Installing Rear Side Panel

Information 

• Apply adhesive evenly over the entire bonding surface. 

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. Tack on sheetmetal insert used as a welding backing strip on the body.

   > 5X00IN10 WELDING ALUMINIUM

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   Welding backing strip

2. Install rear side panel and check that it fits perfectly.

   > 5X00IN GAP DIMENSIONS

3. Remove rear side panel.
4. Apply adhesive on bonding areas -LHD vehicle -  of the body.

   > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

   >Application depth 3 mm 

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   Bonding areas

5. Apply adhesive on bonding areas -LHD vehicle -  of the body.

   > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

   >Application depth 3 mm 

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   Bonding areas

6. Apply body foam filler to the baffle plate.

   > 5X00IN22 WORKING WITH BODY FOAM FILLER

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   Body foam filler

7. Apply adhesive on rear side panel.

   > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

   >Application depth 0.5 mm 

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   Bonding areas

   1. 7.1 Also apply a bead of adhesive all around the bonding surface.

      >Application depth 3 mm 

8. Apply adhesive on bonding areas -LHD vehicle -  of the rear side panel.

   > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

   >Application depth 0.5 mm 

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Bonding areas

   1. 8.1 Also apply a bead of adhesive all around the bonding surface -LHD vehicle -  .

      >Application depth 3 mm 

9. Secure rear side panel.

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   Self-tapping screws

   1. 9.1 Screw in self-tapping screws -1-  .

      > 5X00IN24 SETTING SELF-TAPPING SCREWS

   2. 9.2 Rivet in rear side panel -2-  .

      >BLIND RIVET 999.190.229.01 

10. Rivet in rear side panel.

    >BLIND RIVET 999.190.229.01 

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    Blind rivets

11. Rivet in rear side panel.

    >RIVET 9A7.008.606.00 

    > 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

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    Flow-form rivets

12. Rivet in rear side panel.

    -LHD vehicle -  >BLIND RIVET 999.190.229.01 

    -RHD vehicle -  >RIVET 9A7.008.606.00 

    > 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

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    Rivets

13. Rivet in rear side panel.

    -LHD vehicle -  >RIVET 9A7.008.606.00 

    > 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

    -RHD vehicle -  >BLIND RIVET PAF.912.885 

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    Rivets

14. Apply full aluminium weld on rear side panel.

    > Welding aluminium 

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    Applying full aluminium weld A

15. Apply full aluminium weld on rear side panel.

    > Welding aluminium 

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    Applying full aluminium weld B

16. Make ground connection -1-  .

    > Welding aluminium 

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    Ground connection

17. Bend over folded edges in the door aperture using >VAS 6635 - crimping pliers set, 4-piece  .

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    Folded edges

18. Fold over seam edges in rear wheel arch using >VAS 6635 - crimping pliers set, 4-piece  .

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    Folded edges