Campaign - Possible Engine Overheat Condition
911 Turbo (996)6a/O1 A211
Binder - Camp., Lit., Train., Warr.
Date: 3-21-03
A211 - Installation of Aerokit "Turbo" Spoiler Lip
Attention:
Sales Manager, Service Manager, Parts Manager, Service Technician
This is to inform you of a voluntary Customer Service Campaign Action involving a certain range of 2002 model year 911 Turbo (996) vehicles.
Porsche AG, the manufacturer, initiated a voluntary Customer Campaign involving certain 911 Turbo (996) vehicles that could experience high temperatures in the engine compartment if driven at high speeds. Engine compartment temperature measurements have shown that during trips with high ambient temperatures, while driving at high speeds, or when the vehicle is driven on the racetrack, the ventilation of the engine compartment may not be sufficient.
As a result, this may lead to a high thermal load on individual components.
In order to prevent this condition, an additional spoiler-lip will be attached to the rear lid, which improves airflow and the ventilation of the engine compartment at these relatively higher speeds.
A total of 51 U.S. vehicles fall within the scope of this recall campaign.
Very Important!
Use the VIN range below as a general guideline. The VIN can be checked in the Porsche e-DCS/WWS for confirmation of an open recall campaign. If a vehicle has been retrofitted with an Aerokit, it may not be included in the VIN. List. These vehicles must be retrofitted as well. Refer To Attachment "A" to determine if a particular vehicle is eligible for this recall campaign.
The affected Vehicle Identification Numbers are contained in the following VIN-Range:
US Vehicles:
WP0AB29962S685155 to WP0AB29982S686064
Customer Notification:
Porsche Cars North America, Inc., will notify All Owners of affected vehicles by First Class Mail during the week of March 24, 2003. See enclosed copy of the Recall Notification card to the Porsche Owner. A listing of affected VINs (with owner name and addresses) will be sent to you.
Additionally, an Aerokit "Turbo" sales history will be sent to the corresponding dealers whom have purchased kits in the past. We kindly ask you to check your service file and ascertain customers that have had a kit installed on their vehicle to have the recall completed.
Parts Information:
Time Allowance:
Time Units
70
Following completion of the recall, please enter this information into the Maintenance Booklet (see sample).
Attachment "A" VIN List
Customer Notification Card
Attachment "B" Work Procedure
Information:
Vehicles delivered and/or retrofitted with the Aerokit "Turbo", must be fitted with an additional spoiler lip on the rear spoiler. All current Aerokit packages contain the additional spoiler lip. If you receive a package without the additional spoiler lip, you may use the part numbers contained in this bulletin to order one. In any event, do not install an Aerokit on a vehicle without the additional spoiler lip.
Materials:
Acetone
Cleaning cloth
1 x commercially available double-sided adhesive tape
Tools:
Socket wrench for hexagon sockets a/f 5
Offset screw key for hexagon sockets a/f 5
Hand lamp
Torque wrench up to 10 Nm
Extension 1/4-inch; 100 mm long
Danger!
Damage or warping can occur on the spoiler lip in the event of improper painting and drying processes.
> Observe the specifications and instructions for the painting of plastics as contained in the Paint Manual.
> During the painting and drying process, place the spoiler lip without tension on the painting fixtures provided for this purpose (included in the packages).
Work Procedure:
1. Paint the spoiler lip in the body color in accordance with the Paint Manual. To expedite repairs, in some cases you could paint the lip before the customer comes in to have it installed.
2. Preparatory work. Only: If the Aerokit "Turbo" is already fitted on the vehicle.
Danger!
Damage can occur to the paintwork of the rear lid or spoiler - in the event of improper removal / fitting of the 4 microencapsulated cheese head screws.
> Carefully remove and fit the cheese head screws, allowing for the screw length.
> If necessary, change the tool when removing and fitting the two rear screws.
2.1 Open the rear lid and remove the two front microencapsulated M6 x 18 cheese head screws (Figure 2, Item A) at the underside of the spoiler.
2.2 Close the rear lid and remove the two rear cheese head screws.
2.3 Carefully lift the spoiler (Item B) upwards clear of the rear lid (Item C).
3. Installing the spoiler lip on rear lid.
Important!
Observe the following before and after installing the spoiler lip:
- Room and object temperature mm. 18 °C (64 °F)
- Vehicle must not be washed or waxed for 24 hours after installing on the spoiler lip.
3.1 Use a cleaning cloth and acetone or prep solvent to remove all grease and dust from the bonding surface behind the bottom-cooling louver of the rear lid. Afterwards do not touch the bonding surface!
3.2 Place the template on the rear lid and align to the front corners (Figure 3, Item A), the front edge (Item B) and at the sides of the rear lid.
3.3 Remove protective film (liner) from the adhesive points on the back of the template and press the template onto the rear lid.
Note:
The edge of the template (Item C), which the spoiler lip will be adjacent to, must lie flat on the rear lid. If it doesn't, apply additional adhesive double-faced tape directly to the edge on the back of the template and fix the template to the rear lid.
3.4 Place the spoiler lip without tension in the cutout of the template and check that it fits correctly.
Note:
The outside edge of the spoiler lip must not overlap the edge of the template. Otherwise, after affixing the spoiler lip, it will not be possible to remove the template properly. In this case modify the template if necessary.
3.5 Remove the protective paper (liner) from the bonding surface of the spoiler lip. Be careful not to touch the bonding surface!
3.6 Using the template as a guide, position the spoiler lip over the rear lid and align with the guide edge of the template.
3.7 Without twisting, carefully mount the spoiler lip on the rear lid from above.
3.8 From the center outwards along its entire length, press the spoiler lip onto the rear lid (Figure 4) using the ball of the thumb with as much pressure as possible (approx. 50-80 N).
3.9 Remove template from the rear lid.
4. Fit the spoiler to the rear lid.
4.1 Carefully place the spoiler onto the spoiler base on the rear lid and screw in all four new M6 x 18 microencapsulated cheese head screws by hand.
4.2 Carefully tighten the cheese head screws using the hexagon wrench.
Tightening torque: 10 Nm (7.5 ft-lb.)
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