Installing side section

WARNING: Welding in body components

Danger of injury and material damage

→ Once the spare parts have been fixed in place, repair spotwelds must be placed on the old spotwelds because there is no current flow possible in areas with a hardened adhesive layer. Welding procedures other than resistance spot-welding are not permitted since the thermal effect would destroy the bonded joint over a wide area. Refer to 50 IN Processing structural body adhesive - as of MY 2005 (All Models) .

Fig 1: Fitting the seal

Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Installing seal

1.1. Apply a triangular bead of body sealant Y measuring dimension "X" = approx. 12 mm high all around the seal. Position seal on the inside of the side section and press firmly.

Check dimension for viewing window for inner side section → Length: X = 28 mm

Fig 2: Applying adhesive to the side section

Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Applying adhesive to the side section

2.1. Apply a triangular bead of adhesive - dimension "X" = approx. 8 mm - to the inside of the side section, along the wheel arch and up to the start of the sill.

WARNING: Risk of damage if the processing time is not observed!

The quality of the joint will be affected if the adhesive processing time is not observed.

→ The new part must be welded within 30 minutes in the area of the adhesive, otherwise the adhesion of the adhesive will be affected.

2.2.

Fig 3: Applying adhesive to the inside of the side section

Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. Applying adhesive to the inside of the side section

WARNING: Risk of damage if the processing time is not observed!

The quality of the joint will be affected if the adhesive processing time is not observed.

→ The new part must be welded within 30 minutes in the area of the adhesive, otherwise the adhesion of the adhesive will be affected.

3.1. Apply a triangular bead of adhesive (Teromix-6700) - dimension "X" = approx. 10 mm high - to the inside of the side section.

Fig 4: Fitting rear side section to the body

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4. Welding in the side section

4.1. Secure the rear side section with tensioning clamps. Use test gauge 9748.

4.2. Tack-weld the side section at the rear.

WARNING: Risk of damage if the processing time is not observed!

The quality of the joint will be affected if the adhesive processing time is not observed.

→ The new part must be welded within 30 minutes in the area of the adhesive, otherwise the adhesion of the adhesive will be affected.

4.3. Spot-weld area A of the side section.

Fig 5: Welding in the side section

Courtesy of PORSCHE OF NORTH AMERICA, INC.

Fig 6: Welding in the side section

Courtesy of PORSCHE OF NORTH AMERICA, INC.

5. Welding in the side section

WARNING: Risk of damage if the processing time is not observed!

The quality of the joint will be affected if the adhesive processing time is not observed.

→ The new part must be welded within 30 minutes in the area of the adhesive, otherwise the adhesion of the adhesive will be affected.

5.1. Spot weld areas H, F, G, I of the side section.

Fig 7: Welding in the side section

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6. Welding in the side section

6.1. Spot weld areas B, C, D of the side section.

6.2. Weld area E of the side section using inert gas.

6.3. Plug-weld area P of the side section using inert gas.

Fig 8: Brazing side section

Courtesy of PORSCHE OF NORTH AMERICA, INC.

7. Welding in the side section

7.1. Spot-weld area K of the side section.

7.2. Braze weld area J of the side section

Fig 9: Welding side section using inert gas

Courtesy of PORSCHE OF NORTH AMERICA, INC.

8. Welding in the side section

8.1. Weld area L of the side section using inert gas.