Removing Rear Body (Coupe)

Information

Some of the repair illustrations show only one side of the vehicle. Naturally, some steps also have to be performed on the opposite side of the vehicle as well. These must be carried out as a mirror image of the steps shown.

Information

The rear end cannot be extended until the tabs have been disconnected from the reinforcement.

1. Unscrew self-tapping screws -1-  .

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Reinforcement

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

   > 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Reinforcement

3. Remove reinforcement.
4. Unscrew screws -1 and 2  - and remove connecting piece -3 - 

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Connecting piece

5. Unscrew self-tapping screws 1  and screws

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Self-tapping screws

6. Tie up seat-well cross member.
7. Grind down welded seams

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Welded seams

8. Drill out penetrated joints -A- 

   > Diameter 4 mm <!-- vee -->

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Joints

9. Remove punch rivets -B- 

   > 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Punch rivets

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

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Bonding areas

11. Remove adapter plate for lower door sill.
12. Unscrew self-tapping screws -1  -.

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Self-tapping screws

13. Remove punch rivets using > VAS 852 001 - body dent removal system, aluminium  and > VAS 6790 - compact booster  .

    > 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Punch rivets

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

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Bonding areas

15. Remove filler plate.
16. Unscrew self-tapping screws -1-  .

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Self-tapping screws

17. Punch self-tapping screws -2-  out of the thread.

    17.1  Remove the remaining pieces of self-tapping screw from the side member using a magnet.

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Self-tapping screws

18. Grind down welded seams -1-  .

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Welded seams

19. Grind down welded seams -1-  .

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Welded seams

20. Grind down welded seam.

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Welded seam

21. Remove punch rivets using > VAS 852 001 - body dent removal system, aluminium  and > VAS 6790 - compact booster. 

    > 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Punch rivets

22. Unscrew self-tapping screws -1-  and -2- 

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Self-tapping screws

23. Remove punch rivets using > VAS 852 001 - body dent removal system, aluminium  and > VAS 6790 - compact booster  .

    > ; 5X00IN23 Replacing punch rivets and penetrated joints 

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Punch rivets

24. Cut off the marked tabs -1-  on the rear end.

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Tabs

25. Remove punch rivets using > VAS 852 001 - body dent removal system, aluminium  and > VAS 6790 - compact booster  .

    > 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Punch rivets

26. Bend up seam on lower corner panel using > VAS 6635 - crimping pliers set  , 4-piece  .

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Seam on lower corner panel

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

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Bonding areas

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

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Bonding areas

29. Tilt rear body (Coupe) down slightly and pull it out to the rear while tilting.