Removing side section Porsche Boxster S 987 рестайлинг

Removing side section

Installation Location

Scheme 1164

Note. Separation points on the side section can only be at the marked areas A and B .

Scheme 1165

1. Determining the cut

1.1. Determine separation point on C-pillar -A- to the dimension -X = 18 mm-, then mark the cut. (Scheme 1148)

1.2. Position cut on lower side member -B- so that the replacement body part overlaps the lower side member by approx. 60 mm, then mark the cut. (Scheme 1148)

Scheme 1166

2. Cutting through the lower side member

2.1. Cut through the side section at the marked separation point in the lower side member -A- using the oscillating body saw. (Scheme 1149)

> Only separate parts using the oscillating body saw.

> In the event of damage: Repair affected area by applying inert-gas welds.

Scheme 1167

3. Cutting the C-pillar

3.1. Cut through the side section at the marked separation point in the C-pillar -A- using the oscillating body saw. Do not damage internal components when doing this. (Scheme 1150)

Scheme 1168

4. Milling off spotwelds

4.1. Mill off spotwelds in area -A- using a spotweld cutter. (Scheme 1151)

Scheme 1169

5. Milling off spotwelds

5.1. Mill off spotwelds in area -A- using a spotweld cutter. (Scheme 1152)

Scheme 1170

6. Separating spotwelds

6.1. Separate spotwelds in area -A- using a parting grinder. (Scheme 1153)

Scheme 1171

7. Milling off spotwelds

7.1. Mill off spotwelds in area -A- using a spotweld cutter. (Scheme 1154)

Scheme 1172

8. Milling off spotwelds

8.1. Mill off spotwelds in area -A- using a spotweld cutter. (Scheme 1155)

Scheme 1173

9. Milling off spotwelds

9.1. Mill off spotwelds in areas -A, B, D- using a spotweld cutter. (Scheme 1156)

9.2. Mill off spotwelds in areas -E- and -C- using a spotweld cutter (2 plate thicknesses). (Scheme 1156)

Scheme 1174

10. Separating and milling off spotwelds

10.1. Separate spotwelds in areas -A- and -B- using a parting grinder. (Scheme 1157)

10.2. Mill off spotwelds in area -C- using a spotweld cutter. (Scheme 1157)

Scheme 1175

11. Separating and milling off spotwelds

11.1. Mill off spotwelds in area -A- using a spotweld cutter. (Scheme 1158)

11.2. Separate spotwelds in areas -B- using a parting grinder. (Scheme 1158)

Scheme 1176

12. Separating spotwelds

12.1. Separate spotwelds in area -A- using a parting grinder. (Scheme 1159)

Scheme 1177

13. Milling off spotwelds

13.1. Mill off spotwelds in area -A- using a spotweld cutter. (Scheme 1160)

Scheme 1178

14. Bending up the side section

14.1. Bend side section up in area -A- until the internal spotwelds are accessible. (Scheme 1161)

Scheme 1179

15. Milling off internal spotwelds

15.1. Mill off spotwelds in area -A- using a spotweld cutter. (Scheme 1160)

Note. Removing expanded sealant The outer side section is factory-sealed to the inner side section with expanded sealant in area -Y-. (Scheme 1163) The expanded sealant will be destroyed when you change the side section and must be replaced.

Scheme 1180

Note. Separating body parts In the case of bonded panel joints with a hardened bonded layer on the outer panel, apply a generous amount of heat to heat up the outer panel in the area of the spotwelds. Refer to 50 IN Processing structural body adhesive - as of MY 2005 (All Models) . After removing the loosened body part, old adhesive must be removed and any uneven spots sanded down. The flange area must then be pre-treated for bonding. For the procedure see: Information on the use of structural adhesive in vehicle manufacturing Refer to 50 IN Processing structural body adhesive - as of MY 2005 (All Models) .

Scheme 1181

16. Separating bonded joints and removing expanded sealant

16.1. Heat up bonded joints in the areas -A, B, C- between the side section and body using the Leister Elektron hot-air gun; see Gr. 3.5, Workshop Equipment Manual 00000 and remove side section. see scheme 147

> 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 1182

1. Clean undersealing, adhesive residue and paint off the body connecting flanges in the marked areas -A, B, C- using a hot-air gun or rotary brush. Grind the connecting flanges until bare. see scheme 148

Scheme 1183

2. Clean undersealing, adhesive residue and paint off the body connecting flanges in the marked areas -A, B, C, D- using a hot-air gun or rotary brush. Grind the connecting flanges until bare. see scheme 149

3. Coating spot-weld flange areas with zinc powder paint

3.1. Coat all spot-weld flange areas with zinc powder paint.

Scheme 1184

4. Preparing bonded flanges

4.1. Prepare bonded flanges in the marked area -A-. (Scheme 1164)

See: Working with adhesive Refer to 50 IN Processing structural body adhesive - as of MY 2005 (All Models) ..

Scheme 1185

5. Priming bonded flanges

5.1. Prime bonded flanges on the body in the marked area -A-. (Scheme 1165)

See Working with primer Refer to 50 IN Processing structural body adhesive - as of MY 2005 (All Models) .

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