Installing light frame (section)
Note. 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).
1. Fitting light frame to the body
1.1. Fit the light frame to the body and fix in place with tensioning clamps.
1.2. To complete the fit, install the rear light and set the gap clearance between the rear light and side panel according to the adjustment values. Refer to 50 IN Processing structural body adhesive - as of MY 2005 (All Models) .
2. Welding in light frame
2.1. Tack-weld the light frame and remove rear light.
Scheme 1290
3. Welding in light frame
3.1. Resistance spot-weld the light frame in area -A, B, C, D-. (Scheme 1268)
Scheme 1291
4. Welding in light frame
4.1. Plug-weld the light frame in the areas -A, B, C- under shielding gas. (Scheme 1269)
Scheme 1292
5. Welding in light frame
5.1. Plug-weld the light frame in the areas -A- and -B- under shielding gas. (Scheme 1270)
Scheme 1293
6. Welding in light frame
6.1. Apply a full weld the light frame in the areas -A- and -B- using shielding gas. (Scheme 1271)
1. Remove vehicle from the alignment bench.
2. Clean welded joints and sheetmetal flanges with a wire brush.
3. Prime 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. Paint repair area and adjacent surfaces, if necessary.
7. Install removed accessories in the repair area.
8. Apply cavity preservation.
Designation Type Number Explanation Pneumatic body saw No. PS 1, 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. PS 1, see Gr. 3.5; Workshop Equipment Manual 00000 Angle grinder, see Gr. 3.5; see Workshop Equipment Manual 00000 Oscillating body saw (special electric 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
| 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 1294
1. Clean undersealing, adhesive residue and paint off the body connecting flanges in the marked area -A- using a hot-air gun or rotary brush. Grind the connecting flanges until bare. (Scheme 1281)
2. Coating spot-weld flange areas with zinc powder paint
2.1. Coat all spot-weld flange areas with zinc powder paint.
Scheme 1295
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. (Scheme 1282)
2. Coating spot-weld flange areas with zinc powder paint
2.1. Coat all spot-weld flange areas with zinc powder paint.
| 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 1296
1. Cleaning the welding areas
1.1. Grind both sides of the connecting flanges of the outer rear wheel housing in the marked area -A- until bare using a rotary brush. see scheme 269
2. Coating spot-weld flange areas with zinc powder paint
2.1. Coat all spot-weld flange areas with zinc powder paint.
Scheme 1297
1. Drilling holes for plug welding using inert gas
1.1. Drill holes (Ø = 7 mm) in areas -A, B, C, D, E- for plug welding using inert gas. Maintain spacing between the bores as on the old part. see scheme 270
Scheme 1298
2. Drilling holes for plug welding using inert gas
2.1. Drill holes (Ø = 7 mm) in area -A- for plug welding using inert gas. Maintain spacing between the bores as on the old part. see scheme 271
Scheme 1299
3. Cleaning the welding areas
3.1. Grind both sides of the connecting flanges of the inner rear wheel housing in the marked areas -A, B, C, D, E- until bare using a rotary brush. (Scheme 1283)
Scheme 1300
4. Cleaning the welding areas
4.1. Grind both sides of the connecting flanges of the inner rear wheel housing in the marked areas -A- and -B- until bare using a rotary brush. (Scheme 1284)
5. Coating spot-weld flange areas with zinc powder paint
5.1. Coat all spot-weld flange areas with zinc powder paint.
| WARNING | Risk of fatal injury from high voltage during electric welding! Danger of explosion and fire when welding in the area of highly inflammable materials. Irritation to respiratory tracts from toxic zinc oxide emitted when welding galvanised steel! Danger of injury from unintentional triggering of pyrotechnical safety components! Danger of injury from weld spatters and UV light when welding! |
> Do not perform welding work in a damp environment or on wet ground; there is a risk of fatal injury from the voltage being conducted through the human body. Persons with heart pacemakers should not perform welding work. Use insulating underlays.
> Remove highly flammable materials from the work area; if necessary, remove units with fuel-carrying parts and protect work areas in the vehicle that are at risk of catching fire using fire-proof covers.
> Ventilate the work area well.
> Remove smoke gases with a suitable extraction system (refer to Workshop Equipment Manual).
> Wear suitable protective equipment, such as protective clothing, gloves, a welding shield and, if necessary, a protective mask.
> For welding work, always disconnect both terminals on the battery. In the case of welding work in the immediate vicinity of the control modules for pyrotechnical safety systems, remove the control modules before beginning work.
> In addition, the guidelines of the welding equipment manufacturer and the legal accident prevention regulations and those of the mutual indemnity association (BGV D1) must be observed.
1. Fitting inner rear wheel housing to the body
1.1. Fit inner rear wheel housing to the body and secure to the straightening set.
1.2. Fix the inner rear wheel housing in place with tensioning clamps.
Scheme 1301
2. Welding in inner rear wheel housing
2.1. Resistance spot-weld inner rear wheel housing in area -A-. (Scheme 1285)
Scheme 1302
3. Welding in inner rear wheel housing
3.1. Plug-weld the inner rear wheel housing in areas -A, B, C- using inert gas. (Scheme 1286)
Scheme 1303
4. Welding in inner rear wheel housing
4.1. Plug-weld the inner rear wheel housing in areas -A- and -B- using inert gas. (Scheme 1287)
Scheme 1304
5. Welding in inner rear wheel housing
5.1. Plug-weld the inner rear wheel housing in areas -A- and -B- using inert gas. (Scheme 1288)
Scheme 1305
6. Welding in inner rear wheel housing
6.1. Apply a full weld to the inner rear wheel housing in area -A- using inert gas. (Scheme 1289)
7. Install lower B-pillar reinforcement. Refer to 51 42 55 Replacing B-pillar reinforcement - as of MY 2006 (Cayman S, Cayman S RHD) .
1. Fitting outer rear wheel housing to the body
1.1. Fit outer rear wheel housing to the body and fix in place with tensioning clamps.
Scheme 1306
2. Welding in outer rear wheel housing
2.1. Resistance spot-weld outer rear wheel housing in area -A-. see scheme 279
Scheme 1307
3. Welding in outer rear wheel housing
3.1. Resistance spot-weld outer rear wheel housing in area -A-. see scheme 280
4. Install side panel. > 535555 Replacing side panel - section on "Installing"
1. Remove vehicle from the alignment bench.
2. Clean welded joints and sheetmetal flanges with a wire brush.
3. Prime 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. Paint repair area and adjacent surfaces, if necessary.
7. Install removed accessories in the repair area.
8. Apply cavity preservation.