Preliminary Work

Preliminary work for body repairs (with straightening system)

1. Remove add-on parts in the repair area.
   1. 1.1  Remove add-on parts in the repair area according to the extent of damage on the vehicle.
2. Set up straightening bench with straightening system.
3. Set the vehicle on the straightening bench.
4. Cover add-on parts adjacent to the repair area on the vehicle.
   1. 4.1  Cover all accessories remaining on the vehicle and adjacent areas with fire-proof protective covers.
5. Reshape connection area of the sheetmetal parts to be replaced. See Information on aluminium repairs

   5X00IN05 INFORMATION ON ALUMINIUM REPAIRS - SECTION ON "INFORMATION"

6. Expose joint areas.
   1. 6.1  Remove underbody protection, paint, etc. from the joint areas of the body using a hot-air gun or rotary brush.

1. Remove rear side section.

   535555 REPLACING REAR SIDE SECTION 

2. Remove (inner) D-pillar reinforcement.
   IMPORTANT:

   • Only make cuts in the top plate. Make sure not to damage the plate underneath when doing this.
   1. 2.1  Mark and make cut -A-. Distance approx. 37 mm
      Fig 1: Checking Top Plate Cutting Dimension

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      Cut

   2. 2.2  Unscrew self-tapping screws -1-  .

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      Self-tapping screws

   3. 2.3  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

   4. 2.4  Heat bonding areas using V.A.G 1416 - Hot-Air Blower  .

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      Bonding areas

   5. 2.5  Remove (inner) D-pillar reinforcement.
3. Remove lock carrier.
   1. 3.1  Damaged side:

      Unscrew self-tapping screw -1-  .

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      Self-tapping screw

   2. 3.2  Damaged side:

      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

   3. 3.3  Damaged side:

      Heat bonding areas using V.A.G 1416 - Hot-Air Blower  .

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Bonding areas

   4. 3.4  Perform remaining removal steps as described in Workshop Service Information

      530955 REPLACING LOCK CARRIER - SECTION ON "REMOVING" 

4. Remove boot floor plate.

   53245500 REPLACING REAR BOOT FLOOR PLATE 

5. Remove floorpan.

   517355 REPLACING FLOORPAN

6. Remove rear cross member.

   538255 REPLACING REAR CROSS MEMBER 

7. Remove C-pillar reinforcement.

   532955 REPLACING C-PILLAR REINFORCEMENT 

8. Remove cover plate on seat cross member.
   1. 8.1  Unscrew self-tapping screws -1-  .

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      Self-tapping screws

   2. 8.2  Drill out spotwelds.

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      Spotwelds

   3. 8.3  Heat bonding areas using V.A.G 1416 - Hot-Air Blower  .

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Bonding areas

   4. 8.4  Remove cover plate for seat cross member.
9. Remove seat cross member.
   1. 9.1  Unscrew self-tapping screws -1-  .

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Self-tapping screws

   2. 9.2  Drill out spotwelds.

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Self-tapping screws

   3. 9.3  Heat bonding areas using V.A.G 1416 - Hot-Air Blower  .

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Bonding areas

   4. 9.4  Remove seat cross member.
10. Remove closing panel.
    IMPORTANT:

    • Only make cuts in the top plate. Make sure not to damage the plate underneath when doing this.
    1. 10.1  Mark and make cut -A-  . Distance approx. 120 mm
       Fig 2: Checking Closing Panel Cutting Dimension

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.

       Cut

    2. 10.2  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.

       Rivet area

    3. 10.3  Heat bonding areas using V.A.G 1416 - Hot-Air Blower  .

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.

       Bonding areas

    4. 10.4  Remove closing panel.