Installing Rear Trunk Floor Panel (Section)

Information 

Always use the test gauge 9748  when replacing or repositioning body parts.

1. Aligning rear trunk floor panel to the body
   1. 1.1. Insert the rear trunk floor panel spare part overlapping the side member and the protruding trunk floor panel.
   2. 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
   1. 2.1. Screw test gauge 9748  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.
      Fig 1: Identifying Impact Pipe/Impact Absorber And Sleeves

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   2. 2.2. Align rear trunk floor panel to the body.
   3. 2.3. Position the test gauge with the square pin -C-  on the light frame.

      To complete the fit, adjust the gap clearance between rear lid and side panel according to the adjustment values. → WM 5X00IN DIAGRAM - BODY GAP DIMENSIONS (ALL MODELS)

      Fig 2: Positioning Square Pin On Light Frame

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   4. 2.4. Fix rear trunk floor panel and closing cross member with tensioning clamps.
   5. 2.5. Tack-weld the rear trunk floor panel.
   6. 2.6. Remove test gauge and closing cross member.
3. Welding in rear trunk floor panel
   1. 3.1. Apply a full weld to the overlapping of the rear cross member to cross member in area -A-  using shielding gas (interrupted).
   Fig 3: Identifying Welding Rear Trunk Floor Panel Area (A)

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4. Welding in rear trunk floor panel
   1. 4.1. Resistance spot-weld overlapping of rear trunk floor panel to cross member in area -A-  .
   Fig 4: Identifying Welding Rear Trunk Floor Panel Area (A)

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5. Welding in rear trunk floor panel
   1. 5.1. Plug-weld the rear trunk floor panel in the areas -A-  and -B-  using shielding gas.
   Fig 5: Identifying Welding Rear Trunk Floor Panel Area (A And B)

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6. Welding in rear trunk floor panel
   1. 6.1. Resistance spot-weld rear trunk floor panel in areas -A-  and -B-  .
   Fig 6: Identifying Welding Rear Trunk Floor Panel Area (A And B)

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
7. Install closing cross member. → Installing Closing Cross Member