Installing Rear Body (Coupe)

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. Install rear body (Coupe) and check that it fits perfectly.
2. Apply adhesive evenly on the entire bonding surface of the body. > Application depth 0.5 mm 

   > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Bonding areas

3. Apply adhesive evenly over the entire bonding surface. > Application depth 0.5 mm 

   Also apply a bead of adhesive all around the bonding surface. > Application depth 3 mm  <!-- vee -->

   > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Bonding areas

4. Rivet in rear body (Coupe).

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Blind rivets

   PARTS DESCRIPTION 

   A	> BLIND RIVET999.190.229.01
   B	> BLIND RIVET999.190.227.01

5. Rivet in rear body (Coupel). > BLIND RIVET 999.190.230.01 

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Blind rivets

6. Rivet in rear body (Coupe). > BLIND RIVET 999.190.230.01 

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Blind rivets

7. Set self-tapping screw -1-  .

   > 5X00IN24 SETTING SELF-TAPPING SCREWS

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Self-tapping screw

8. Rivet in rear body (Coupe). > BLIND RIVET 999.190.229.01 

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Blind rivets

9. Rivet in rear body (Coupe). > BLIND RIVET 999.190.229.01 

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Bore holes

10. Rivet in rear body (Coupe). > BLIND RIVET 999.190.227.01 

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Blind rivets

11. Make ground connection -1-  by applying a full aluminium weld.

    > 5X00IN10 WELDING ALUMINIUM

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    Applying full aluminium weld

12. Install closing element and check that it fits perfectly.
13. Apply adhesive evenly to the entire bonding surface of the lower side member reinforcements (rear section) (Coupe). > Application depth 0.5 mm 

    > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Bonding areas

14. Apply adhesive evenly over the entire bonding surface. > Application depth 0.5 mm 

    Also apply a bead of adhesive all around the bonding surface. > Application depth 3 mm 

    > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Bonding areas

15. Rivet in filler plate. > BLIND RIVET 999.190.227.01 

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Punch rivets

16. Tighten self-tapping screws -1-  .

    > 5X00IN24 SETTING SELF-TAPPING SCREWS

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Self-tapping screws

17. Install adapter plate for lower door sill and check that it fits perfectly.
18. Apply adhesive evenly to the entire bonding surface of the lower side member reinforcements (rear section) (Coupe). > Application depth 0.5 mm 

    > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Bonding areas

19. Apply adhesive evenly over the entire bonding surface. > Application depth 0.5 mm 

    Also apply a bead of adhesive all around the bonding surface. > Application depth 3 mm 

    > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Bonding areas

20. Rivet in adapter plate for lower door sill.

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Joints

    PARTS DESCRIPTION 

    A	> BUND RIVET PAF.912.885
    B	> BLIND RIVET 999.190.229.01

21. Apply an aluminium weld to adapter plate for lower door sill using inert gas -1-  .

    > 5X00IN10 WELDING ALUMINIUM

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Welded seams

22. Apply adhesive evenly over the entire bonding surface of the rear body. > Application depth 0.5 mm 

    > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Bonding areas

23. Apply adhesive on the marked area.
    1. 23.1  Apply adhesive evenly over the entire bonding surface. > Application depth 0.5 mm  <!-- vee -->
    2. 23.2  Also apply an adhesive bead of sealant all around the bonding surface. > Application depth 3 mm 

       > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.

       Bonding areas

    3. Position seat-well cross member (Coupe).
    4. Set self-tapping screws -1-  .

       > 5X00IN24 SETTING SELF-TAPPING SCREWS

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.

       Self-tapping screws

24. Tighten screws -2-  .

    > Tightening torgue 30 (22 ft.lbl Nm 

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Self-tapping screws

25. Tighten screws

    > Tightening torgue 40 Nm (30 ft.lb) 

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    Connecting piece

26. Tighten screws -2-  .

    > Tightening torgue 25 (19 ft.lb) Nm  <!-- vee -->

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Connecting piece

27. Install reinforcement and check that it fits perfectly.
28. Drill bore holes for self-tapping screws through the existing holes.

    > Diameter 4.0 mm  <!-- vee -->

    > 5X00IN24 SETTING SELF-TAPPING SCREWS

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Reinforcement

29. Drill holes for blind rivets through the existing holes.

    > Diameter 6.6 mm  <!-- vee -->

    > 5X00IN24 SETTING SELF-TAPPING SCREWS

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Reinforcement

30. Remove reinforcement.
31. Prepare marked areas for bonding and riveting.

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Bonding areas

32. Apply adhesive evenly in the marked area on the joint area of the body. > Application depth 0.5 mm 

    > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Bonding areas

33. Apply adhesive evenly over the entire bonding surface of the reinforcement.

    > Application depth 0.5 mm  <!-- vee -->

    Also apply a bead of adhesive all around the bonding surface. > Application depth 3 mm  <!-- vee -->

    > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Bonding areas

34. Rivet in reinforcement. > BLIND RIVET 999.190.227.01 

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Reinforcement

35. Tighten self-tapping screws -1- . 

    > 5X00IN24 SETTING SELF-TAPPING SCREWS

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Reinforcement