Porshe 911 (997). Manual - part 335

Preparing connection areas of body for installation of inner
front side member

Safety instructions for flying sparks during grinding and welding work

ATTENTION

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!

Preparing connection areas of body for installing inner front side member

Cleaning the welding areas

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.

2. Coat spot-weld flange areas with zinc powder paint.

2.1. Coat all spot-weld flange areas with zinc powder

paint.

Diagnostic system: reading out fault memory and activating systems

 Preparing connection areas of body for installation of inner front side member

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Fitting inner front side member and preparing for installation

Safety instructions for sharp-edged body and unit parts

ATTENTION

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!

Fitting inner front side member and preparing for installation

Drilling holes for plug welding using inert gas

1. Drill holes for plug welding using inert gas.

1.1. Drill holes (Ø = 7 mm) in the area for plug welding using inert

gas.

Cleaning the welding areas

2. Cleaning the welding

areas

Diagnostic system: reading out fault memory and activating systems

 Fitting inner front side member and preparing for installation

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2.1. Grind both sides of the connecting flanges of the inner side member and the reinforcement plate in the

marked areas -A, B, C, D- until bare using a rotary brush.

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

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

paint.

Installing inner front side member

Danger of injury when welding

DANGER

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.

Installing inner front side member

1. Fit outer front side member to the body.

1.1. Place the outer front side member on the body and secure to the straightening

Diagnostic system: reading out fault memory and activating systems

Fitting inner front side member and preparing for installation

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set.

Welding in inner front side member

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).

2. Weld in inner front side member.

2.1. Plug-weld the inner front side member in area -A- using inert

gas.

Welding in inner front side member

3. Weld in inner front side member.

3.1. Apply a full weld to the outer front side member in area -A- using inert gas.

Welding in reinforcement plate

4. Weld in the reinforcement plate.

4.1. Resistance spot-weld the reinforcement plate in areas -A,

C, D-

 .

Diagnostic system: reading out fault memory and activating systems

Installing inner front side member

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