Installing side section
| WARNING | Welding in body components Danger of injury and material damage |
> Once the spare parts have been fixed in place, repair spotwelds must be placed on the old spotwelds because there is no current flow possible in areas with a hardened adhesive layer. Welding procedures other than resistance spot-welding are not permitted since the thermal effect would destroy the bonded joint over a wide area. Refer to 50 IN Diagram - body gap dimensions - as of MY 2005 (Cabrio 2, Cabrio 2S) . Refer to 50 IN Diagram - body gap dimensions - as of MY 2005 (Cabrio 4, Cabrio 4) .
Scheme 986
1. Fitting in water drain hose
Press water drain hose Q through the water drip pan R ; observe specified marking. The groove of the water drain hose must fit all the way around the hole in the water drip pan. Route water drain hose through the grommet to the wheel housing and cut the hose so that approx. dimension Z = 35 mm projects outwards.
2. Installing water drip pan
2.1. Apply a triangular bead of body sealant - dimension "X" = approx. 12 mm high - to the inside of the side section O .
Scheme 987
Apply a triangular bead of body sealant - dimension "X" = approx. 12 mm high - to the wheel housing in area P .
Scheme 988
Position water drip pan R on the inside of the side section and press on firmly. Route the water drain hose Q . Apply a triangular bead of body sealant - dimension "X" = approx. 12 mm high - to the outside of the side section S .
Scheme 989
3. Installing seal
3.1. Apply a triangular bead of body sealant Y - dimension "X" = approx. 12 mm high - to all sides of the seal. Apply seal to the prepared holes on the inside of the side section, position the pins of the seal and press into place.
4. Applying adhesive to the side section
| WARNING | Risk of damage if the processing time is not observed! The quality of the joint will be affected if the adhesive processing time is not observed. |
> The new part must be welded within 30 minutes in the area of the adhesive, otherwise the adhesion of the adhesive will be affected.
4.1. Apply a triangular bead of adhesive measuring - dimension "X" = approx. 8 mm - to the inside of the side section, along the edge of the wheel arch and up to the start of the door sill.
5. Applying adhesive to the inside of the side section
| WARNING | Risk of damage if the processing time is not observed! The quality of the joint will be affected if the adhesive processing time is not observed. |
> The new part must be welded within 30 minutes in the area of the adhesive, otherwise the adhesion of the adhesive will be affected.
5.1. Apply a triangular bead of adhesive (Teromix-6700) - dimension "X" = approx. 10 mm high - to the joint between the light housing and the inside of the side section. The light housing must lie flush with the inside of the side section.
Scheme 990
6. Applying adhesive to the window slot reinforcement
| WARNING | Risk of damage if the processing time is not observed! The quality of the joint will be affected if the adhesive processing time is not observed. |
> The new part must be welded within 30 minutes in the area of the adhesive, otherwise the adhesion of the adhesive will be affected.
6.1. Apply a triangular bead of adhesive (Teromix-6700) - dimension "X" = approx. 10 mm high - to the joint between the window slot reinforcement and the side section.
Scheme 991
7. Applying adhesive to the inside of the side section
| WARNING | Risk of damage if the processing time is not observed! The quality of the joint will be affected if the adhesive processing time is not observed. |
> The new part must be welded within 30 minutes in the area of the adhesive, otherwise the adhesion of the adhesive will be affected.
7.1. Apply a triangular bead of adhesive (Teromix-6700) - dimension "X" = approx. 10 mm high - to the inside of the side section in area V .
Scheme 992
8. Welding in the side section
8.1. Secure the side section at the rear with tensioning clamps.
8.2. Tack-weld the side section at the rear.
| WARNING | Risk of damage if the processing time is not observed! The quality of the joint will be affected if the adhesive processing time is not observed. |
> The new part must be welded within 30 minutes in the area of the adhesive, otherwise the adhesion of the adhesive will be affected.
8.3. Resistance spot-weld areas A, B, C of the side section.
Scheme 993
9. Welding in the side section
9.1. Resistance spot-weld area H of the side section.
Scheme 994
10. Welding in the side section
10.1. Resistance spot-weld areas E, F, G of the side section.
10.2. Plug-weld the side section in area I using inert gas.
Scheme 995
11. Welding joint using inert gas
11.1. Apply a full weld to joint J of lower side member using inert gas.
1. Removing vehicle from straightening bench
2. Cleaning spot-welded joints and sheetmetal flanges with a wire brush
3. Priming flange areas with 2K primer
4. Restore standard sealing with body sealant Refer to 50 IN Diagram - body gap dimensions - as of MY 2005 (Cabrio 2, Cabrio 2S) . Refer to 50 IN Diagram - body gap dimensions - as of MY 2005 (Cabrio 4, Cabrio 4) .
5. Restore standard undersealing with underbody sealant Refer to 50 IN Diagram - body gap dimensions - as of MY 2005 (Cabrio 2, Cabrio 2S) . Refer to 50 IN Diagram - body gap dimensions - as of MY 2005 (Cabrio 4, Cabrio 4) .
6. Painting repair area and adjacent surfaces, if necessary
7. Install removed add-on parts in the repair area
8. Apply cavity preservation.
Designation Type Number Explanation Pneumatic body saw No. PS1, see Gr. 3.5; Workshop Equipment Manual special tool 00000 Press-out tool special tool 97290 Star gauges for body gap dimensions special tool NR.127-1 Spotweld drill special tool NR.129 Inverter welding equipment ATL Inverterspot workshop equipment WE1194
Spotweld drill NR.129 Star gauges for body gap dimensions NR.127-1 Press-out tool 97290 Pneumatic body saw No. PS1, see Gr. 3.5; Workshop Equipment Manual 00000 Angle grinder, see Gr. 3.5; see Workshop Equipment Manual 00000 Oscillating body saw (special electrical cutter), see Gr. 3.5; Workshop Equipment Manual 00000 Rotary brush, see Gr. 3.5; Workshop Equipment Manual 00000 Hole punch, see Gr. 3.5; Workshop Equipment Manual 00000 Leister Elektron hot-air gun, see Gr. 3.5; Workshop Equipment Manual 00000 Inverter welding equipment ATL Inverterspot WE1194 Basic straightening attachments for 911 Carrera (996), see Gr. 3.5; Workshop Equipment Manual 00000 Additional straightening attachments for 911 Carrera (997), see Gr. 3.5; Workshop Equipment Manual 00000 Pneumatic spotweld remover, Vario Drill No. WS 90, see Gr. 3.5; Workshop Equipment Manual 00000
Note. If it can be ensured there has been no deformation of the vehicle structure, the following repair can be carried out without the need of a straightening bench. In this case, the vehicle must not be raised when welding the component; it must stand on its wheels on an even surface.
1. Removing add-on parts in the repair area
1.1. Remove add-on parts in the repair area according to the extent of damage to the vehicle.
2. Equipping straightening bench with straightening attachments
2.1. Equip straightening bench with the straightening attachments according to the plans included with the straightening attachments.
3. Placing vehicle on the straightening bench
3.1. Position vehicle on the straightening bench, align according to the reference holes and bolt firmly to the attachment set.
4. Covering add-on parts adjacent to the vehicle repair area
4.1. Cover all add-on parts remaining on the vehicle and the neighboring areas with fire-proof, protective covers.
5. Reshaping connection area of the sheetmetal parts to be replaced
6. Exposing welding areas
6.1. Remove undersealing, paint, etc. from the welding areas of the body with a hot-air gun or rotary brush.