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Home >> Porsche >> 2016 >> 911 Turbo, 2D Convertible >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> 50 - Body Front - 911 CARRERA (991) >> WM 509555 Replacing Body Front Section (Except CARRERA "Edition", CARRERA Cabriolet "Edition", CARRERA 4 "Edition", CARRERA 4 Cabriolet "Edition") >> Installing Body Front Section

Installing Body Front Section

  1. Install body front section and check that it fits perfectly. Check gap dimensions. → WM 5X00IN GAP DIMENSIONS (EXCEPT CARRERA "EDITION", CARRERA CABRIOLET "EDITION", CARRERA 4 "EDITION", TARGA 4, TARGA 4S, TARGA 4 GTS, CARRERA 4 CABRIOLET "EDITION")

    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. → Application depth: 3.0 mm 

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

    Fig 1: Identifying Body Front Section Adhesive Applying Areas
    G10005432Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  3. Rivet in body front section in upper longitudinal member area. → BLIND RIVET 999.190.229.01
    Fig 2: Identifying Upper Longitudinal Member Area
    G10005433Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  4. Rivet in body front section in wheel housing area. → BLIND RIVET 999.190.229.01
    Fig 3: Identifying Wheel Housing Rivet Area - Body Front Section
    G10005434Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  5. Weld and rivet in body front section in inner bulkhead area.
    1. 5.1. Apply a full weld to the body front section area -A-  using inert gas.
    2. 5.2. Rivet in body front section area -B-  . → BLIND RIVET 999.190.229.01
      Fig 4: Identifying Inner Bulkhead Rivet Area - Body Front Section
      G10005435Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  6. Rivet in body front section in the bulkhead area. → BLIND RIVET 999.190.229.01
    Fig 5: Identifying Bulkhead Rivet Area - Body Front Section
    G10005436Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  7. Rivet in body front section in the underbody area. → BLIND RIVET 999.190.230.01
    Fig 6: Identifying Underbody Area Rivet Areas - Body Front Section
    G10005437Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 7.1. Do not use rivets at the position shown.

      Once installation is complete, use a ground connection at this position.

  8. Rivet in body front section in the footwell area. → BLIND RIVET 999.190.230.01
    Fig 7: Identifying Footwell Rivet Area - Body Front Section
    G10005438Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  9. Rivet in body front section in the footwell area. → BLIND RIVET 999.190.229.01
    1. 9.1. Screw in (self-tapping) fastening screws -1-  . → TORX SCREW 999.073.541.01
      Fig 8: Identifying Footwell Rivet Area - Body Front Section
      G10005439Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  10. Install cowl panel.

    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. 
  11. Apply adhesive. → Application depth: 3.0 mm 

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

    1. 11.1. Fit and secure the cowl panel.

      Check gap dimensions. → WM 5X00IN GAP DIMENSIONS (EXCEPT CARRERA "EDITION", CARRERA CABRIOLET "EDITION", CARRERA 4 "EDITION", TARGA 4, TARGA 4S, TARGA 4 GTS, CARRERA 4 CABRIOLET "EDITION")

      Fig 9: Identifying Cowl Panel Adhesive Applying Areas
      G10005440Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  12. Apply foam filler to area -1-  . → WM 5X00IN WORKING WITH BODY FOAM FILLER (EXCEPT CARRERA "EDITION", CARRERA CABRIOLET "EDITION", CARRERA 4 "EDITION", CARRERA 4 CABRIOLET "EDITION")

    Make sure that all openings and gaps are closed off with the foam filler.

    Fig 10: Identifying Connection Areas On Cowl Panel
    G10005441Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  13. Resistance spot-weld the cowl panel.
    1. 13.1. Apply a full weld to area -A-  using inert gas.
      Fig 11: Identifying Cowl Panel Spot-Weld Areas
      G10005442Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  14. Prepare connection areas on bracket for longitudinal member for wheel housing.
    Fig 12: Identifying Connection Areas On Bracket For Longitudinal Member And Wheel Housing
    G10005443Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  15. Straighten sealing surface and connection areas of the body.
  16. De-burr connection areas and prepare for welding.

    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. 
  17. Prepare marked areas for welding and bonding.
  18. Fit bracket for longitudinal member for wheel housing.
    1. 18.1. For better positioning of the bore holes, fit the wing holder -2-  .
    2. 18.2. Drill holes for rivets in the marked areas -1-  using a drill bit with → Diameter: 6.6 mm  Drill bit diameter of 6.6 mm.
      Fig 13: Identifying Drilling Holes For Longitudinal Member And Wheel Housing
      G10005444Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      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. 
  19. Apply adhesive. → Application depth: 3.0 mm 

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

    1. 19.1. Fit and secure supporting plate for longitudinal member for wheel housing.
      Fig 14: Identifying Longitudinal Member For Wheel Housing Adhesive Applying Area
      G10005445Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  20. Rivet in bracket for longitudinal member for wheel housing in area -B-  . → BLIND RIVET 999.190.230.01
    1. 20.1. Resistance spot-weld bracket for longitudinal member for wheel housing in area -A-  .
      Fig 15: Identifying Supporting Plate For Longitudinal Member And Wheel Housing
      G10005446Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  21. Make ground connections using a through bolt. → Making ground connections 
    1. 21.1. Make a ground connection -1-  on both sides of the vehicle.

      Check screw-in direction.

    2. 21.2. Between the two rivets -2 and 3-  , make a ground connection -1-  .
      Fig 16: Identifying Ground Connection
      G10005447Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Check screw-in direction.

      Countersunk screw → COUNTERSUNK SCREW 999.073.549.01

      Hexagon nut → HEXAGON NUT 900.377.003.01

      Fig 17: Identifying Ground Connection
      G10005448Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    3. 21.3. Tighten threaded joint to the specified torque. → Tightening torque: 15 Nm (11 ftlb.) 
    4. 21.4. Seal threaded joint.
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