Installing Inner Side Panel (Saloon)

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. Install inner side panel (Saloon) and check that it fits perfectly.
2. Install new baffle plate -1-  after applying adhesive.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   New baffle plate

   Information 

   • Apply adhesive evenly over the entire bonding surface. 
3. Apply adhesive on joint areas of the body.

   > 5X00IN21 Working with body structural adhesive

   > Application depth 0, 5 mm 

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Joint areas

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Joint areas

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Joint areas

   Information 

   • Apply adhesive evenly over the entire bonding surface. 
4. Apply adhesive on marked areas of the inner side panel.
   1. 4.1 Apply adhesive evenly on the bonding surface. > Application depth 0.5 mm 
   2. 4.2 Also apply a bead of adhesive all around the bonding surface. > Application depth 3 mm 

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Applying adhesive

5. Apply body structural foam in the marked area on the reinforcement.

   > 5X00IN20 WORKING WITH BODY STRUCTURAL FOAM

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Body structural foam

6. Rivet in inner side panel (Saloon) using flow-form rivets. > FLOW-FORM RIVET 9A7.008.606.00 

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Flow-form rivets

7. Rivet in inner side panel (Saloon).
   1. 7.1 Rivet in inner side panel (Saloon). > BLIND RIVET 999.190.229.01 
   2. 7.2 Rivet in rivets in the marked area -A-  from the wheel housing.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Blind rivets

8. Rivet in inner side panel (Saloon).
   1. 8.1 Rivet in inner side panel (Saloon). > BLIND RIVET 999.190.229.01 
   2. 8.2 Rivet in the marked area -A-  using > BLIND RIVET 999.190.227.01  .

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Blind rivets

9. Rivet in inner side panel (Saloon).
   1. 9.1 Rivet in inner side panel (Saloon). > BLIND RIVET 999.190.229.01 
   2. 9.2 Rivet in the marked area -A-  using > BLIND RIVET 999.190.227.01  .
   3. 9.3 Rivet in rivets in the marked area -B-  from the wheel housing.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Blind rivets

10. Plug-weld the inner side panel (Saloon) using inert gas.

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Plug-welding using inert gas

11. Apply a full weld to the inner side panel (Saloon) in the marked area -A-  .

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Applying full weld

    Information 

    • Apply adhesive evenly over the entire bonding surface. 
12. Apply adhesive on marked areas of the inner side section. > Application depth 0.5 mm 

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Bonding area

13. Fold over roll fold in the door entry area using > VAS 6635 - crimping pliers set, 4-piece-1-  (-arrow-  ).

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Roll fold

14. Stick sound absorber -1-  on the inside.

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Sound absorber