Installing side section Porsche Boxster S 987

Installing side section

> The new part must be welded within 30 minutes in the area of the adhesive, otherwise the adhesion of the adhesive will be affected.

Scheme 1193

1. Installing seal

1.1. Apply a triangular bead of body sealant measuring -dimension X = approx. 12 mm- high all around the seal. Position seal on inside of side section and press on firmly. (Scheme 1175)

Check dimension -Y= 20 mm- with respect to roof reinforcement. (Scheme 1175)

Scheme 1194

2. Apply adhesive on the inside of the side section

2.1. Apply a triangular bead of Betamate 2096 adhesive measuring -dimension X = approx. 8 mm- in height to the joint between the light housing and the inside of the side section. The light frame must lie flush with the inside of the side section. (Scheme 1176)

Scheme 1195

3. Applying adhesive to the side section

3.1. Apply a triangular bead of adhesive (Teromix-6700) measuring -dimension X = approx. 8 mm- to the inside of the side section, along the wheel arch up as far as the start of the door sill. (Scheme 1177)

Note. Determine the position of the new part and secure with tensioning clamps. When butt welding body sheet panels with a sheet thickness of > 1.5 mm, there must be a welding slit width s = 1 x sheet thickness to guarantee the required welding quality (welding through).

4. Fitting the side section to the body

4.1. Secure the side section with tensioning clamps. Use test gauge 9748 .

4.2. Tack-weld the side section.

Scheme 1196

5. Welding in the side section

5.1. Resistance spot-weld the side section in area -A-. (Scheme 1179)

Scheme 1197

6. Welding in the side section

6.1. Resistance spot-weld the side section in area -A-. (Scheme 1180)

Scheme 1198

7. Welding in the side section

7.1. Resistance spot-weld the side section in area -A-. (Scheme 1181)

> 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 Processing structural body adhesive - as of MY 2005 (All Models) .

Scheme 1199

8. Welding in the side section

8.1. Resistance spot-weld the side section in area -A-. (Scheme 1182)

Scheme 1200

9. Welding in the side section

9.1. Resistance spot-weld the side section in area -A-. (Scheme 1183)

Scheme 1201

10. Welding in the side section

10.1. Resistance spot-weld the side section in area -A, B, C, D, E-. (Scheme 1184)

Scheme 1202

11. Welding in the side section

11.1. Resistance spot-weld the side section in areas -A- and -B-. (Scheme 1185)

Scheme 1203

12. Welding in the side section

12.1. Resistance spot-weld the side section in areas -A- and -C-. see scheme 172

12.2. Plug-weld the side section in area -B- using inert gas. see scheme 172

13. Welding in the side section

13.1. Resistance spot-weld the side section in area -A-. see scheme 173

Scheme 1204

14. Welding in the side section

14.1. Plug-weld the side section in area -A- using inert gas. (Scheme 1186)

Scheme 1205

15. Welding in the side section

15.1. Apply a full weld to the side section in area -A- using inert gas. (Scheme 1187)

Scheme 1206

16. Welding in the side section

16.1. Apply a full weld to the side section in area -A- using inert gas. (Scheme 1188)

> When there are repairs in the area of the structure bond, the vehicle may not be used until the curing time has elapsed.

> For details of curing time, see Refer to 50 IN Processing structural body adhesive - as of MY 2005 (All Models) .

1. Removing vehicle from alignment 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 Processing structural body adhesive - as of MY 2005 (All Models) .

5. Restore standard undersealing with underbody sealant Refer to 50 IN Processing structural body adhesive - as of MY 2005 (All Models) .

6. Painting repair area and adjacent surfaces, if necessary

7. Installing removed accessories 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

> 5000AW AW Safety instructions - Chapter entitled "General warning notes"

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 Additional straightening attachments for 911 Carrera (997), see Gr. 3.5; Workshop Equipment Manual 00000 Straightening attachments for Boxster (986), see Gr. 3.5; Workshop Equipment Manual 00000 Pneumatic spotweld remover, Vario Drill No. WS 90, see Gr. 3.5; Workshop Equipment Manual 00000 Test gauge 9748, see Porsche special tools, 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 1207

1 - Side section

Y - Seal

Scheme 1208

1. Determining cut

1.1. Position the cut L on the lower side member so that the replacement body part overlaps the lower side member by approx. 60 mm. Mark the cut.

Scheme 1209

2. Cutting through the lower side member

2.1. Cut through the side section at the marked connection point L .

Scheme 1210

3. Mill off spotwelds.

3.1. Mill off spotwelds in area A using a spotweld cutter.

Scheme 1211

4. Mill off spotwelds.

4.1. Mill off spotwelds in areas B, C, D, P with a spotweld cutter.

4.2. Cut through the shielding gas weld in area E using the parting grinder.

Scheme 1212

5. Cutting the spotwelds

5.1. Mill off spotwelds in areas F, G, H, I using a spotweld cutter.

Scheme 1213

6. Mill off and cut through spotwelds

6.1. Mill off spot welds in area K using a spotweld cutter.

6.2. Cut through the side section at the connection point J with the parting grinder.

Scheme 1214

7. Remove expanded sealant

7.1. The outer side section is factory sealed to the inner side section with expanded sealant Y . The expanded sealant will be destroyed when replacing the side section and must be replaced.

> 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 1215

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.

> Wear protective gloves when working in the area of sharp-edged body and unit parts!

> Use the test gauge 9748 for positioning when replacing and aligning the side section and rear closing panel.

> The Boxster and Cayman have functional dimensions; body parts are positioned interdependently with very close tolerance values; parts cannot be positioned/centerd with respect to other parts.

1. Screw test gauge securely to side member (impact pipe/impact absorber mount) A . On the closing panel, position the fastening screws for the retaining strip with the positioning sleeves B and screw in positioning screws.

1.1. Fitting rear side section to the body

1.2. Position side section on the light housing with the square pin C at the test gauge 9748.

To do the alignment, install the doors and rear lid and set the gap dimensions between rear door, rear lid and side section according to the respective adjustment values. Refer to 50 IN Processing structural body adhesive - as of MY 2005 (All Models) .

1.3. Securing rear side section with tensioning clamps

Scheme 1216

Scheme 1217

2. Fitting in side section joints and making the cuts

2.1. Use a body saw to cut the two sheetmetal plates in the area of the overlap between the side section and body. Do not damage internal components when doing this. Use test gauge 9748.

Scheme 1218

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, J with a rotary brush until they are bare.

> 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 Processing structural body adhesive - as of MY 2005 (All Models) .

Scheme 1219

1. Installing seal

1.1. Apply a triangular bead of body sealant Y measuring dimension "X" = approx. 12 mm high all around the seal. Position seal on the inside of the side section and press firmly.

Check dimension for viewing window for inner side section --> Length: X = 28 mm

Scheme 1220

2. Applying adhesive to the side section

2.1. Apply a triangular bead of adhesive - dimension "X" = approx. 8 mm - to the inside of the side section, along the wheel arch and up to the start of the sill.

> The new part must be welded within 30 minutes in the area of the adhesive, otherwise the adhesion of the adhesive will be affected.

2.2.

Scheme 1221

3. Applying adhesive to the inside of the side section

> 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 - to the inside of the side section.

4. Welding in the side section

4.1. Secure the rear side section with tensioning clamps. Use test gauge 9748.

4.2. Tack-weld the side section at the rear.

> The new part must be welded within 30 minutes in the area of the adhesive, otherwise the adhesion of the adhesive will be affected.

4.3. Spot-weld area A of the side section.

Scheme 1222

Scheme 1223

5. Welding in the side section

> 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. Spot weld areas H, F, G, I of the side section.

Scheme 1224

6. Welding in the side section

6.1. Spot weld areas B, C, D of the side section.

6.2. Weld area E of the side section using inert gas.

6.3. Plug-weld area P of the side section using inert gas.

Scheme 1225

7. Welding in the side section

7.1. Spot-weld area K of the side section.

7.2. Braze weld area J of the side section

Scheme 1226

8. Welding in the side section

8.1. Weld area L of the side section using inert gas.

> When there are repairs in the area of the structure bond, the vehicle may not be used until the curing time has elapsed.

> For details of curing time, see Refer to 50 IN Processing structural body adhesive - as of MY 2005 (All Models) .

1. Removing vehicle from alignment 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 Processing structural body adhesive - as of MY 2005 (All Models) .

5. Restore standard undersealing with underbody sealant Refer to 50 IN Processing structural body adhesive - as of MY 2005 (All Models) .

6. Painting repair area and adjacent surfaces, if necessary

7. Installing removed accessories 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

> 5000AW AW Safety instructions - Chapter entitled "General warning notes"

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 Elektron hot-air gun from Leister, see Gr. 3.5; Workshop Equipment Manual 00000 Inverter welding equipment ATL Inverterspot WE1194 Additional straightening attachments for 911 Carrera (997), see Gr. 3.5; Workshop Equipment Manual 00000 Straightening attachments for Boxster (986), see Gr. 3.5; Workshop Equipment Manual 00000 Pneumatic spotweld remover, Vario Drill No. WS 90, see Gr. 3.5; Workshop Equipment Manual 00000 Betamate Kleber 2096 see Gr. 8, Parts Catalogue 00000 Primer for Betamate adhesive 2096 see Gr. 8 Parts Catalogue 00000 Processing nozzle for Betamate adhesive 2096 see Gr. 8 Parts Catalogue 00000

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 1227

1. Remove outer rear wheel housing. > 536855 Replacing rear wheel housing - section on "Removing"

Scheme 1228

2. Milling off spotwelds

2.1. Mill off spotwelds in area -A- using a spotweld cutter. (Scheme 1209)

Scheme 1229

3. Milling off spotwelds

3.1. Mill off spotwelds in areas -A- and -B- using a spotweld cutter. (Scheme 1210)