Porshe 911 (997). Manual - part 466

 

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Porshe 911 (997). Manual - part 466

 

 

4. Separating inert-gas welded seams

4.1. Separate inert-gas welded seams in areas -A- and -B- using a parting

grinder.

Preparing connection areas of the body for installing the door
hinge (on body side)

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 door hinge (on body
side)

Preparing connecting flanges

1. Clean undersealing, adhesive residue and paint off the body connecting flanges from inside in the

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

Diagnostic system: reading out fault memory and activating systems

 Preparing connection areas of the body for installing the door hinge (on body side)

2021

Preparing connecting flanges

2. 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 door hinge (on body side) 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 door hinge (on body side) for installation

Cleaning the welding areas

Diagnostic system: reading out fault memory and activating systems

Preparing connection areas of the body for installing the door hinge (on bodyside)

2022

1. Cleaning the welding

areas

1.1. Grind both sides of the connecting flanges of the door hinge in the marked areas -A, B, C, D- until bare

using a rotary brush.

Installing door hinge (on body side)

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 door hinge (on body side)

1. Fitting door hinge to the body

Diagnostic system: reading out fault memory and activating systems

Preparing door hinge (on body side) for installation

2023

Installing door hinge

1.1. Position door hinge on the body, align it and screw down

securely.

1.2. Install wing, door lock and striker pin before

fitting.

1.2.1. → 505520 23 Removing and installing front wing - section on

"Installing"

1.2.2. → 571719 Removing and installing door lock - section on "Installing"

1.2.3. → 572619 Removing and installing striker pin - section on "Installing"

Note

Two persons are needed to install the door hinges!

2. Fitting door to the

body

Adjusting the door hinge

2.1. Fit the door to the body and adjust gaps between the door, wing and outer side member according to the

adjustment values. → 501000 IN Diagram - body gap dimensions - section on "Information"

2.2. Fix the door in place.

Diagnostic system: reading out fault memory and activating systems

Installing door hinge (on body side)

2024

 

 

 

 

 

 

 

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