Removing side section
Installation Location
Scheme 958
1 - Side section
Y - Sealing
Scheme 959
1. Determine cut.
1.1. Position the cut K on the lower side member so that the replacement body panel overlaps with the lower side member by approx. 60 mm. Mark the cut.
1.2. Position the cut L on the B-pillar so that the replacement body panel overlaps with the B-pillar by approx. 60 mm. Mark the cut.
1.3. Position the cut M on the C-pillar so that the replacement body panel overlaps with the C-pillar by approx. 60 mm. Mark the cut.
2. Mill off spotwelds.
2.1. Using a spotweld cutter, mill off spotwelds in areas A, B, C, D .
Mill off spotwelds in areas E, F, G, H, I using a spotweld cutter. Use a parting grinder to cut open the gas-shielded arc weld in area I .
Scheme 960
Cut out a viewing window from the rear center section reinforcement N = dimension 20 x 50 mm . Using a spotweld cutter, mill off spotwelds in area J .
Scheme 961
3. Cut through the side section at the marked joints K, L, M .
Scheme 962
4. Remove expanded sealant
4.1. The side section is factory sealed with expanded sealant Y from the light housing to the rear center section connection. The expanded sealant will be destroyed when replacing the side section and must be replaced.
| CAUTION | Danger of explosion and fire from flying sparks during grinding and welding work! Danger of injury and danger of damage to vehicle parts and other vehicles due to flying sparks |
> Cover vehicle parts such as battery, fuel system, paintwork, glass and passenger compartment parts with fire-proof covers and, if necessary, remove batteries and fuel-carrying components.
> No other vehicles may be left unprotected in areas used for body repair!
Scheme 963
1. Clean the body connection flanges of undersealing, adhesive residue and paint in the marked areas using a hot-air gun or rotary brush. Grind the connection flanges until bare.
| CAUTION | Danger of injury! Sharp-edge burrs on body and unit parts! Injuries from sharp edges on body and unit parts. |
> Wear protective gloves when working in the area of sharp-edged body and unit parts!
Scheme 964
1. Fit in side section to the body at the rear
1.1. Cut the replacement part so that there is approx. 60 mm overlap at the joints.
1.2. To complete the fit, install the doors and lid at the rear and set the gap dimensions between the door and lid at the rear and the side section according to the respective adjustment values. Refer to Diagram - body gap dimensions in --> FRONT article.
1.3. Fix the side section at the rear with tensioning clamps.
Scheme 965
2. Fit in side section joints and make the cuts
2.1. Use a body saw to cut the two sheetmetal panels in the area of the overlap between the side section and body. Do not damage the internal components when doing this.
Scheme 966
3. Cleaning welding and sealing areas
3.1. Grind both sides of the connecting flanges of the side sections in the marked areas A, B, C, D, F, G, H, I, L, J, K, L, M with a rotary brush until they are bright.
3.2. Drill Ø 7 mm holes in area J for the plug welds under shielding gas.
Scheme 967
1. Install seal
1.1. Apply a triangular bead of body sealant Y - dimension "X" = approx. 12 mm high - on 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.
2. Apply adhesive on the side section
Scheme 968
2.1. Apply the adhesive as a triangular bead - dimension "X" = approx. 8 mm - on the inside of the side section, along the wheel arch and up to the start of the sill.
Scheme 969
2.2. Apply the adhesive material (replacement part: Klebt and Dichtet from Wurth) as a triangular bead - dimension "X" approx. 4 mm. - on the area of the side section at the transition to the rear center section.
Scheme 970
3. Apply adhesive on 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.
3.1. Apply a triangular bead of adhesive (Teromix-6700) - dimension "X" = approx. 10 mm high - on the connection 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 971
4. Weld in the side section
4.1. Fix the side section at the rear with tensioning clamps.
4.2. Tack-weld the side section at the rear.
| 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 (Carrera 4) . Refer to 50 IN Diagram - body gap dimensions - as of MY 2005 (Carrera 4) . Refer to 50 IN Diagram - body gap dimensions - as of MY 2005 (Carrera 2 & Carrera 2S) . Refer to 50 IN Change identification data plate - as of MY 2005 (All Models) .
4.3. Spot weld areas A, B, C, D of the side section.
Scheme 972
5. Weld in the side section
5.1. Spot weld areas E, F, G, H of the side section.
5.2. Plug-weld side section in area I under shielding gas.
Scheme 973
6. Weld in viewing window
6.1. Plug-weld side section in area J under shielding gas.
6.2. Weld viewing window N of rear center section reinforcement with a continuous weld under shielding gas.
Scheme 974
7. Weld joints under shielding gas
7.1. Weld joints K, L, M (lower side member, B-pillar, C-pillar) with a continuous weld under shielding 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 (Carrera 4) . Refer to 50 IN Diagram - body gap dimensions - as of MY 2005 (Carrera 4) . Refer to 50 IN Diagram - body gap dimensions - as of MY 2005 (Carrera 2 & Carrera 2S) . Refer to 50 IN Change identification data plate - as of MY 2005 (All Models) .
5. Restore standard undersealing with underbody sealant Refer to 50 IN Diagram - body gap dimensions - as of MY 2005 (Carrera 4) . Refer to 50 IN Diagram - body gap dimensions - as of MY 2005 (Carrera 4) . Refer to 50 IN Diagram - body gap dimensions - as of MY 2005 (Carrera 2 & Carrera 2S) . Refer to 50 IN Change identification data plate - as of MY 2005 (All Models) .
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.
1. Removing accessories in the repair area
1.1. Remove accessories in the repair area according to the extent of damage to the vehicle.
2. Equipping alignment bench with straightening kit
2.1. Equip alignment bench with the basic straightening attachments according to the plans included with the straightening attachments.
3. Placing vehicle on the alignment bench
3.1. Position vehicle on alignment bench, align according to the reference holes and bolt firmly to the attachment set.
4. Covering accessories adjacent to the vehicle repair area
4.1. Cover all accessories 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.
Installation Location
Scheme 975
1 - Side section
Y - Seal
R - Water drip pan
Scheme 976
1. Determine cut.
1.1. Position the cut K on the lower side member so that the replacement body panel overlaps with the lower side member by approx. 60 mm. Mark the cut.
Scheme 977
2. Milling off spotwelds
2.1. Use a spotweld cutter to mill off spotwelds in areas A, B, C .
In area N (Inset), the underlying reinforcement weld to the side section must be milled off (4 spot-weld connections).
Scheme 978
3. Milling off spotwelds
Mill off spotwelds in areas E, F, G, J using a spotweld cutter. Separate inert-gas welded seam in area I using a parting grinder.
Scheme 979
4. Milling off spotwelds
Mill off spot welds in area H using a spotweld cutter.
Scheme 980
5. Cutting the side section
Cut through the side section at the marked separation point K using the oscillating body saw.
Scheme 981
6. Removing expanded sealant
6.1. The side section is factory-sealed with expanded sealant Y from the light housing to the rear center panel joint. The expanded sealant will be destroyed when you change the side section and must be replaced.
| CAUTION | Danger of explosion and fire from flying sparks during grinding and welding work! Danger of injury and danger of damage to vehicle parts and other vehicles due to flying sparks |
> Cover vehicle parts such as battery, fuel system, paintwork, glass and passenger compartment parts with fire-proof covers and, if necessary, remove batteries and fuel-carrying components.
> No other vehicles may be left unprotected in areas used for body repair!
Scheme 982
1. Clean the body connection flanges of undersealing, adhesive residue and paint in the marked areas using a hot-air gun or rotary brush. Grind the connection flanges until bare.
| CAUTION | Danger of injury! Sharp-edge burrs on body and unit parts! Injuries from sharp edges on body and unit parts. |
> Wear protective gloves when working in the area of sharp-edged body and unit parts!
Scheme 983
1. Fitting side section to the body at the rear
1.1. Cut the replacement part so that there is approx. 60 mm overlap at the joints.
1.2. To complete the fit, install the doors and lid at the rear and set the gap dimensions between the door and lid at the rear and the side section according to the respective adjustment values. Refer to Diagram - body gap dimensions in --> FRONT article.
1.3. Secure the side section at the rear with tensioning clamps.
Scheme 984
2. Cutting through side section joints
Cut through the side section at the marked separation point K using the oscillating body saw.
Scheme 985
3. Cleaning welding and sealing areas
3.1. Grind both sides of the connecting flanges of the side section in the marked areas A, B, C, D, F, G, H, I, J, K, L until they are bare using a rotary brush.