Porshe 911 (997). Manual - part 345

Cutting out viewing window with the body saw

2. Cut out the viewing window with the body saw

2.1. Cut the marked area A out of the inner lower side member using the body saw.

Preparing connection areas of the body for installation of the
threaded bushing

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 the body for installation of the threaded
bushing

Diagnostic system: reading out fault memory and activating systems

Removing thread for belt fastening

1537

Preparing connection areas of the body for installation of the threaded bushing

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.

Fitting in threaded bushing 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 in threaded bushing and preparing for installation

Note

The replacement threaded bushing for belt fastening is cut out of the replacement inner lower side member as
a viewing window measuring 60 x 35 mm.

Diagnostic system: reading out fault memory and activating systems

Preparing connection areas of the body for installation of the threadedbushing

1538

Marking the cut

1. Mark the cut.

1.1. Mark the cut for removal of the threaded bushing on the inner lower side member. Cut out a viewing

window measuring 60 x 35 mm in the lower side member.

Cutting out viewing window with the body saw

2. Cut out viewing window with the body saw

2.1. Cut the marked area A out of the inner lower side member using the body saw.

Removing primer on welding areas of the replacement part using a rotary brush

3. Remove the factory-applied primer in area A of the replacement parts using the rotary brush.

Diagnostic system: reading out fault memory and activating systems

Fitting in threaded bushing and preparing for installation

1539

Installing thread for belt fastening

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.

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!

Diagnostic system: reading out fault memory and activating systems

 Installing thread for belt fastening

1540