Reworking If Cowl Panel Cover Deformed

Possible causes for difficulty in fitting battery cover: 

• A deformed connecting flange on the cowl panel cover or a cowl panel cover installed twisted. 
  Fig 1: Identifying Cowl Panel Cover Deformation

  Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1. Loosen all threaded joints of cowl panel cover.

   → REMOVING COWL PANEL COVER

2. Loosen antenna holder fastening screws.
3. Mask off the Velcro connection for plenum panel cover on left and right using commercially available adhesive tape.

   Information 

   Lightly grease the hook of the battery cover with the following grease, Part No. 000.043.204.68.

   Fig 2: Greasing Battery Cover Hook

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Fit the battery cover as follows:
   1. 4.1. Engage battery cover with external hooks in left and right mounting points of cowl panel cover.
   2. 4.2. Insert battery cover as far as it will go by screwing in  and applying simultaneous pressure  in direction of windscreen.
   3. 4.3. Do not  engage turn-lock fasteners.
   4. 4.4. Release tension from the entire set of covers (covers: plenum panel, battery, cowl panel) by sideways shifting. Make sure there is no warping in the area where the plenum panel adjoins the luggage compartment seal  .
   5. 4.5. Align turn-lock fasteners fore-and-aft and engage by pressing down lightly.
5. If the battery cover still protrudes at the sides then it is deformed and must be replaced.
6. If the gaps look correct, screw down the cowl panel cover at its three fastening points in the area of the windscreen to the specified tightening torque. → Tightening torque: 4.0 Nm (3.0 ftlb.) → Tightening torque: 2.0 Nm (1.5 ftlb.) 
7. Remove battery cover and tighten the two fastening screws of the cowl panel cover (to rear of battery) to the specified tightening torque. → Tightening torque: 2.0 Nm (1.5 ftlb.) 
8. Tighten fastening screws for telephone antenna holder.
9. Fit cowl panel cover and battery cover as described.