Porshe 911 (997). Manual - part 364

 

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Porshe 911 (997). Manual - part 364

 

 

Expanded sealant

This expanded sealant is destroyed when replacing the rear centre panel reinforcement and must be
replaced.

• 

Separating bonded joints and removing expanded sealant

2. Separating bonded joints and removing expanded sealant

2.1. Heat up bonded joints in the areas -A, B, C, D- between the rear centre panel reinforcement and rear

cross member using the Leister Elektron hot-air gun; see Gr. 3.5, Workshop Equipment Manual
00000

 and remove rear centre panel reinforcement.

Preparing connection areas of the body for installing rear
centre panel reinforcement

Safety instructions for flying sparks during grinding and welding work

ATTENTION

Danger of explosion and fire from flying sparks during grinding and welding work!

Diagnostic system: reading out fault memory and activating systems

 Preparing connection areas of the body for installing rear centre panel reinforcement

1613

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 installing rear centre panel
reinforcement

Preparing connection areas of the body for installing rear centre panel reinforcement

1. Clean undersealing, adhesive residue and paint off the body connecting flanges in the marked areas

-A-

 and -B- using a hot-air gun or rotary brush. Grind the connecting flanges until bare.

Preparing connection areas of the body for installing rear centre panel reinforcement

2. Clean undersealing, adhesive residue and paint off the body connecting flanges in the marked areas

-A, B, C, D-

 using a hot-air gun or rotary brush. Grind the connecting flanges until bare.

Note

Keep bonding areas clean and free of grease and do not coat with zinc powder paint.

• 

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

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

paint.

Diagnostic system: reading out fault memory and activating systems

Safety instructions for flying sparks during grinding and welding work

1614

Preparing rear centre panel reinforcement 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!

Preparing rear centre panel reinforcement for installation

Cleaning the welding areas

1. Cleaning the welding

areas

1.1. Grind both sides of the connecting flange of the rear centre panel reinforcement in the marked

areas -A- and -B- until bare using a rotary brush.

Note

Keep bonding areas clean and free of grease and do not coat with zinc powder paint.

• 

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

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

Diagnostic system: reading out fault memory and activating systems

Preparing connection areas of the body for installing rear centre panelreinforcement

1615

Installing rear centre panel 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
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 rear centre panel reinforcement

WARNING

Risk of damage if the processing time is not observed!

The quality of the joint will be affected if the adhesive processing time is not observed.

• 

→ The new part must be welded within 30 minutes in the area of the adhesive, otherwise the adhesion of the

adhesive will be affected.

Diagnostic system: reading out fault memory and activating systems

 Installing rear centre panel reinforcement

1616

 

 

 

 

 

 

 

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