Porshe 911 (997). Manual - part 397

Preparing outer rear wheel housing for installation

Cleaning the welding areas

1. Cleaning the welding

areas

1.1. Grind both sides of the connecting flanges of the outer rear wheel housing in the marked area -A- until

bare using a rotary brush.

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

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

Installing rear wheel housing

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.

Diagnostic system: reading out fault memory and activating systems

Preparing outer rear wheel housing for installation

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→ 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 inner rear wheel housing

1. Fitting inner rear wheel housing to the body

1.1. Place the inner rear wheel housing against the body and secure to the straightening

set.

1.2. Fix the inner rear wheel housing in place with tensioning clamps.

Welding in inner rear wheel housing

2. Welding in inner rear wheel housing

2.1. Resistance spot-weld the inner rear wheel housing in areas -A, B, C, D, E- .

Welding in inner rear wheel housing

3. Welding in inner rear wheel housing

3.1. Plug-weld the inner rear wheel housing in areas -A, B, C- using inert

gas.

Diagnostic system: reading out fault memory and activating systems

Danger of injury when welding

1746

Welding in inner rear wheel housing

4. Welding in inner rear wheel housing

4.1. Plug-weld the inner rear wheel housing in areas -A, B, C- using inert

gas.

Welding in inner rear wheel housing

5. Welding in inner rear wheel housing

5.1. Apply a full weld to the inner rear wheel housing in areas -A- and -B- using inert gas.

Welding in inner rear wheel housing

6. Welding in inner rear wheel housing

6.1. Apply a full weld to the inner rear wheel housing in area -A- using inert

gas.

7. Install side reinforcement (frame for light). → 531755 23 Side reinforcement - section on

"Installing"

8. Installing inner side section

8.1. Only on the Coupé

8.1.1. Install inner side section (lower part). → 536155 21 Replacing inner side section - section on

"Removing"

8.2. Only on the Cabriolet

Diagnostic system: reading out fault memory and activating systems

Installing inner rear wheel housing

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8.2.1. Install inner side section. → 536155 23 Replacing inner side section - section on

"Installing"

Installing outer rear wheel housing

1. Fitting outer rear wheel housing to the body

1.1. Place the outer rear wheel housing against the body and secure to the straightening

set.

1.2. Fix the outer rear wheel housing in place with tensioning clamps.

Welding in outer rear wheel housing

2. Welding in outer rear wheel housing

2.1. Resistance spot-weld outer rear wheel housing in area -A- .

3. Installing side section

3.1. Only on the Coupé

3.1.1. Install side section. → 535555 Replacing side section - section on "Installing" [997110 997111 997120

997121 997410 997411 997430 997431]→ 535555 Replacing side section - section on
"Installing" [997310 997311 997320 997321]→ 535555 23 Replacing side section - section on
"Installing" [997610 997611 997620 997621]

3.2. Only on the Cabriolet

3.2.1. Install side section. → 535555 Replacing side section - section on "Installing" [997110 997111 997120

997121 997410 997411 997430 997431]→ 535555 Replacing side section - section on
"Installing" [997310 997311 997320 997321]→ 535555 23 Replacing side section - section on
"Installing" [997610 997611 997620 997621]

Subsequent work

Subsequent work for body repairs

1. Removing vehicle from straightening bench

2. Cleaning spot-welded joints and sheetmetal flanges with a wire brush

Diagnostic system: reading out fault memory and activating systems

Installing outer rear wheel housing

1748