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Porshe 911 (997). Manual - part 351

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 roof pillar (pipe) and preparing for installation

Cleaning the welding areas

1. Cleaning the welding

areas

1.1. Grind both sides of the connecting flanges of the roof pillar (pipe) in the marked areas -A, B, C, D- until

bare using a rotary brush.

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

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

paint.

Fitting roof frame reinforcement and preparing for installation

Diagnostic system: reading out fault memory and activating systems

Safety instructions for sharp-edged body and unit parts

1561

Cleaning the welding areas

1. Cleaning the welding

areas

1.1. Grind both sides of the connecting flange of the roof frame reinforcement in the marked areas

-A-

and -B- until bare using a rotary brush.

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

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

paint.

Installing roof frame reinforcement and roof pillar (pipe)

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.

Diagnostic system: reading out fault memory and activating systems

Fitting roof frame reinforcement and preparing for installation

1562

→ 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 roof frame reinforcement

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).

1. Fitting roof frame reinforcement to the body

1.1. Position roof frame reinforcement on the body and fix in place with tensioning

clamps.

Welding in roof frame reinforcement

2. Welding in roof frame reinforcement

2.1. Resistance spot-weld the roof frame reinforcement in areas -A- and -B- .

Welding in roof frame reinforcement

3. Weld in roof frame reinforcement.

3.1. Apply a full weld to the roof frame reinforcement in areas -A- and -B- using inert gas.

Diagnostic system: reading out fault memory and activating systems

Danger of injury when welding

1563