Porsche training p51 panamera body and structural repair

® AfterSales Training Panamera Body & Structural Repair P51 Porsche AfterSales Training Student Name: Training Center Location: Instructor Name: Date: _ © 2011 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.SM and the model numbers and distinctive shapes of Porsche's automobiles such as, the federally registered 911 and Boxster automobiles The third party trademarks contained herein are the properties of their respective owners Specifications, performance standards, options, and other elements shown are subject to change without notice Some vehicles may be shown with non-U.S equipment Porsche recommends seat belt usage and observance of traffic laws at all times Printed in the USA Part Number - PNA P51 001 Edition - 7/11 Table of Contents Description Section Foreword ii Panamera Overview Porsche Information Systems Dedicated Bench Systems Panamera Body Technology General Information Spring Strut Mount Replacement Front Longitudinal Member Front Section Replacement Panamera Body & Structural Repair Page i Foreword The Panamera was created for those who believe that Porsche engineering isn't a luxury, but a necessity After all, there is no reason why the highest standards of performance should be sacrificed simply because you require some additional room for your passengers Featuring 4.8-liter V8 engines, either naturally aspirated or twin-turbocharged, producing 400 horsepower or 500 horsepower Both engines feature VarioCam Plus and Direct Fuel Injection (DFI) for efficient combustion, a distinct advantage in power and torque, and comparatively good fuel economy for this engine power class Another new feature helping to improve fuel economy is the Auto Start Stop function which can be activated/deactivated by the push of a button If, for example, you are stopped at a traffic light with your foot on the brake pedal, the system can automatically turn off the engine The engine will restart as soon as you release the brake pedal In all Panamera models, power is delivered through the standard 7-speed Porsche Doppelkupplung (PDK) Additionally, the Panamera 4S and Panamera Turbo feature Porsche Traction Management (PTM), an active all-wheel drive with an electronic and map controlled multiplate clutch for optimal traction and driving stability The Panamera S accelerates from 0-60 mph in 5.2 seconds, with a top track speed of 175 mph Thanks to PTM, the Panamera 4S accelerates from 0-60 mph in only 4.8 seconds, reaching up to 175 mph The Panamera Turbo, meanwhile, completes the sprint in just 4.0 seconds and achieves a top track speed of 188 mph With the introduction of the Panamera S and Turbo in model year 2010, Porsche successfully established itself as the leader in the sporty luxury saloon segment Porsche extended the series line with the model year 2011 Panamera V6, featuring a 300-hp V6 engine Page ii Panamera Body & Structural Repair Panamera Overview Subject Page Vehicle Identification Number (VIN) Information Vehicle Data Labels and Locations V8 and V6 Engines – General Information Exhaust Systems and Emission Control 11 Porsche Doppelkupplung (PDK) Transmission 12 Chassis – General Information 20 Brake Systems 25 Body – General Information 28 Powerlift Rear Hatch 30 Front View 32 Rear View 33 Window Glass 33 Sunroof 34 Rear Spoiler 36 Passive Safety 38 Interior – General Information 40 Steering Wheel 41 Seat System 42 Rear Spoiler Settings 50 Adaptive Cruise Control (ACC) 52 Panamera Body & Structural Repair Page 1.1 Panamera Overview Example Below: 2005 911 (997) Model Years 1981–2009: Used VIN positions 7, & 12 as Porsche model type designation digits USA model years in ( ) As of Model Year 2010: VIN position was changed to a “A”, leaving positions & 12 as Porsche model type designation digits 911 = 911 (1981-89) 924 = 924/S (1981-88) 928 = 928 (1981-95) 930 = 911 Turbo (1981-89) 931 = 924 Turbo (1981-82) 944 = 944 (1985-91) A87 = Boxster/Cayman (2010-on) A97 = 911 (997) (2010-on) A70 = Panamera (2010-on) APA = Cayenne (2010) A2A = Cayenne (2011-on) 951 = 944 Turbo (1986-90) 964 = 911 (964) (1989-94) 968 = 968 (1992-95) 980 = Carrera GT (2004-06) 986 = Boxster (1997-04) 987 = Boxster (2005-on) 987 = Cayman (2006-on) 993 = 911 (993) (1995-98) 996 = 911 (996) (1999-05) 997 = 911 (997) (2005-on) 9PA = Cayenne (2003-09) Make Porsche WP0 = Sports Cars Panamera WP1 = Cayenne * ** * Position uses alpha characters A, B, C, etc to indicate model types, such as; Coupe, Cabriolet, Targa, SUV (Cayenne), sedan (Panamera), etc This character can vary from year to year Position uses alpha characters A, B, C, etc to indicate engine types, such as; normally aspirated, turbo, Hybrid, etc This character can vary from year to year Page 1.2 L M N P R S T V W X Y A B C D E F = 1990 = 1991 = 1992 = 1993 = 1994 = 1995 = 1996 = 1997 = 1998 = 1999 = 2000 = 2001 = 2002 = 2003 = 2004 = 2005 = 2006 = 2007 = 2008 = 2009 = 2010 = 2011 = 2012 = 2013 = 2014 = 2015 N = Neckarsulm S = Stuttgart - Zuffenhausen U = Uusikaupunki, Finland - 987 Models L = Leipzig Footnotes: * Please check the specific VIN in the Model Information, PPK Group 17, D2 series for exact vehicle specific Model Type and Engine Type ** See PPK Bulletin Group 16 D12 for complete list Panamera Body & Structural Repair Panamera Overview Model Designations Used In Parts Catalogs and Workshop Manuals 911 911 (Various models 1981-89) 924 924 (Various models 1981-88) 928 928 (Various models 1981-95) 92A .Cayenne (E2) (2011) 930 911 Turbo (1981-1989) 931 924 Turbo (1981-82) 944 944 (Various models 1985-91) 951 944 Turbo (1986-90) 964 911 Carrera (Various models 1989-94) 968 968 (Various models 1992-1995) 970 .Panamera (2010-on) 980 .Carrera GT (2004-06) 986 Boxster (Various models 1997-04) 987 Boxster (1st Generation) (2005-08) 987 Boxster (2nd Generation) (2009-on) 987 Cayman (1st Generation) (2006-08) 987 Cayman (2nd Generation) (2009-on) 993 .911 (1995-98) 996 .911 (1999-05) 997 .911 (1st Generation) (2005-08, Turbo 2007-09) 997 .911 (2nd Generation) (2009-on) 9PA Cayenne (E1 - 1st Generation) (2003-06) 9PA Cayenne (E1 - 2nd Generation) (2008-10) Panamera Body & Structural Repair Page 1.3 Panamera Overview Model – Panamera (970) Vehicle Data Label Vehicle identification label is on the inside of the maintenance book This label contains the following information: Vehicle identification number (VIN) Vehicle code ● Engine and transmission code ● Paint Code/Interior Code ● Option codes ● ● Engine Number (4) The engine number is located on the bottom of the crankcase, left side (5-8 cylinder bank), by the oil pan sealing surface Note: Underside paneling needs to be removed Tire Pressure (2) Tire pressure label is on the left driver door sill area Vehicle Identification Number (1) In accordance with Federal Safety Regulations, the vehicle identification number of your car is located at the bottom left of the windshield frame and can be seen from the outside Vehicle Identification Number (5) The vehicle identification number is also under the front passenger seat Safety Compliance Sticker (3) Transmission Number Refer to Repair Manual for location Paint Data The paint data is included on the Vehicel Data Label Page 1.4 The safety compliance sticker is your assurance that your new Porsche complies with all applicable Federal Motor Vehicle Safety Standards which were in effect at the time the vehicle was manufactured This sticker also shows the month and year of production and the vehicle identification number of your car (perforations) as well as the Gross Vehicle Weight Rating and the Gross Axle Weight Rating Panamera Body & Structural Repair Vehicle Identification Number Tire Pressure Sticker Safety Compliance Sticker Engine Number Vehicle Indentification Number Panamera Overview General Information – V8 Engines V8 Naturally Aspirated Engine An enhanced generation of V8 engines is used for the new Panamera models: A 4.8-liter V8 naturally aspirated engine for the Panamera S and a 4.8-liter V8 bi-turbo engine for the Panamera Turbo The enhanced and optimized engines used in the Panamera are based on the Cayenne engines This made it possible to achieve the ambitious targets for fuel consumption and CO2 emissions despite the enhanced performance Development Objectives Reduction in weight using lightweight design measures, such as: • Timing case and valve covers made of magnesium (5.5 lbs./2.5 kg lighter) • Fully aluminum, lightweight camshaft controllers (3.7 lbs./1.7 kg lighter) • Aluminum bolts for magnesium parts and for connecting engine and transmission (2.2 lbs./1.0 kg lighter) • Lighter crankshaft and connecting rods designed specifically for naturally aspirated engines (5 lbs./2.3 kg lighter) • Magnesium oil guide housing specifically for the Panamera S Lower fuel consumption and lower emissions by installing various systems, such as: • Start/stop systems • Heat management using a map-controlled thermostat (with integrated flow suppression) • Direct fuel injection (DFI) • VarioCam Plus • Demand-controlled oil pump Engine type M48.20 for 2WD Engine type M48.40 for 4WD The 4.8-liter V8 naturally aspirated engine in the Panamera S and 4S has the following main features: • Newly designed, lighter crankshaft and lighter connecting rods • Oil guide housing made of magnesium (Panamera S) or aluminum (Panamera 4S) • Intake camshafts optimized for power output and torque curves • Intake system with variable intake manifold • Larger throttle valve for greater power Notes: High performance due to: • Larger throttle valve, 82 mm (Panamera S) • Pressure sensor for measuring mass air flow • Sport button as standard • Intake system with variable intake manifold Compact design with: • Front-axle differential flanged to the engine • Engine installed at a lower position • Very flat oil guide housing made of magnesium (S) or aluminum (Turbo, 4S) • Manifold and turbocharger produced as a single unit without an intermediate flange (Turbo only) • Integrated dry-sump lubrication Panamera Body & Structural Repair Page 1.5 Panamera Overview Engine Power/Torque Graph – Panamera S/4S V8 Turbo Engine Similar to the Cayenne engines, it has also been possible here to achieve a very flat torque curve for the Panamera engines To highlight the flat curve, the graph shows that the engine provides a torque of approx 215 Nm at only 1000 rpm A maximum torque of 400 Nm is achieved at a governed speed of 6700 rpm Engine type M48.70 Engine Power/Torque Graph – Panamera Turbo The 4.8-liter V8 bi-turbo engine in the Panamera is noted for its high power output and torque with low fuel consumption and has the following main features: • • • • Adapted intake system Positive crankcase ventilation Charge-air cooling Manifold and turbocharger produced as a single unit without an intermediate flange • Weight-optimized crankshaft • Optimized oil guide with aluminum oil guide housing Sport Chrono Turbo Package (Optional) The torque can be increased to 770 Nm in conjunction with the Sport Chrono Turbo Package The Overboost function is activated when the Sport or Sport Plus button is active and when fast pedal movements are detected and/or when kickdown is activated When this occurs, the boost pressure is increased by up to 10% for max 10 seconds between 3000 and 4000 rpm, i.e 770 Nm instead of 700 Nm Page 1.6 The maximum torque is the same as for the naturally aspirated engine at 1000 rpm because the turbocharger has not yet kicked in Shortly afterwards, the torque increases considerably due to turbocharging The maximum possible torque is 700 Nm at 2250 rpm and stays at this high level up to 4000 rpm A torque of more than 500 Nm is achieved even at a governed speed of 6700 rpm Panamera Body & Structural Repair Spring Strut Mount 19 Install countersunk rivets (Part Number: 000 043 207 59) in the indicated area (See Figure 11) Figure 11 20 Install rivets (Part Number: 000 043 207 58) in the indicated area (See Figure 12) 21 Remove excess adhesive Figure 12 Notes: Page 6.8 Panamera Body & Structural Repair Spring Strut Mount 22 Fit plenum panel section removed previously and weld in with a continous MIG weld (See Figure 13) 23 Clean connection areas and apply 2K primer 24 Apply body sealant to all flanges in the repair area Figure 13 Notes: Panamera Body & Structural Repair Page 6.9 Spring Strut Mount Notes: Page 6.10 Panamera Body & Structural Repair Front Longitudinal Member Subject Page Front Longitudinal Member Front Section Replacement Panamera Body & Structural Repair Page 7.1 Front Longitudinal Member Spring Strut Mount Replacement The following is a general outline of the steps involved in replacing the front longitudinal member front section This information should not be considered definitive, rather always refer to the Porsche Integrated Workshop Information System (PIWIS) for the most complete and up to date work instructions Remove attachment parts in the repair area Set up straightening bench and anchor vehicle to the bench Cut off damaged side member in accordance with the new part (See Figure 1) Figure Notes: Page 7.2 Panamera Body & Structural Repair Front Longitudinal Member If there are any punch rivets that would interfere with the fit of the replacement part, grind them until the interference has been removed (See Figure 2) Fit replacement part using the straightening bench Shorten the side member as required to ensure an exact fit Figure Measure and mark 15mm from the edge of the side member on both sides (See Figure 3) Figure Notes: Panamera Body & Structural Repair Page 7.3 Front Longitudinal Member Insert the new part into the longitudinal member and mark the center of the chambers If the intersection of the marks is on a punch rivet, slightly offset the mark to avoid the punch rivet (See Figures & 5) Figure Figure Page 7.4 Panamera Body & Structural Repair Front Longitudinal Member Fit replacement part using the straightening bench and using a 4.7mm drill bit, drill through all component layers (See Figures & 7) Figure Notes: Panamera Body & Structural Repair Page 7.5 Front Longitudinal Member Remove the replacement part and using an 8mm drill bit, enlarge the 4.7mm holes in the longitudinal member to 8mm 10 Deburr holes on all sides of both parts Figure Notes: Page 7.6 Panamera Body & Structural Repair Front Longitudinal Member 11 Prepare connection areas of all parts by sanding with silicon carbide (SIC) sandpaper with a grain of P100 to P150 (See Figures & 9) 12 Mix and apply SIP kit to connection areas on all parts Check for correct result; if necessary repeat preparation until correct result is achieved 13 Apply adhesive to the connection areas of all parts to a thickness of 0.5mm Figure Figure Notes: Panamera Body & Structural Repair Page 7.7 Front Longitudinal Member 14 Apply a bead of adhesive to the front edge of the replacement part to a thickness of 5mm (See Figure 10) Figure 10 Notes: Page 7.8 Panamera Body & Structural Repair Front Longitudinal Member 15 Install self-tapping screws (000 043 207 60) and tighten to 9.5 Nm (7 ftlb.)+/-1 Nm (+/-0.5 ftlb.) (See Figures 11 & 12) 16 Clean connection areas and apply 2K primer 17 Apply body sealant to all flanges in the repair area 18 Apply standard cavity preservation Figure 11 Figure 12 Panamera Body & Structural Repair Page 7.9 Front Longitudinal Member Notes: Page 7.10 Panamera Body & Structural Repair Part Number - PNA P51 001 Edition - 7/11 ... new Panamera S and Panamera 4S models have a steel suspension with PASM as standard Page 1.20 Panamera Body & Structural Repair Panamera Overview Adaptive air suspension with levelling system and. .. diameter of 17.2 x 2.5 mm for the Panamera/ S, 17.2 x 2.5 mm for the Panamera 4/4S and 18.5 x 2.5 mm for the Panamera Turbo Notes: Panamera Body & Structural Repair Panamera Overview Adaptive Air... Sport Plus Panamera Body & Structural Repair Page 1.25 Panamera Overview Panamera Turbo Brakes Porsche Ceramic Composite Brake (PCCB) 6-piston aluminum monobloc fixed caliper brakes and compound