Installing Side Panel

Information 

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.

1. Fitting in water drain hose

   Press water drain hose Q  through the water drip pan R  ; observe specified marking. The groove of the water drain hose must fit all the way around the hole in the water drip pan. Route water drain hose through the grommet to the wheel housing and cut the hose so that approx. dimension Z = 35 mm  projects outwards.

   Fig 1: Fitting Water Drain Hose

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. Installing water drip pan
   1. 2.1. Apply a triangular bead of body sealant - dimension "X" = approx. 12 mm high -  to the inside of the side section O  .

      Apply a triangular bead of body sealant - dimension "X" = approx. 12 mm high -  to the wheel housing in area P  .

      Fig 2: Identifying Body Sealant Applying

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
      Fig 3: Identifying Water Drip Pan

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Position water drip pan R  on the inside of the side section and press on firmly. Route the water drain hose Q  . Apply a triangular bead of body sealant - dimension "X" = approx. 12 mm high -  to the outside of the side section S  .

3. Installing seal
   1. 3.1. Apply a triangular bead of body sealant Y  --dimension "X" = approx. 12 mm high  - to all sides of the seal. Apply seal to the prepared holes on the inside of the side section, position the pins of the seal and press into place.
      Fig 4: Identifying Body Sealant Seal

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Applying adhesive to the side section
   NOTE: Non-observance of setting time for adhesive

   • Risk of damage to side panel

   → Weld in the new part within 30 minutes.

   1. 4.1. Apply a triangular bead of adhesive measuring - dimension "X" = approx. 8 mm -  to the inside of the side section, along the edge of the wheel arch and up to the start of the door sill.
      Fig 5: Identifying Adhesive Applying Area To Side Section

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. Applying adhesive to the inside of the side section
   NOTE: Non-observance of setting time for adhesive

   • Risk of damage to side panel

   → Weld in the new part within 30 minutes.

   1. 5.1. Apply a triangular bead of adhesive (Teromix-6700) - dimension "X" = approx. 10 mm high -  to the joint between the light housing and the inside of the side section. The light housing must be flush with the inside of the side section.
      Fig 6: Identifying Adhesive Applying Area To Inside Of Side Section

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
6. Applying adhesive to the window slot reinforcement
   NOTE: Non-observance of setting time for adhesive

   • Risk of damage to side panel

   → Weld in the new part within 30 minutes.

   1. 6.1. Apply a triangular bead of adhesive (Teromix-6700) - dimension "X" = approx. 10 mm high -  to the joint between the window slot reinforcement and the side section.
      Fig 7: Identifying Adhesive Applying To Window Slot Reinforcement

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
7. Applying adhesive to the inside of the side section
   NOTE: Non-observance of setting time for adhesive

   • Risk of damage to side panel

   → Weld in the new part within 30 minutes.

   1. 7.1. Apply a triangular bead of adhesive (Teromix-6700) - dimension "X" = approx. 10 mm high -  to the inside of the side section in area V  .
      Fig 8: Identifying Adhesive Applying Area To Inside Of Side Section

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
8. Welding in the side section
   1. 8.1. Secure the side section at the rear with tensioning clamps.
   2. 8.2. Tack-weld the side section at the rear.
      NOTE: Non-observance of setting time for adhesive

      • Risk of damage to side panel

      → Weld in the new part within 30 minutes.

   3. 8.3. Resistance spot-weld areas A, B, C  of the side section.
      Fig 9: Identifying Welding Areas In Side Section

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
9. Welding in the side section
   1. 9.1. Resistance spot-weld area H  of the side section.
      Fig 10: Identifying Welding Areas In Side Section

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
10. Welding in the side section
    1. 10.1. Resistance spot-weld areas E, F, G  of the side section.
    2. 10.2. Plug-weld the side section in area I  using inert gas.
       Fig 11: Identifying Welding In Side Section

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
11. Welding joint using inert gas
    1. 11.1. Apply a full weld to joint J  of lower side member using inert gas.
       Fig 12: Identifying Welding Joints Using Inert Gas

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.