Removing Rear Side Panel

Information 

Only make cuts in the top plate. Make sure not to damage the plate underneath when doing this.

Information 

Mark cuts in accordance with the new part. Make sure to leave an overlap of approx. 30 mm with respect to the body.

1. Mark and make cut -A -  on the roof pillar.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Cut A

2. Mark and make cut. >Distance 40 mm 
   Fig 1: Checking Rear Side Panel Cutting Dimension

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Cut B

3. Loosen joints.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Joint connections

   1. 3.1 Remove punch rivet -2-  using >VAS 852 001 - body dent removal system, aluminium  and >VAS 6790 - compact booster  .

      > 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

   2. 3.2 Unscrew self-tapping screws -1-  .

      > 5X00IN24 SETTING SELF-TAPPING SCREWS

4. Remove punch rivets using >VAS 852 001 - dent removal unit  and >VAS 6790 - compact booster  .

   > 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Punch rivets

5. Remove punch rivets using >VAS 852 001 - dent removal unit  and >VAS 6790 - compact booster  .

   > 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Punch rivets

6. Remove punch rivets -A -  and -B -  using >VAS 852 001 - dent removal unit  and >VAS 6790 - compact booster  .

   > 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Punch rivets

7. Loosen rear side panel in the rear lid area.

   > 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Joint areas

   1. 7.1 Remove punch rivets -A -  using >VAS 852 001 - dent removal unit, aluminium  and >VAS 6790 - compact booster  .
   2. 7.2 Drill out penetrated joints -B -  using >diameter 4 mm  .
   3. 7.3 Grind down welded seam -1-  .
8. Grind down welded seams -1-  .

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Welded seams

9. Bend up seam in the door aperture using >VAS 6635 - crimping pliers set, 4-piece  .

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Seams

10. Bend up seams in rear wheel arch using >VAS 6635 - crimping pliers set, 4-piece  .

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Seams

11. Heat bonding areas using >V.A.G 1416 - hot-air blower  .

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Bonding areas

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Bonding areas

12. Remove rear side panel.