheetmetal insert

Apply adhesive on joint areas > Bonding area of the body. > Application depth 0.5 mm

Working with body structural adhesive

5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE - SECTION ON "INFORMATION"

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Bonding area

Yellow	Bonding and resistance spot-welding
	> 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE
Orange	Bonding and riveting
	> 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE

Apply adhesive in the marked area > Outer side member.

> Application depth 0.5 mm

Working with body structural adhesive

> 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE - SECTION ON "INFORMATION"

Fig 1: Outer Side Member Component Location

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outer side member

Yellow	Bonding and resistance spot-welding
	> 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE
Orange	Bonding and riveting
	> 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE

3.1 Also apply a bead of adhesive all around the bonding surface. > Application depth 3 mm

Fit and secure outer side member.
Check gap dimensions.

5X00IN GAP DIMENSIONS
Apply a full aluminum weld to the outer side member in areas -A, B and C- using inert gas.
5X00IN10 WELDING ALUMINIUM

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Outer side member and body

Install outer side member.

6.1 Resistance spot-weld the outer side member in area -A- .

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Rivet areas

6.2 Rivet in the outer side member in area -B-. > FLOW-FORM RIVETS 9A7.008.606.00

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Rivet areas

6.3 Resistance spot-weld the outer side member in area -A- .

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Rivet areas

6.4 Rivet in the outer side member in areas -B- > FLOW-FORM RIVETS 9A7.008.473.00

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Rivet areas

6.5 Rivet in the outer side member in area -C- > FLOW-FORM RIVETS 9A7.008.606.00

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Rivet areas

Flare edges -1- in the front door aperture using > VAS 6635/5 - crimping pliers.

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Edges in door apertures