Porshe 911 (997). Manual - part 354

Preparing connection areas of body for installing the rear cross member

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.

Preparing connection areas of body for installing the rear cross member

2. 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.

Preparing connection areas of body for installing reinforcement plate for rear
cross member

Preparing connection areas of body for installing reinforcement plate for rear cross member

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. Coating spot-weld flange areas with zinc powder paint

Diagnostic system: reading out fault memory and activating systems

Preparing connection areas of body for installing the rear cross member

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

paint.

Fitting rear cross member (side impact reinforcement) 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 rear cross member and preparing for installation

Cleaning the welding areas

1. Cleaning the welding

areas

1.1. Grind both sides of the connecting flanges of the rear cross member in the marked areas -A, B, C- until

bare using a rotary brush.

Diagnostic system: reading out fault memory and activating systems

Preparing connection areas of body for installing reinforcement plate for rearcross member

1574

Fitting reinforcement plate for rear cross member and preparing for
installation

Cleaning the welding areas

1. Cleaning the welding

areas

1.1. Grind both sides of the connecting flanges of the reinforcement plate for the rear cross member

in the marked areas -A, B, C- 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 rear cross member (side impact reinforcement)

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

Diagnostic system: reading out fault memory and activating systems

Fitting reinforcement plate for rear cross member and preparing for installation

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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 reinforcement plate for rear cross member

1. Fitting reinforcement plate for rear cross member to the body

1.1. Position the reinforcement plate for the rear cross member on the body and fix in place with tensioning

clamps.

Welding in reinforcement plate for rear cross member

2. Welding in reinforcement plate for rear cross member

2.1. Resistance spot-weld the reinforcement plate for the rear cross member in areas -A- and -B- .

Welding in reinforcement plate for rear cross member

3. Welding in reinforcement plate for rear cross member

3.1. Resistance spot-weld the reinforcement plate for the rear cross member in area -A- .

Diagnostic system: reading out fault memory and activating systems

Danger of injury when welding

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