Porsche training p50 intro to porsche collision repair

® AfterSales Training Introduction To Porsche Collision Repair P50 Porsche AfterSales Training Student Name: Training Center Location: Instructor Name: Date: _ © 2010 Porsche Cars North America, Inc All Rights Reserved Reproduction or translation in whole or in part is not permitted without written authorization from publisher AfterSales Training Publications Dr Ing h.c F Porsche AG is the owner of numerous trademarks, both registered and unregistered, including without limitation the Porsche Crest®, Porsche®, Boxster®, Carrera®, Cayenne®, Cayman®, Panamera®, Tiptronic®, VarioCam®, PCM®, 911®, 4S®, FOUR, UNCOMPROMISED.® and the model numbers and the distinctive shapes of the Porsche automobiles such as, the federally registered 911 and Boxster automobiles The third party trademarks contained herein are the properties of their respective owners Porsche Cars North America, Inc believes the specifications to be correct at the time of printing Specifications, performance standards, standard equipment, options, and other elements shown are subject to change without notice Some options may be unavailable when a car is built Some vehicles may be shown with non-U.S equipment Please ask your dealer for advice concerning the current availability of options and verify the optional equipment that you ordered Porsche recommends seat belt usage and observance of traffic laws at all times Printed in the USA Part Number - PNA P50 001 Edition - 1/10 Table of Contents Description Section Porsche Porsche History 1.2 Locations 1.6 Business Disciplines 1.8 Product Knowledge Models 2.2 Vehicle Numbering Systems 2.7 Parts Numbering System 2.18 Service Numbering System 2.20 Porsche Information Systems Porsche Partner Network (PPN) 3.2 PIWIS Information System 3.3 PET – Electronic Parts Catalog 3.9 Parts & Service Bulletin Numbering System 3.25 Mechanical and Chassis Systems Engines – Sports Cars 4.2 Engines – Cayenne 4.4 Cooling Systems 4.6 Exhaust Systems 4.8 Direct Fuel Injection (DFI) 4.10 Porsche Doppelkupplung (PDK) 4.11 Porsche Traction Management (PTM) 4.13 Chassis Design 4.14 Brakes Systems 4.20 Porsche Active Suspension Management (PASM) 4.23 Tires & Wheels 4.25 Body Construction Boxster/Cayman (987) 5.2 911 (997) 5.4 Panamera (970) 5.5 Cayenne (9PA) 5.6 Carrera GT (980) 5.7 Carrera GT Carbon Fiber Components 5.8 Collision Repair Guidelines Safety Guidelines 6.2 General Guidelines 6.3 Joining Processes 6.6 Introduction To Porsche Collision Repair Introduction To Porsche Collision Repair Porsche Subject Page Porsche Heritage and History Historical Timeline The Porsche Crest Dr Wendelin Wiedeking – Kaizen Company Locations Porsche In North America Porsche Business Disciplines Introduction To Porsche Collision Repair Page 1.1 Porsche Porsche History and Heritage Ferdinand Porsche (1875-1951) Ferdinand Porsche’s creations for Lohner, Austro-Daimler, Daimler-Benz and Steyr had a fundamental effect on the development of Porsche Although the first Porsche was not made until 1948, the name of Porsche was already well known worldwide thanks to his revolutionary designs of engines and vehicles People generally talk about “Porsche designs” even though they were created while he was employed at other companies Ferry Porsche (1909-1998) Ferry Porsche once said, “At the beginning I looked around but couldn’t find the car of my dreams So I decided to build it myself.” A few interesting facts: • Porsche is currently the most profitable carmaker in the world • Porsche is owned and controlled exclusively by the Porsche family Although shares of Porsche stock are available, only non voting stock can be purchased • Porsche began as an engineering company • Porsche Cars North America is currently the largest market for Porsche • There are approximately 214 US and Canadian dealerships • The largest US markets are currently southern California and south Florida • Two-thirds (about 70%) of all Porsches ever built are still in use **Facts above were current as of January 9, 2009.** Page 1.2 The father of Porsche as a car manufacturer left his mark on the history, development and attitude of the company After leaving school, Ferry Porsche completed a one-year practical course at Bosch in Stuttgart After this, he spent a year on theoretical, intensive private instruction on automotive technology and was one of his father’s first staff members at the design office in Stuttgart As Ferdinand’s son, Ferry’s responsibilities increased steadily In 1934, Porsche was contracted to build a Volkswagen (Porsche Type 60), and he coordinated the implementation of test drives The steadily growing demands on his father for the construction of the Volkswagen plant in Wolfsburg led to Ferry Porsche becoming the acting manager of the entire operation in Zuffenhausen Introduction To Porsche Collision Repair Porsche A Historical Timeline 1900 – The Lohner-Porsche Electric Car debuted at the World’s Fair in Paris 1928 – As Daimler Technical Director and Board member, among other things, Ferdinand Porsche developed the now legendary Mercedes SS and SSK supercharged sports cars 1931 – Ferdinand Porsche founded the Porsche Engineering Office in Stuttgart This laid the foundation for Porsche AG today 1933 – The Type 32 was designed, a predecessor of the Volkswagen 1949 – The Cisitalia racing car is presented at the Torino Motor Show It featured a 12-cylinder dual compressor boxer engine in midship arrangement, 1493 cc, 385 bhp at 10,600 rpm, a top speed 186 mph and four-wheel drive with individual drive activation of the front wheels 1951 – Porsche returns to Zuffenhausen, near Stuttgart This began a new chapter in Porsche history In rooms rented from the Reutter coachworks factory, production facilities are set up Porsche becomes an independent automobile factory 1951 – The Porsche 356 scores its first international success in motor racing, winning the 1100cc category in the 24 Hours of Le Mans 1956 – Commemorating the 25th anniversary of the Company, the 10,000th Porsche 356 leaves the production hall Porsche has already scored 400 victories in motor racing The 1.5 liter 550 Spyder, driven by Richard von Frankenberg, competed against cars with more horsepower 1938 – Under the direction of Ferdinand Porsche, the first assembly lines for Volkswagen were erected in Wolfsburg The finishing touches were put to the Type 60, which readied it for series production Unfortunately, the Second World War got in the way A jeep was created on the basis of the Type 60 It was not until 1946 that the Volkswagen went into series production 1963 – At the Frankfurt International Auto Show, Porsche presents the 911 with an air-cooled flat engine in the rear 1964 – 911 production begins 1969 – The 914-4 and 914-6 mid-engined sports cars are presented at the Frankfurt Auto Show 1947 – Under Ferdinand Porsche Jr., a Grand Prix racing car is created in Gmünd, Austria on behalf of Cisitalia 1970 – The Porsche 917, (4.5-liter 12-cylinder boxer engine) shown to the public for the first time in Geneva, wins virtually all races the world over, including the World Championship of Makes and the Endurance World Championship 1948 – Under the direction of Ferry Porsche, a sports car is built in Gmünd based on Volkswagen parts: the 356 On June 8, 1948 the first sports car (a roadster of light metal) bearing the name Porsche is born 1971 – Work begins at the Weissach Research and Development Center Introduction To Porsche Collision Repair Page 1.3 Porsche 1972 – Under the guidance of Ferry Porsche as Chairman of the Supervisory Board, Porsche goes public 1974 – With the 911 Turbo a new era begins: exhaust turbocharged autos 1975 – Porsche introduces the 924, the first Transaxle sports car with the engine at the front and transmission and drive wheels at the rear 1977 – Production of the "big Porsche", the 928, starts in Stuttgart with a V8 light-alloy engine, Transaxle configuration and Weissach axle 1997 – The new Porsche 911 is presented with a watercooled six-cylinder boxer engine 2002 – The Cayenne SUV is introduced 1982 – The Porsche 956, the most successful racing/ sports car of all times, begins its victorious career 1985 – The 959 is launched, and is a spearhead in new technology A limited number are built In 1986, it is the first sports car to win the Paris-Dakar Rally 2006 – The Cayman is introduced 0_14_04 2008 – The second generation Cayenne is introduced 1988 – The new 911 Carrera is launched 2008 – The Porsche Doppelkupplung (PDK) seven speed dual-clutch transmission makes it's debut on the 2009 Porsche 911 Generation II models Dramatic improvements in vehicle acceleration and fuel efficiency are realized with this optional new transmission 1989 – The Tiptronic four-speed automatic transmission is introduced It is featured for the first time in the new 911 Carrera 2009 – The Porsche Doppelkupplung (PDK) seven speed dual-clutch transmission makes it's Boxster and Cayman debut 1993 – The first Boxster concept car is presented at the Detroit Auto Show The new 911 Carrera is launched at the Frankfurt Auto Show 2009 – The first production four door Porsche sports car, Panamera, makes its global debut Only Grand Turismo to utilize a dual clutch transmission 1995 – The new 911 Turbo with its bi-turbo engine becomes the first production car in the world with on-board diagnosis II, friction-welded hollow-spoke wheels and the lowest emission rating of all production cars in the market 1996 – Production starts on the all-new Porsche Boxster mid-engined roadster after only 1/2 years of development (counting from the completion of the car's specifications) Weissach celebrates its 25th anniversary Page 1.4 Introduction To Porsche Collision Repair Porsche The Crest Dr Wendelin Wiedeking - Kaizen “If all you need is a badge, we can give you one too.” ® The quote above, allegedly stated in 1952 at New York City’s “21” restaurant, was Ferry Porsche’s response to a request by Max Hoffman As the first Porsche importer in America, Hoffman felt Porsche should have an emblem on their vehicles Ferry Porsche laid out a napkin on the table, picked up a pen and began to draw Crest Information The crest has three parts – the Porsche family name, and emblems of the state of Wurttemberg and the city of Stuttgart More specifically: • The red and black bars with antlers originate from the coat of arms of the state of Wurttemberg • The horse originates from Stuttgart’s coat of arms Kaizen Restructuring • Modern cost centers instead of centralization • Manufacturing areas (ex - body shop, paint shop or the assembly department) are managed as independent company sectors • Sector managers are responsible for planning, logistics and quality assurance Interesting Facts: • The name Stuttgart is derived from the city’s history of fine horse breeding Legend has it that in 950, Duke Ludolph of Swabia founded a horse breeding center and riding school on the spot of present day Stuttgart • The crest appeared for the first time in 1953 on the horn button In 1957 it appeared on the front hood of a 356 coupe Production Times • 911 production time reduced by as much as 50% • Warehouse inventory reduced by more than 40% • Production employee statistically builds cars per year (Previously 4.9) Notes: Introduction To Porsche Collision Repair Page 1.5 Porsche Company Locations Zuffenhausen Porsche has – although deeply rooted in Germany – always been an export-oriented company Subsidiaries, importers and official retailers today form a strong international network – the world-wide Porsche family In Germany, several offices are located in suburbs around the city of Stuttgart Zuffenhausen is Corporate Headquarters It is also the production facilities for a limited number of Boxsters and all 911s Due to space restrictions, this facility makes a unique use of space by using a bridge over the street to move cars from building to building Engines and custom upholstery are created here Ludwigsburg Leipzig Sales, Marketing and AfterSales are located in Ludwigsburg A workforce of around 700 ensures the distribution of Porsche vehicles and spare parts to the dealer network and optimum services for Porsche customers around the globe Page 1.6 Leipzig is the home to Cayenne final assembly It was previously the home of Carrera GT production This location is also home to the Customer Center, which is known as “The Diamond.” On each of the five levels of the building, visitors are able to rediscover the multi-faceted character of the Porsche brand For those customers who participate in the European Delivery program, the Customer Center offers the most intimate encounter with the world of Porsche Introduction To Porsche Collision Repair Body Construction 911 (997) Sheet steel Tailored blanks High-strength steel Ultra-high-strength steel Aluminum Information! For the 911 Carrera (997) models the front hood is aluminum, on the 911 Turbo/GT2 (997) the front hood and doors are aluminum As of MY 2010 911 GT3 (997) also had aluminum doors Body Structure The purpose of redesigning the body structure of the new 911 Carrera/S (997) was to increase torsional and flexural rigidity in comparison with the previous 911 Carrera (996) and also to further improve crash safety in a frontal or offset crash (frontal crash with head-on collision on one side of the vehicle) The designers also managed to enlarge the passenger compartment without changing the exterior dimensions These improvements were achieved with four main changes: • Use of the spot welding/bonding method • Redesigning of the joint areas (A-pillar, roof frame connection) • Use of a new bulkhead cross member made of boron steel • Optimization of the upper load path for transmission of forces in frontal and side impacts The Porsche body structure is still executed as a lightweight design with high-strength and maximum strength steels This concept ensures excellent passive safety Page 5.4 The spot welding/bonding method used to join the side sections and the floor assembly has further increased the torsional and flexural rigidity of the body structure (torsional values increased by 8% while flexural rigidity rose by 40%) The redesigned joint areas (A-pillar joins, connection for the roof frame tube) have also contributed to these excellent results The bulkhead cross member in the front of the vehicle has been completely re-engineered and is now made of boron steel This has allowed the cross section to be matched to the package conditions and available footwell space and at the same time the rigidity increased The increased rigidity of the cross member and the improved anchorage have significantly reduced footwell penetration in the event of a crash The reduction in the cross section has also allowed the anchorage for the pedals and the pedals themselves to be moved forwards by 10 mm, thereby providing taller drivers with more legroom The seat anchorage has been lowered by 10 mm as part of the redesign of the body This results in a lower seat position, which lowers the center of gravity of the vehicle and provides more headroom for taller passengers Introduction To Porsche Collision Repair Body Construction Panamera (970) Magnesium Aluminum Mild steel High-strength low-alloy steel Multiphase steel Boron steel Body Structure The Panamera body shell is a hybrid structure, which is made up of several grades of advanced high-strength steels, stainless steel, aluminum and magnesium Advantages: • Low vehicle weight - Vehicle mass: approx 3858 lbs (1750 kg) - Bodyshell mass: approx 772 lbs (350 kg) • Low fuel consumption • Optimum weight distribution • Excellent occupant protection This fully galvanized body makes for an extremely robust passenger cell and provides excellent impact protection for the occupants A longitudinal and cross member structure at the front, patented by Porsche, absorbs deformation energy through two load paths that lie directly above one another This structure then distributes the forces, minimizing deformation of the passenger compartment As a second load path beside the longitudinal member structure, the aluminum subframe of the front axle increases passive safety by means of a defined deformation In the event of minor collisions, impact elements mounted to the front structure protect the bodyshell These are easy to replace which helps keep repair costs reasonable In the case of a more severe collision, a rigid bulkhead cross member prevents deformation of the footwell area and improves protection for occupants’ lower extremities The reinforced doors also help to stiffen the overall structure In the event of a frontal crash, the collision energy is transferred via an upper load path around the passenger cell, through the doors and to the rear of the vehicle Manufacturing the front hood, fenders, doors and rear lid in aluminum also helped to reduce weight and consequently fuel consumption Introduction To Porsche Collision Repair Page 5.5 Body Construction Cayenne (9PA) High-strength steel High-strength steel Sheet steel Aluminum Tailored Blanks Body Structure – Cayenne (9PA) Through optimized design and use of the most modern materials, the Cayenne achieves enviable static and dynamic body stiffness This is due to the particular competence of Porsche in the area of lightweight steel construction The extraordinary body stiffness provides the ideal basis for precise suspension tuning since body twist and vibration caused by the road surface irregularities are minimized by the stiff body structure Structural and Material Concepts A side and cross member structure intelligently distributes forces arising from a crash Three tiers absorb deformation energy, distributing the forces to the rigid floor side member, body sill, tunnel and doorframe areas, thus reducing passenger compartment deformation The front chassis subframe made of high-strength hydroformed steel tubes forms the bottom load-absorbing tier The center load absorbing tier consists of the joined front side member and the front bulkhead cross member Page 5.6 The top load-absorbing tier is made of the frame side member The result is a tough passenger compartment offering a high level of rider protection The high-impact zones with limited allowable deformation in a crash, such as the doors and doorsills, are reinforced with highstrength steel The parts are made in a press quenching process The sheet metal is hotstamped and then cooled according to specification The treated material then has superior shape and strength characteristics An innovation is the use of multi-phase steels in the body These steels are used both when high strength is required and when complex drawn parts must be used Examples include the rear area of the front cross member, the cross member in the front wall, the seat rail and heel cross members, the door sill inner section and tunnel crash reinforcement Introduction To Porsche Collision Repair Body Construction Cayenne (92A) Body Structure – New For MY 2011 Cayenne (92A) Further developments in steel processing techniques have allowed the use of extremely thin-walled steels, which have very high rigidity values in order to comply with all relevant safety regulations The weight enhancements are not restricted to the crash-relevant structures of the bodyshell The use of aluminum for the hood and tailgate and new structures in the door also contribute to a significant reduction in the body weight The use of high-strength materials and hot-formed steels also makes a decisive contribution to reducing the overall vehicle weight Lightweight construction measures on the body contributed to reducing the weight of the vehicle by 245 lbs (111 kg) compared with previous models The doors, hood and tailgate account for a reduction of 86 lbs (39 kg) alone In spite of the increased level of safety, it was possible to improve the driving dynamics as well as the fuel consumption values The design of the vehicle body is crucial for a high degree of passive safety Modern metal processing techniques were used in the design of individual body elements on the new Cayenne models The forces generated when an accident occurs are dissipated in a defined way throughout the longitudinal and cross member structures in the front and rear of the car The multi-phase steels that are used ensure a high degree of strength, specific deformation properties and optimal energy absorption Reinforcements made from high-strength, hot-formed steel also protect occupants in the event of a side impact They surround the passenger cell like a cage and provide extreme dimensional stability that makes a decisive contribution to ensuring the preservation of the interior and protection of the occupants Hot-formed steel that has the required dimensional stability and deformation proper-ties is used in the area around the B-pillar, for example This new material made it possible to implement both requirements in a single component The efficient use of heat-formed steel in the roof structure also considerably reduces the weight compared to the previous model while simultaneously improving safety All elements of the vehicle body are designed and joined in such a way that the forces from an impact are initially dampened and then absorbed in a defined manner, protecting the occupants Introduction To Porsche Collision Repair Page 5.7 Body Construction Carrera GT (980) Aluminum Magnesium Stainless steel Body Structure The body of the Carrera GT employs the highly innovative and expensive technique of body construction using carbon fiber reinforced composite (CFRP) This type of body with a monocoque as the core of the vehicle and connection for attachment of important components originates from racing car construction A further innovation is the equipment support beam bolted directly to the monocoque, which also is made entirely of CFRP, and carries the entire drive train (engine, transmission and rear axle) Notes: Page 5.8 Introduction To Porsche Collision Repair Collision Repair Guidelines Subject Page Safety Guidelines General Guidelines Joining Processes Introduction To Porsche Collision Repair Page 6.1 Collision Repair Guidelines Safety Guidelines Important! The following is not a complete list of safety guidelines; always refer to the workshop manual contained within the Porsche Integrated Workshop Information System (PIWIS) for the most up to date and complete work instructions and safety guidelines Additionally, always use Personal Protective Equipment relevant to the job being performed Airbag System • The ground strap of the battery must be disconnected during work on the airbag system and when the body is being repaired on a dedicated bench! • After the battery is disconnected, assembly work or work on the vehicle with a hammer or similar tools must not be started until after a waiting period of minute! Welding • • • • • When performing welding work, always disconnect both battery terminals Remove control units that are in the immediate vicinity of welding work Ensure that there are no electrically insulated parts between the work clamp and the welding point Connect the work clamp of MIG welding equipment as near as possible to the welding point on the part to be welded Do not touch electronic control units or electric cables with the work clamp or the welding electrode Air Conditioning System Components • In the case of extreme heating of filled air-conditioning systems, a very strong overpressure may be caused in the system which could lead to an explosion • No welding, brazing or hot-air heating may be performed on parts of the filled air-conditioning system! • Make sure that parts of the air-conditioning system not heat up during welding or brazing work on the vehicle! • While drying after painting work, the temperature burden on the vehicle must not exceed two hours at a maximum temperature of 176° F (80° C)! Doors • There is danger of damage and or malfunctions in the alarm system if the door lock is installed incorrectly! • The door lock should be installed only when the actuating lever is in basic position! • The locking element at the bottom part of the plug connection must be released before the plug connection is disconnected! • There is a danger of injury if the door window traps fingers or hands if the comfort function is triggered while carrying out work inside the door! Notes: Page 6.2 Introduction To Porsche Collision Repair Collision Repair Guidelines General Guidelines Before initiating repairs to any Porsche vehicle, the technician should consult the Workshop Manual in PIWIS and follow the work instructions strictly For the purposes of this training course, below are a selection of the procedures and techniques found in the workshop manual across all Porsche models Always refer to the Workshop Manual contained within PIWIS for the most up to date and complete work instructions Battery Trickle Charge To prevent the vehicle battery from discharging while at the workshop, a battery charging unit with a rated current of at least 40 A must be connected when the vehicle is brought into the workshop Possible Damage When Raising Vehicles • Lift the vehicle only at the approved take-up points! • Raising the vehicle in the sill area will lead to the deformation of body parts and to leakage in the underbody area! Deformation Element • Deformation elements cannot be repaired • The deformation elements must be replaced in the event of visible damage or pressure marks Deformation Element Corrosion Protection Measures • • • • • • Always apply weld thru primer to both sides of the welding flange when resistance spot welding Prime repair areas from outside, prime on both sides in the accessible areas Seal all sheet metal overlaps, sheet metal edges, butt joints, weld seams, etc with body sealant When replacing structurally bonded body parts, proceed according to the information in the respective repair instructions Only apply body sealant to primed sheet metal parts, never apply to bright metal Apply top coat paint to the inside of the outer sheet metal shell before welding; see document “Paint build-up” found in the Paint Manual • Repair or create standard under sealing by applying long-life under sealing material • Preserve cavities in the repair area with cavity preservative following refinishing operations • Check that the standard water drains (plugs) function or clean them out after the cavity preservation material has dried Notes: Introduction To Porsche Collision Repair Page 6.3 Collision Repair Guidelines General Guidelines (cont’d) Requirement for Maintaining the Corrosion Limited Warranty (USA) All body repair work must be carried out correctly and according to the specific Porsche instructions for sheet metal, paint and corrosion protection/preservation work Electronic Control Modules The replacement of electronic control modules after an accident is necessary in any of the following conditions: • • • • The housing is noticeably deformed or damaged The supporting surface or bracket is deformed (the unit shows no external damage) The plug connection is damaged and or shows evidence of being corroded by moisture Functional checks or self-diagnosis of the unit reveals the fault “Control module faulty” If electronic components, e.g ABS control module, have been removed for repair work and are then reused, they must undergo a functional check after reinstallation in accordance with existing specifications Cayenne Front Module Service Position To make removing and installing the front cooling module easier, the module can be put into the “service position” This is done by replacing the screws attaching the module to the longitudinal members with longer screws (M10 x 105mm) that allow the module to be moved away from the engine Carrier Service Bolt Notes: Page 6.4 Introduction To Porsche Collision Repair Collision Repair Guidelines General Guidelines (cont’d) Possible Separation Points on Inner Side Member (9x7) • The possible separation points on the inner front side member are 30mm in front of the tailored blanks (laser weld) against the direction of travel • Ensure that the outer front side member separation point is offset by a minimum of 50mm in front of the inner tailored blank, against or in the direction of travel Possible Separation Points Bake Hardened Steel • Only “Genuine Porsche parts” or sections of “Genuine Porsche parts” may be used for repair work! • The spare parts are heat-treated; “Genuine Porsche Parts” attain their final strength only after the production stage of cathodic immersion painting and drying Information on Ultra High Strength Steel • • • • • Straightening and reshaping Ultra High Strength Steel body parts is not permitted Ultra High Strength Steel body parts must only be replaced as a complete unit Use special drill bits for drilling Ultra High Strength Steel Resistance welding can only be carried out using the equipment currently approved by Porsche AG MIG plug welding Ultra High Strength Steel does not produce sufficiently strong joints; if plug welds are used, additional welding seams must be applied • For butt, overlap and reinforcement welding, full welds must be performed in 30mm segments • Resistance welds can also be replaced by blind rivets and adhesive Notes: Introduction To Porsche Collision Repair Page 6.5 Collision Repair Guidelines Joining Processes MIG Welding • • • • MIG plug welds are made through a 7mm diameter hole Full welds are used for section joints Interrupted full welds are used for very long section joints (e.g 987 trunk floor) MIG welding is not used in conjunction with adhesive Resistance Spot Welding • Use Porsche Approved equipment only • Resistance welding can be used in conjunction with structural adhesive • When installing welded panels without adhesive or with new adhesive, place resistance welds away from factory resistance welds • When removing only the outer panel of a three layer flange where the inner two layers are bonded, care must be taken to drill out the existing resistance welds without damaging the remaining layers and adhesive bond • When installing the outer panel of a three layer flange where the inner two layers are bonded, place the spot welds directly over the existing factory resistance welds General Information About Structural Adhesives The use of structural adhesive in body shell construction contributes stiffness, durability and crash strength During the body shell production a high strength, single component epoxy resin adhesive that cures in the paint drying oven is used It is not possible to use this same material for repairs due to the extremely high curing temperature necessary Rather, a temperature independent, two component epoxy resin adhesive is provided Repairs using weld bonding require good planning and preparation All fit up, alignment and surface preparation must be completed before application of the adhesive The two part adhesive has a limited working time If the joining processes (e.g welding, riveting) are not completed within the working time, serious problems can arise due to the adhesive being partially cured, potentially causing the entire job to be redone Notes: Page 6.6 Introduction To Porsche Collision Repair Example of Adhesives Collision Repair Guidelines Joining Processes (cont’d) Symbols Used in PIWIS = Structural adhesive = MIG plug weld = Continuous weld (Also called stitch or seam weld) = Resistance spot weld Adhesive Part Number Reference • TEROMIX 6700: Part Number, 999 915 650 40, Applicator Part Number, 000 043 300 48 • TEROKAL 5045: Part Number, 000 043 300 95 Applicator Part Number, VAS5237 • BETAMATE 2096: Set Part Number, 000 043 206 29 - Adhesive Part Number, 000 043 206 30 - Mixing Part Number, 000 043 206 32 - Applicator Part Number, 000 043 206 31 - Sealing compound Part Number, 000 043 206 82 • Windshield Adhesive Set: All models except Panamera (970) – Part Number, 000 043 300 94, applicator gun Part Number, VAS5237 Panamera (970) – Part Number, 000 043 301 14 Notes: Introduction To Porsche Collision Repair Page 6.7 Collision Repair Guidelines Notes: Page 6.8 Introduction To Porsche Collision Repair Part Number - PNA P50 001 ... 6.6 Introduction To Porsche Collision Repair Introduction To Porsche Collision Repair Porsche Subject Page Porsche Heritage and History Historical... Wolfsburg led to Ferry Porsche becoming the acting manager of the entire operation in Zuffenhausen Introduction To Porsche Collision Repair Porsche A Historical Timeline 1900 – The Lohner -Porsche Electric... those customers who participate in the European Delivery program, the Customer Center offers the most intimate encounter with the world of Porsche Introduction To Porsche Collision Repair Porsche