Body - Hardtop Noises While Driving
911 (996)1/02 6117
Binder - Group 6 - Body
This bulletin replaces Group 6, # 1/02, Dated, 9-6-02.
10/11/02
Modified Rear Hardtop Locks
Vehicle Type:
911 Carrera (996)/911 Carrera 4 (996)
Model Year:
As of MY 1999 (X)
Equipment:
Cabriolet
Concerns:
Modified rear hardtop locks.
Information:
Noise disturbances when driving with assembled hardtop.
Note:
After the introduction dates listed below, modified hardtop locks (with the lock and insert at the mounting point; see Figure 1) will be installed in the C-pillar area to eliminate noise. See Figure 1 for Mounting tab with insert, New version/Previous version. Locking bolts Insert (Position C) is depicted in Figure 2.
Modification:
A plastic sleeve is incorporated in the locking bolts of the modified hardtop lock (Figure 1, arrow a). An alignment pin is also visible on the upper side of the new version (Figure 1, arrow b). The interior of the insert (Position C) used to mount the locking bolts is coated with Teflon (Figure 2, arrow).
Introduction:
Modified rear hardtop locks (lock and insert)
May 2, 2002 from VIN: 99 2 2S 65 4528 USA - Cabriolet
Part Numbers
Repairs:
In Cabriolet vehicles which are manufactured before the introduction date referred to, the hardtop lock should be converted in pairs (left/right) on the new version in the case of complaints of "flap noises at the rear of the hardtop lock on assembled hardtops". The parts of the old version are no longer available.
Mixed construction, with an old version on one side and a new version on the other, is not permitted.
Work Procedure:
Repairing locks for hardtop locks left/right of the rear of the hardtop.
Requirement:
Hardtop cleaned outside - risk of paint damage! Hardtop removed and laid with the outer roof on the assembly structure (see Technical Manual, Group 6, pages 61-69).
Removal:
- Unclip the lock cover. (Figure 3, Position 1).
- Unclip inner cover on left side of hardtop (necessary to separate the electrical plug connection).
- Mark the left/right position of the lock on the hardtop metal plate insert in pencil or chalk.
- Release and unscrew three fastening screws (A/F 10 mm; Figure 4, Position 2).
- Separate the electrical plug connection on the left lock.
- Remove lock (Figure 4, Position. 3).
Installation:
- Position the new hardtop lock on the hardtop according to the appropriate removal identification and fix in place with 3 hexagon-head bolds (M6 x 20). Only tighten the bolts slightly, as the hardtop will have to be reassembled on the vehicle.
- Insert the electrical plug connection into the left lock.
- Assemble new plastic retainer clips (999 507 764 40) on the left side of the inner cover of the removed hardtop and clip the inner cover in place. If metal retainer clips were assembled on the inner cover, the right side of the inner cover of the hardtop should also be removed and the metal retainer clips should be exchanged for plastic retainer clips (see Technical Information Group 6; No. 7/01, page 7).
Replacing the insert in the mounting console for hardtop locking bolts left/right of the C-pillar.
Removal:
- Preparing the convertible top for use (see Technical Manual, Group 61-1, page 7).
- Remove cover above the roll-over protection system. Remove the lining of the convertible top compartment at the top in the region of the cover and fold back slightly. Loosen 3 fastening screws (Figure 5, arrow). Pull cover up and off.
Note:
- In older vehicles, the cover is attached with 5 screws on top of the roll-over protection system (Figure 6, arrows). In order to loosen the front screws (2), the rear wall cover at the back must also be removed.
- Remove mounting console with left/right insert (Figure 7, arrow 1R/1L), loosen and unscrew 4 hexagon-head bolts (A/F 10 mm - Figure 7, Position 2) from each one. Separate the electrical plug connection at the left mounting point.
- Clamp console (left/right) in the vice - use protective jaws! Unscrew 3 countersunk screws (Figure 8, arrows) with a socket key (4 mm hexagon socket head).
- Remove insert with an appropriate mandrel and hammer.
Installation:
- New insert (Teflon coated) with the following identification: Left = "L" / "657.01" and right = "R" / "658.01". Position on the corresponding mounting console (left/right) and slot in carefully using an appropriate mandrel and hammer. Screw firmly in place with 3 countersunk screws (Figure 8, arrows - 4 mm hexagon socket head).
Tightening torque: 8 Nm (6 ftlb.)
- Insert mounting console to left/right in the vehicle and screw firmly in place with 4 hexagon-head bolts M6 x 20 - A/F 10 mm (Figure 7, Pos. 2).
Tightening torque: 10 Nm. (7.5 ftlb.)
Insert the electrical plug connection at the left mounting point.
- Install all the removed parts in the following sequence:
Install cover above the roll-over protection system. Install lining of the convertible-top compartment.
- In older vehicles, also install the rear wall if it had to be removed.
- Adjust convertible top from operational to normal position.
Adjusting the hardtop
Note:
When the rear hardtop locks have been replaced, the position of the hardtop on the vehicle must be checked and possibly readjusted.
- Adjusting the hardtop - service No. 61 02 15 (see 911 Carrera (996) Technical Manual , Group 6, pages 61 - 137).
- After adjusting the hardtop, firmly screw in the fastening screws and lock nuts on the rear hardtop lock with the recommended tightening torque: Fastening screws (M6 x 20 - A/F 10 mm) for left/right hardtop lock.
Tightening torque: 10 Nm. (7.5 ftlb.)
Lock nuts (A/F 24 mm) for the locking bolts on the hardtop lock to left/right.
Tightening torque: 5 Nm (3.5 ftlb.).
- Clip in hardtop lock cover to left/right.
New handling requirements for locking or opening the new hardtop lock.
Note:
The new rear hardtop locks differ in appearance on the upper side of the locking bolts in their lack of color markings to indicate whether the hardtop is open or locked (Figure 9).
When locking or opening the new hardtop locks, the following elements should be taken into account:
Lock:
Turn unlocking lever D to the right (clockwise) to the point of resistance A, then firmly turn further to stop B until you can hear and feel the lock engaging (Figure 10).
Open:
Turn unlocking lever D firmly to the left past the point of resistance (anti-clockwise) as far as the stop.
Enclosure:
A copy of the (multilingual) supplement to the owner's manual model 02 concerning modified hardtop locks (WKD 911 017 02) is shown in this technical bulletin.
Please provide the customers concerned with a photo copy of this supplement after converting the hardtop locks.
Working Time
Literature:
911 Carrera (996) Technical Manual, Group 6:
> Repairs: 61 02 19 - Removing and installing hardtop
61 02 37 Disassembling and assembling hardtop
61 02 15 - Adjusting hardtop
61 42 19 - Removing and installing rear side panel flap (point 1 to 4)
Owner's manual shown (Model Year 02): WKD 911 017 02 "Modified hardtop locks". Make a copy of this page and cutout along outline and insert in owner's manual.
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