Porshe 911 (997). Manual - part 389

Fitting side section to the body at the rear

1. Fitting side section to the body at the rear

1.1. Cut the replacement part so that there is approx. 60 mm overlap at the joints.

1.2. To complete the fit, install the doors and lid at the rear and set the gap dimensions between the door and

lid at the rear and the side section according to the respective adjustment values. → 501000  Diagram -
body gap dimensions

1.3. Secure the side section at the rear with tensioning clamps.

Cutting through side section joint

2. Cutting through side section joints

Cut through the side section at the marked separation point K using the oscillating body
saw.

Cleaning welding and sealing areas

3. Cleaning welding and sealing areas

3.1. Grind both sides of the connecting flanges of the side section in the marked areas A, B, C, D, F,

G, H, I, J, K, L

 until they are bare using a rotary brush.

Diagnostic system: reading out fault memory and activating systems

Fitting side section and preparing for installation

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Installing side section

Installing side section

WARNING

Welding in body components

Danger of injury and material damage

• 

→ Once the spare parts have been attached, repair spotwelds must be placed on the old spotwelds because

there is no current flow possible in areas with a hardened bonded layer. Welding procedures other than
resistance spot-welding are not permitted since the thermal effect would destroy the bonded joint over a
wide area. → 5000IN IN - Processing structural body adhesives - section on "Welding in body
components"

Fitting water drain hose

1. Fitting in water drain hose

Press water drain hose Q through the water drip pan R; observe specified marking. The groove of the
water drain hose must fit all the way around the hole in the water drip pan. Route water drain hose through
the grommet to the wheel housing and cut the hose so that approx. dimension Z = 35 mm projects
outwards.

2. Installing water drip pan

2.1. Apply a triangular bead of body sealant - dimension "X" = approx. 12 mm high - to the inside of

the side section O.

Diagnostic system: reading out fault memory and activating systems

 Installing side section

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Applying body sealant

Apply a triangular bead of body sealant - dimension "X" = approx. 12 mm high - to the wheel
housing in area P.

Installing water drip pan

Position water drip pan R on the inside of the side section and press on firmly. Route the water drain hose Q.
Apply a triangular bead of body sealant - dimension "X" = approx. 12 mm high - to the outside of the side
section S.

Fitting the seal

3. Installing

seal

3.1. Apply a triangular bead of body sealant Y -dimension "X" = approx. 12 mm high - to all sides of the

seal. Apply seal to the prepared holes on the inside of the side section, position the pins of the seal and
press into place.

4. Applying adhesive to the side section

WARNING

Risk of damage if the processing time is not observed!

Diagnostic system: reading out fault memory and activating systems

Installing side section

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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.

Applying adhesive to the side section

4.1. Apply a triangular bead of adhesive measuring - dimension "X" = approx. 8 mm - to the inside of the

side section, along the edge of the wheel arch and up to the start of the door sill.

Applying adhesive to the inside of the side section

5. Applying adhesive to the inside of the side section

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.

5.1. Apply a triangular bead of adhesive (Teromix-6700) - dimension "X" = approx. 10 mm high - to the

joint between the light housing and the inside of the side section. The light housing must lie flush with
the inside of the side section.

Diagnostic system: reading out fault memory and activating systems

Installing side section

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