Porshe 911 (997). Manual - part 358

Cleaning the welding areas

2. Cleaning the welding

areas

2.1. Grind both sides of the connecting flanges of the windscreen frame in the marked areas -A, B, C, D-

until bare using a rotary brush.

Cleaning the welding areas

3. Cleaning the welding

areas

3.1. Grind both sides of the connecting flanges of the windscreen frame in the marked areas -A, B, C, D-

until bare using a rotary brush.

Diagnostic system: reading out fault memory and activating systems

Fitting in windscreen frame and preparing for installation

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Cleaning the welding areas

4. Cleaning the welding

areas

4.1. Grind both sides of the connecting flanges of the cowl panel reinforcement in the marked areas

-A-

 and -B- until bare using a rotary brush.

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

5.1. Coat all spot-weld flange areas with zinc powder

paint.

Installing windscreen frame

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.

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 Installing windscreen frame

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→ 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 windscreen frame

Note

Determine the position of the new part and secure with tensioning clamps.
When butt welding body sheet panels with a sheet thickness of > 1.5 mm, there must be a welding slit
width s = 1 x sheet thickness to guarantee the required welding quality (welding through).

1. Fitting windscreen frame to the body

1.1. Place the windscreen frame against the body and secure to the

straightening set.

1.2. Secure the windscreen frame with tensioning clamps.

Welding in windscreen frame at the left and right

2. Welding in windscreen frame at the left and

right

2.1. Resistance spot-weld the windscreen frame at the left and right in area -A- .

2.2. Apply a full weld to the windscreen frame at the left and right in area -B- using inert gas.

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Danger of injury when welding

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Welding in windscreen frame at the left and right

3. Welding in windscreen frame at the left and

right

3.1. Resistance spot-weld the windscreen frame at the left and right in area -A- .

Welding in windscreen frame at the left and right

4. Welding in windscreen frame at the left and

right

4.1. Resistance spot-weld the windscreen frame at the left and right in area -A- .

4.2. Resistance spot-weld the windscreen frame at the left and right in area -B- .

Welding in windscreen frame at the left and right

5. Welding in windscreen frame at the left and

right

5.1. Plug-weld the windscreen frame at the left and right in areas -A- and -B- using inert gas.

Diagnostic system: reading out fault memory and activating systems

Installing windscreen frame

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