Porshe 911 (997). Manual - part 392

2.1. Use a spotweld cutter to mill off spotwelds in areas A, B, C.

In area N (Inset), the underlying reinforcement weld to the side section must be milled off (4 spot-weld
connections).

Milling off spotwelds

3. Milling off spotwelds

Mill off spotwelds in areas E, F, G, J using a spotweld cutter. Separate inert-gas welded seam in
area I using a parting grinder.

Milling off spotwelds

4. Milling off spotwelds

Mill off spot welds in area H using a spotweld
cutter.

Cutting the side section

5. Cutting the side section

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

Diagnostic system: reading out fault memory and activating systems

Removing side section

1725

Removing expanded sealant

6. Removing expanded sealant

6.1. The side section is factory-sealed with expanded sealant Y from the light housing to the rear

centre panel joint. The expanded sealant will be destroyed when you change the side section and
must be replaced.

Preparing connection areas of the body for installing the side
section

Safety instructions for flying sparks during grinding and welding work

ATTENTION

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

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 the side section

Diagnostic system: reading out fault memory and activating systems

 Preparing connection areas of the body for installing the side section

1726

Preparing connection areas of the body for installing the side members

1. Clean the body connection flanges of undersealing, adhesive residue and paint in the marked areas

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

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 side section and preparing for installation

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

Diagnostic system: reading out fault memory and activating systems

Preparing connection areas of the body for installing the side section

1727

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.

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

Diagnostic system: reading out fault memory and activating systems

Fitting side section and preparing for installation

1728