Porshe 911 (997). Manual - part 384

 

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Porshe 911 (997). Manual - part 384

 

 

Preliminary work for body repairs

Note

If it can be ensured there has been no deformation of the vehicle structure, the following repair can
be carried out without the need of a straightening bench. In this case, the vehicle must not be raised
when welding the component; it must stand on its wheels on an even surface.

• 

1. Removing add-on parts in the repair area

1.1. Remove add-on parts in the repair area according to the extent of damage to the

vehicle.

2. Equipping straightening bench with straightening attachments

2.1. Equip straightening bench with the straightening attachments according to the plans included with

the straightening attachments.

3. Placing vehicle on the straightening bench

3.1. Position vehicle on the straightening bench, align according to the reference holes and bolt firmly

to the attachment set.

4. Covering add-on parts adjacent to the vehicle repair area

4.1. Cover all add-on parts remaining on the vehicle and the neighbouring areas with fire-proof, protective

covers.

5. Reshaping connection area of the sheetmetal parts to be replaced

6. Exposing welding areas

6.1. Remove undersealing, paint, etc. from the welding areas of the body with a hot-air gun or rotary brush.

Preliminary work for body repairs with alignment bench

1. Removing accessories in the repair area

1.1. Remove accessories in the repair area according to the extent of damage to the vehicle.

2. Equipping alignment bench with straightening kit

2.1. Equip alignment bench with the basic straightening attachments according to the plans included

with the straightening attachments.

3. Placing vehicle on the alignment bench

3.1. Position vehicle on alignment bench, align according to the reference holes and bolt firmly to the

attachment set.

4. Covering accessories adjacent to the vehicle repair area

4.1. Cover all accessories remaining on the vehicle and the neighbouring areas with fire-proof, protective

Diagnostic system: reading out fault memory and activating systems

Tools and materials

1694

covers.

5. Reshaping connection area of the sheetmetal parts to be replaced

6. Exposing welding areas

6.1. Remove undersealing, paint, etc. from the welding areas of the body with a hot-air gun or rotary brush.

Removing side section

Removing side section

Installation Location:

Side section installation location

1

- Side section

Y

- Sealing

Diagnostic system: reading out fault memory and activating systems

Preliminary work for body repairs with alignment bench

1695

Marking the cut

1. Determine

cut.

1.1. Position the cut K on the lower side member so that the replacement body panel overlaps with the

lower side member by approx. 60 mm. Mark the cut.

1.2. Position the cut L on the B-pillar so that the replacement body panel overlaps with the B-pillar by

approx. 60 mm. Mark the cut.

1.3. Position the cut M on the C-pillar so that the replacement body panel overlaps with the C-pillar by

approx. 60 mm. Mark the cut.

Cutting the spotwelds

2. Mill off spotwelds.

2.1. Using a spotweld cutter, mill off spotwelds in areas A, B, C, D.

Mill off spotwelds in areas E, F, G, H, I using a spotweld cutter. Use a parting grinder to cut open the
gas-shielded arc weld in area I.

Cutting the spotwelds

Cut out a viewing window from the rear centre section reinforcement N = dimension 20 x 50 mm . Using a
spotweld cutter, mill off spotwelds in area J.

Diagnostic system: reading out fault memory and activating systems

Removing side section

1696

 

 

 

 

 

 

 

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