Removing Rear Side Panel

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: Drill out spotwelds A through two plate thicknesses.

IMPORTANT: The insulating mat will be damaged irreparably during removal and must be replaced.

IMPORTANT: Only make cuts in the top plate. Make sure not to damage the plate underneath when doing this.

IMPORTANT: Mark cuts in accordance with the new part. Make sure to leave an overlap of approx. 30 mm with respect to the body.

IMPORTANT: Loosen connection points on one side only. Do not damage the sheet-metal panel underneath.

Mark cuts.
1. 1.1 Mark cut on the C-pillar at -dimension A- Distance 50 mm .
  
  Fig 1: Checking C-Pillar Cutting Dimension
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Cut on C-pillar
2. 1.2 Mark cut on the D-pillar in the window aperture area at -dimension B- Distance 22 mm .
  
  Fig 2: Checking D-Pillar Cutting Dimension In Window Aperture
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Cut in window aperture area
3. 1.3 Mark cut on the D-pillar in the water drain channel area at -dimension A- Distance 80 mm .
  
  Fig 3: Checking D-Pillar Cutting Dimension In Water Drain Channel
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Cut in water drain channel area
4. 1.4 Mark cut on the lower side panel at -dimension A- Distance 30 mm .
  
  Fig 4: Checking Lower Side Panel Cutting Dimension
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Cut on lower side panel
Make cuts.

Disconnect connection points.

3.1 Drill through clinch points in area -A- using a drill bit with a diameter of Diameter 4 mm .

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Clinch points

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Clinch points

3.2 Remove punch rivets in area -B- using VAS 852 001 - dent removal unit , VAS 6790 - compact booster .

5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

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Punch rivets

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Punch rivets

Remove punch rivets Punch rivets using VAS 852 001 - body dent removal system, aluminium , and VAS 6790 - compact booster .
5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

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Punch rivets
Heat sheetmetal brackets V.A.G 1416 - Hot-air blower

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Sheetmetal brackets
Heat bonding areas Bonding areas. V.A.G 1416 - Hot-air blower

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Bonding areas
Heat bonding area Bonding area . V.A.G 1416 - Hot-air blower

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Bonding area
Heat bonding areas Bonding areas . V.A.G 1416 - Hot-air blower

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Bonding areas
Bend up sheetmetal brackets -1- using VAS 6635/5 - seaming pliers .

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Sheetmetal brackets
Remove rear side section.