Installing Rear Side Panel

Fig 1: Identifying Rear Side Panel

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Information 

• When fitting the side section using the alignment bench, the side portal can also be used. 

1. Fit the rear side panel to the body.
   1. 1.1. To complete the fit, install the rear doors and lid and set the gap dimensions between the rear doors and lid and the side panel according to the respective adjustment values.
   2. 1.2. Fix the rear side panel with tensioning clamps.
   3. 1.3. Mark the installation position of the side panel.
2. Fit the side panel joints.
   1. 2.1. Use a body saw to cut the two sheetmetal plates in the area of the overlap between the side panel and body. Do not damage the internal components.
   2. 2.2. Remove the accessories and side panel.
   3. 2.3. Remove remaining pieces.
3. Applying body sealant to the wheel housing and in the area of the catch bar
   NOTE: Non-observance of setting time for adhesive

   • Risk of damage to side panel

   → Weld in the new part within 30 minutes.

   1. 3.1. Apply Teromix-6700 two-component adhesive  to the outside of the wheel housing and close to the catch bar (areas -J, K-  ).

      -U-  → Application depth: 6 mm 

      Fig 2: Identifying Tool (Teromix-6700)

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      Fig 3: Identifying Adhesive Applying Area To Wheel Housing

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      Fig 4: Identifying Adhesive Applying Area Application Depth

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4. Fit side panel.
   1. 4.1. Fit side panel according to the markings and fix in place with tensioning clamps.
5. Resistance spot-weld the side panel.
   1. 5.1. Resistance spot weld the side panel in the areas -A, B-; -F-; -G-  and -I- (-I-)  .
      Fig 5: Identifying Spot Weld Side Panel Cutting Areas (A - B - C)

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      Fig 6: Identifying Spot Weld Side Panel Cutting Areas (A - D - E - F)

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      Fig 7: Identifying Spot Weld Side Panel Cutting Areas (G - H)

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      Fig 8: Identifying Spot Weld Side Panel Cutting Areas (I - H)

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      Fig 9: Identifying Spot Weld Side Panel Cutting Areas (I)

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6. Welding side panel using inert gas
   1. 6.1. Apply a full weld to the side panel in areas -C-, -D and E-  using inert gas.

      Plug-weld the side panel in area -H-  using inert gas.

      Fig 10: Identifying Welding Applying Area On Side Panel (A, B And C)

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      Fig 11: Identifying Welding Applying Area On Side Panel (A, D, E And F)

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      Fig 12: Identifying Welding Applying Area On Side Panel (H And I)

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
7. Flange edge of wheel arch.
8. Grind inert gas arc weld areas, which are visible following installation, until bare, apply body solder to body joints and align as required.