LEMON Manuals: Even more car manuals for everyone
Home >> Porsche >> 2013 >> Boxster S, Automatic DCT Trans >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> 53 - Body Rear - BOXSTER & CAYMAN (981) >> WM 530255 Replacing Rear End (Except BOXSTER GTS, BOXSTER SPYDER) >> Installing Rear End

Installing Rear End

  1. Install rear end and check that it fits perfectly. Check gap dimensions. →  5X00IN DIAGRAM - BODY GAP DIMENSIONS  . 

    Information 

    • Before final assembly, make sure you fully understand all the work steps involved and carry out a trial assembly without applying adhesive  .
    • The bonding process can only be carried out reliably when a smooth and swift sequence of operations is guaranteed  .
    • Do not begin bonding work until all materials and tools necessary for later repair work are available  .
  2. Apply adhesive. → ADHESIVE 000.043.206.30 → Application depth: 5.0 mm 

    Working with body structural adhesive → 5X00IN WORKING WITH BODY STRUCTURAL ADHESIVE .

    G10023232Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    G10023233Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  3. Fit in and secure the rear end.
    1. 3.1. Rivet in area -A-  . → BLIND RIVET 999.190.227.01
    2. 3.2. Screw in ground connection in area -B-  . → Tightening torque: 15 Nm (11 ftlb.)  . → COUNTERSUNK SCREW 999.073.549.01 and → HEXAGON NUT 900.377.003.01 → 5X00IN25 MAKING GROUND CONNECTIONS .
    3. 3.3. Rivet in area -C-  . → BLIND RIVET 999.190.230.01
      G10023234Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  4. Rivet in area -A-  . → BLIND RIVET 999.190.227.01
    G10023235Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  5. Rivet in area -A-  . → BLIND RIVET 999.190.227.01
    G10023236Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  6. Resistance spot-weld the end plate area.
    G10023237Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  7. Resistance spot-weld the wheel housing area.
    G10023238Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  8. Resistance spot-weld the air intake area.
    G10023239Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  9. Bond in molded part. → 5X00IN22 WORKING WITH BODY FOAM FILLER .
    G10023240Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  10. Install filler plate.

    Information 

    • Before final assembly, make sure you fully understand all the work steps involved and carry out a trial assembly without applying adhesive  .
    • The bonding process can only be carried out reliably when a smooth and swift sequence of operations is guaranteed  .
    • Do not begin bonding work until all materials and tools necessary for later repair work are available  .
    1. 10.1. Apply adhesive. → 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE → ADHESIVE 000.043.206.30 → Application depth: 5.0 mm 
      G10023241Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  11. Rivet in filler plate. → BLIND RIVET 999.190.229.01
    G10023242Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  12. Resistance spot-weld the filler plate.
    G10023243Courtesy of PORSCHE CARS NORTH AMERICA, INC.
scientia non olet · About LEMON Manuals