Installing rear trunk floor panel (section)

CAUTION: Subsequent damage to the body following repair work!

Rear body parts cannot be replaced without using the test gauge 9748
The rear spoiler joint cannot be adjusted.
The rear apron can only be fitted braced.

→ Use the test gauge 9748 for positioning when replacing and aligning rear body parts.

→ The Boxster and Cayman have functional dimensions; body parts are positioned interdependently with very close tolerance values; parts cannot be positioned/centerd with respect to other parts.

1. Aligning rear trunk floor panel to the body

1.1. Insert the rear trunk floor panel spare part overlapping the side member and the protruding trunk floor panel.

1.2. Insert the closing cross member and fit it on the side panels on the left and right.

2. Aligning rear trunk floor panel to the body

Fig 1: Installing test gauge 9748

Courtesy of PORSCHE OF NORTH AMERICA, INC.

2.1. Screw test gauge 9748, see Porsche special tool Workshop Equipment Manual 00000 securely to side member (impact pipe/impact absorber) -A- . On the closing cross member, position the fastening screws for the retaining strip with the positioning sleeves -B- and screw in positioning screws. See Fig 1.

2.2. Align rear trunk floor panel to the body.

Fig 2: Positioning square pin on light frame

Courtesy of PORSCHE OF NORTH AMERICA, INC.

2.3. Position the test gauge with the square pin -C- on the light frame. See Fig 2.

To complete the fit, adjust the gap clearance between rear lid and side panel according to the adjustment values. Refer to 50 IN Processing structural body adhesive - as of MY 2005 (All Models) .

2.4. Fix rear trunk floor panel and closing cross member with tensioning clamps.

2.5. Tack-weld the rear trunk floor panel.

2.6. Remove test gauge and closing cross member.

Fig 3: Welding in rear trunk floor panel

Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. Welding in rear trunk floor panel

3.1. Apply a full weld to the overlapping of the rear cross member to cross member in area -A- using shielding gas (interrupted). See Fig 3.

Fig 4: Welding in rear trunk floor panel

Courtesy of PORSCHE OF NORTH AMERICA, INC.

4. Welding in rear trunk floor panel

4.1. Resistance spot-weld overlapping of rear trunk floor panel to cross member in area -A- . See Fig 4.

Fig 5: Welding in rear trunk floor panel

Courtesy of PORSCHE OF NORTH AMERICA, INC.

5. Welding in rear trunk floor panel

5.1. Plug-weld the rear trunk floor panel in the areas -A- and -B- using shielding gas. See Fig 5.

Fig 6: Welding in rear trunk floor panel

Courtesy of PORSCHE OF NORTH AMERICA, INC.

6. Welding in rear trunk floor panel

6.1. Resistance spot-weld rear trunk floor panel in areas -A- and -B- . See Fig 6.

7. Install closing cross member. → 531655 Replacing closing cross member- chapter on "Installing"