Fitting side section and preparing for installation
| CAUTION | Subsequent damage to the body following repair work! The side section and rear closing panel cannot be replaced without using the test gauge 9748 The rear spoiler joint cannot be adjusted. The rear apron can only be fitted braced. |
> 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 9748 securely to side member (impact pipe/impact absorber mount) -A-. On the closing plate, position the fastening screws for the retaining strip with the positioning sleeves -B- and screw in positioning screws. (Scheme 1166)
1.1. Fitting rear side section to the body
1.2. Position the side section on the light frame with the square pin -A- at the test gauge 9748. (Scheme 1167)
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 side section with tensioning clamps
Scheme 1186
Scheme 1187
2. Aligning side section joints and making the cuts
2.1. Use the oscillating body saw to cut the two sheetmetal panels in the area -A- of the overlap between the side section and lower side member. Do not damage internal components when doing this. Use test gauge 9748. (Scheme 1169)
Scheme 1188
3. Drilling hole for plug welding using inert gas
3.1. With the side section fitted, drill a hole (diameter = 7 mm) in area -A- for plug welding using inert gas (2 panel strengths). Always maintain original spacing. (Scheme 1170)
Scheme 1189
4. Drilling holes for plug welding using inert gas
4.1. Drill holes (diameter = 7 mm) in area -A- for plug welding using inert gas (2 panel strengths). Maintain spacing as on roof frame between the bores. (Scheme 1171)
Scheme 1190
5. Cleaning welding and sealing areas
5.1. Grind both sides of the connection flanges of the side section in the marked areas -A, B, C, D, E- until bare using a rotary brush. (Scheme 1172)
6. Coat spot-weld flange areas with zinc powder paint.
6.1. Coat all spot-weld flange areas with zinc powder paint.
Scheme 1191
7. Preparing bonded flanges
7.1. Prepare bonded flanges in the marked areas -A-. (Scheme 1173)
See: Working with body structural adhesive Refer to 50 IN Processing structural body adhesive - as of MY 2005 (All Models) ..
Scheme 1192
8. Priming bonded flanges
8.1. Prime bonded flanges on the body in the marked areas -A-. (Scheme 1174)
See Working with primer Refer to 50 IN Processing structural body adhesive - as of MY 2005 (All Models) .
| 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.