Installing Outer And Inner D-Pillar With Reinforcements

Fig 1: Identifying Installation Position Of D-Pillar Reinforcement

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

D-pillar, outer
D-pillar reinforcement, top
D-pillar, inner
D-pillar gusset plate
Seal
D-pillar reinforcement, bottom
End piece

Fit outer and inner D-pillar with reinforcements to the body.
Information

The rear side section and end plate must be inserted in order to fit the outer and inner D-pillar.
1. 1.1. Install rear side section and end plate first.
  
  Fig 2: Overview Of D-Pillar - Outside
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fix lower D-pillar reinforcement and end piece in place with tensioning clamps.
Weld in lower D-pillar reinforcement and end piece.
1. 3.1. Resistance spot-weld the lower D-pillar reinforcement and end piece in areas -A, B and C- .
  
  Fig 3: Identifying Welded Joints On Lower D-Pillar Reinforcement And End Piece
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 3.2. Resistance spot-weld the lower D-pillar reinforcement in area -A- .
  
  Fig 4: Identifying Welded Joints On Lower D-Pillar Reinforcement
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 5: Overview Of D-Pillar - Outside
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Fix inner D-pillar in place using tensioning clamps.
Weld in inner D-pillar.
1. 5.1. Resistance spot-weld the inner D-pillar in areas -A and D- .
  
  Fig 6: Identifying Welded Joints On Inner D-Pillar
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 5.2. Plug-weld the inner D-pillar in areas -B and C- using inert gas.
  
  Fig 7: Overview Of D-Pillar - Inside
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Weld in lock carrier and side floor section.
1. 6.1. Weld lock carrier in area -A- using inert gas.
  
  Fig 8: Identifying Welded Joints On Lock Carrier And Side Floor Section
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 6.2. Resistance spot-weld the side floor section in area -B- .
  
  Fig 9: Overview Of D-Pillar - Outside
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fix upper D-pillar reinforcement in place using tensioning clamps.
Weld in upper D-pillar reinforcement.
1. 8.1. Resistance spot-weld the upper D-pillar reinforcement in areas -A and B- .
  
  Fig 10: Identifying Welded Joints On Upper D-Pillar Reinforcement
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 11: Overview Of D-Pillar - Outside
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fix outer D-pillar in place using tensioning clamps.
Weld in outer D-pillar at the point where it connects to the C-pillar.
1. 10.1. Plug-weld the outer D-pillar in area -A- using inert gas.
  
  Fig 12: Identifying Welded Joints On Outer D-Pillar
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 10.2. Resistance spot-weld the outer D-pillar in areas -B and C- .
  
  Fig 13: Overview Of D-Pillar - Outside
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Weld in outer D-pillar at the point where it connects to the top end piece of the D-pillar.
1. 11.1. Plug-weld the outer D-pillar in areas -A and B- using inert gas.
  
  Fig 14: Identifying Welded Joints On Top End Piece Of D-Pillar
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 15: Overview Of D-Pillar - Outside
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Weld in outer D-pillar at the point where it connects to the inner D-pillar.
1. 12.1. Resistance spot-weld the outer D-pillar in area -A- .
  
  Fig 16: Identifying Welded Joints On Lower D-Pillar
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 12.2. Plug-weld the outer D-pillar in area -B- using inert gas.
  
  Fig 17: Overview Of D-Pillar - Outside
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Weld in outer D-pillar at the points where it connects to the inner D-pillar and upper D-pillar reinforcement.
1. 13.1. Resistance spot-weld the outer D-pillar in areas -A, B and C- .
  
  Fig 18: Identifying Welded Joints On Upper D-Pillar
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 13.2. Resistance spot-weld the outer D-pillar in area -A- .
  
  Fig 19: Identifying Welded Joints On Centre D-Pillar
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 20: Overview Of D-Pillar - Outside
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Weld in outer D-pillar at the point where it connects to the rear side member.
1. 14.1. Weld outer D-pillar in area -A- using inert gas.
  
  Fig 21: Identifying Welded Joints On Side Member
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 22: Overview Of D-Pillar - Inside
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Plug-weld the inner D-pillar in areas -A and B- using inert gas.

Fig 23: Identifying Welded Joints On Inner D-Pillar
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Fig 24: Overview Of D-Pillar - Inside
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Fix D-pillar gusset plate in place using tensioning clamps.
Weld in D-pillar gusset plate.
1. 17.1. Weld D-pillar gusset plate in areas -A- using inert gas.
  
  Fig 25: Identifying Welded Joints On D-Pillar Gusset Plate
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 17.2. Resistance spot-weld the D-pillar gusset plate in areas -B- .
  Information
  
  The seal between the outer and inner D-pillar must be filled with foam before applying cavity preservation. The contact area on the outer and inner D-pillar and on the surface of the seal must be fully sealed in this way.
Fill seal with foam through the existing openings in the inner D-pillar. → 5000IN WORKING WITH ACOUSTIC BODY FOAM 2K AFS VARIO
Install rear side section → Installing Rear Side Panel
Install end plate. → Installing End Plate