Aerokit "Cup II" Installation Instructions
Aerokit "Cup II" Installation Instructions
Vehicle Type: 911 Carrera 2 Coup� (996)
Model Year: As of '02 (2)
Information: Installation of Aerokit "Cup II" retrofit kit. This kit consists of a front spoiler (A) including spoiler lip, two side member panels (B) and a rear lid (C) with rigid spoiler.
These tested parts reduce the front-axle lift and rear-axle lift.
Authorized retrofitting options:
1. Front spoiler with spoiler lip only in conjunction with rear spoiler.
2. Front spoiler with spoiler lip only in conjunction with rear spoiler and both side member panels.
3. Only side member panels.
Other retrofitting options are not permissible !
Under Exclusive option No. "XAA" the new Aerokit "Cup" II is also available for new vehicles - 911 Carrera 2 Coupe (996) - ex works
Information: The Porsche logo and the part numbers are visible on the underside of the front spoiler, the side member panels, and the rear lid.
Caution:
- Damage to the Aerokit or to the overall vehicle - due to the smaller overhang angle of the front spoiler in relation to that of the standard part.
- The bottom of the spoiler can scrape on the ground when the vehicle is loaded or unloaded or driven in parking garages with very steep ramps.
- Avoid steep access and exit ramps wherever possible.
- Adopt your driving style to the local situation.
- Damage to the Aerokit or to the overall vehicle - due to cleaning the vehicle in automatic car washes.
- The Aerokit spoilers may not be adequately recognized by the car wash sensors under certain circumstances. In cases of doubt, consult the car wash operator or only manually wash the vehicle.
- Damage to the Aerokit or to the overall vehicle - due to misuse or improper use.
- Rapid opening of the rear lid can cause damage to the spoiler or rear wiper. Check and optimize the gap dimensions of the rear lid. Open rear lid carefully.
- Never use the spoiler to push the vehicle.
Please inform the customer of these "warnings" and provide the customer with a copy.
Parts Information:
Part Number Description
000 044 802 02 Aerokit "Cup II", Complete Retrofit Kit (see parts list)
Retrofit Kit includes:
996 512 901 02 G2X Rear Spoiler Set
996 512 992 02 1x Z rear spoiler; primered, - 2 x Z bracket and - 2 x Torx screws (fitted in support foot) Rear lid
Material: EP-GF30 Spoiler
Material: EP-GF30, PUR foam core
996 512 976 00 1 x Cover set; primered (cover for screws top/bottom part)
- 1 x cap, left (996 512 965 00 G2X)
- 1 x cap, right (996 512 966 00 G2X)
Material: PP-T20_HI
996 612 070 51 1 x Electrical wiring harness
996 651 269 40 3 x Fastening clips
900 378 177 09 3 x Screw M6 x 30
996 512 611 01 1 x Sealing lip (dust protection, engine compartment) with prefitted double-sided adhesive tape on the underside
999 512 987 00 2 x Adjusting element
000 044 802 15 Side Member Panel Set
996 559 983 04 1 x Left cover with fitted adhesive tape; primered incl.
- 1 x small part set (000 044 801 65)
Material: PTL 4037 type B-PUR-RRIM-GF18
996 559 984 04 1 x Right cover with fitted adhesive tape; primered incl.
- 1 x small part set (000 044 801 65)
Material: PTL 4037 type B-PUR-RRIM-GF18
000 044 802 28 Front Spoiler Set With Spoiler Lip
964 505 103 00 G2X 1 x Cover cap for towing lug
999 651 225 40 1 x Securing cord
996 505 983 02 G2X 1 x Front spoiler, primered; without inner frame and spoiler-mounting of headlights
Material: PTL 4037-PUR-RRIM-GF18
996 505 986 02 G2X 1 x Spoiler lip; primered; incl. prefitted adhesive tape
Material: PTL 4037 - PUR - GF15 - SW
999 507 497 40 21 x Expanding rivet (for fitting spoiler lip to front spoiler & fitting wheel housing cover)
Spare Parts For the Above Kits Sold Separately
000 044 801 65 2 x Small part set (for 1 side member panel): - 1 x sheetmetal nut (999 591 699 02) - 9 x U-clips (999 507 640 09) - 10 x sheetmetal screws (999 073 231 09)
996 505 986 02 G2X 1 x Spoiler lip; primered; incl. prefitted adhesive tape Material: PTL 4037 - PUR - GF15 - SW
999 507 497 40 Expanding rivet
Tools:
Removal tool No. 21
Allen Wrench a/f 2.5 / 4 / 5
Phillips screwdriver
Torx T25 / T30 socket wrench
Thread cutter / tap M4/M5/M6
Plastic spatula
Plastic hammer
Shop light
Porsche System Tester II (PST 2)
Torque wrench up to 120 Nm
Open-end wrench a/f 10/13
Crosshead bit
Needle nose pliers
Roller with rubber roller (commercially available)
Shop Supplies: Cleaning agent for bonding area of side member panel, underside of rear lid and spoiler lip (see Parts Catalog (PET) Ill. 8/11/01.
Work Procedure:
1. Work before painting.
NOTE: The installation set is generally delivered primed. Only perform the following work when the rear lid (A) (Figure 2) and spoiler (B) have been delivered prefitted.
1.1 Remove wiring harness (C) (2 clips).
1.2 Unclip both rubber buffers (D) with mounts.
1.3 Remove cover trim (A) (Figure 3) and unscrew the fastening screw (B) and spring washer located behind it.
1.4 Perform the work steps for the opposite side in a similar manner.
1.5 Press back the pins (A) (Figure 4) and remove the upper part of the spoiler (B).
NOTE: The upper part of the spoiler is secured on both sides.
2. Painting the front spoiler, spoiler lip, side member panels, rear lid, and spoiler taking the materials into consideration - refer to Paint Manual.
Caution: Damage or warping can occur on components - as a result of improper painting and drying processes.
- Observe the specifications and instructions for painting plastics as contained in the Paint Manual.
- During the painting and drying process, place the parts without tension on the painting fixtures provided for this purpose (included in the packages).
3. Assembling the rear spoiler.
3.1 Press back the pins and fit the spoiler on the trunk lid.
NOTE: Use screws and spring washers of the delivered rear lid.
Tightening torque: 15 Nm (11 ftlb.)
3.2 Clip in the right and left cover trim. Clip in rubber buffers (A) (Figure 5) with mounts. Fit wiring harness (B).
3.3 Stick on a new sealing lip (C) - center between the water drain holes.
NOTE: First clean the surface for the label. Cleaning agent - see Parts Catalog (PET) Ill.8/11/01.
3.4 Remove standard rear lid.
NOTE: Electrical wiring harness (D) (Figure 6) is also secured with a clip (F) in area (E) - only accessible by removing the right tail light.
3.5 Convert the fan blower (A) with new screws (see parts list).
Tightening torque: 9.7 Nm (7.5 ftlb.)
3.6 Convert air cowl (B) (clipped). Remove upper part of lock (C).
3.7 Fasten clip (F) on new electrical wiring harness.
3.8 Remove and fit rear lid.
3.9 Attach and fit upper part of lock (A) (Figure 7)
Tightening torque: 9.7 Nm (7.5 ftlb.).
3.10 Connect the fan blower.
4. Installing the right rear light.
5. Fitting both side member panels.
5.1 Preparatory work.
5.1.1 Take off wheels.
5.1.2 Remove side cover (A) (Figure 8) and wheel housing liner (B).
5.1.3 Remove fastening nut (A) (Figure 9). Remove plastic expanding rivet (B). (Removal tool No. 21).
5.1.4 Clip in a sheetmetal nut (C) on the metal clip behind the wheel housing liner (999 591 699 02 from list of parts).
5.1.5 Attach fastening nut (A).
5.1.6 Insert retaining clip.
5.1.7 Distance "A" (Figure 10) is approx. 50 mm.
5.1.8 Clean side member panel up to a height of 20 to 30 mm above the stone shield. Cleaning agent -see "Materials" (Gr. 8/11/01 Parts Catalog).
5.1.9 Unclip the sheetmetal nut (A) (Figure 11) from the removed side cover and attach as depicted onto the side member panel (B).
5.2 Attaching the side member panel.
Important: Place the side member panel exactly, bonding can only be done once. The stone shield must no longer be visible. Use special tool No. 9655/1 as an aid.
5.2.1 Place side member panel and secure with front fastening screw (A) (Figure 12).
5.2.2 Secure side member panel with rear fastening screw (B), remove adhesive film.
5.2.3 Press on side member panel with the roller (A) (Figure 13) from the middle to the wheel housings.
5.2.4 Insert the retaining clips for the side member panel to the body flange of the vehicle underside and attach fastening screws.
5.2.5 Attach rear wheel housing liners.
5.2.6 Perform the work steps 5.2.1 - 5.2.5 for the right side of vehicle in a similar manner.
6. Installing the front spoiler with spoiler lip.
6.1 Preparatory work.
6.1.1 Remove the front spoiler.
6.1.2 Convert inner frame (A) Figure 14) of front spoiler (clipped).
6.1.3 Convert both covers (B).
6.1.4 Insert the cover for the towing lug (C).
6.1.5 Convert both sheetmetal nuts (D).
NOTE: In some cases, the scope of parts includes the inner frame and spoiler-mounting of the headlights! If the inner frame matches what is installed on the standard production vehicle, the new inner frame can be clipped into the front spoiler. Otherwise install the one from the vehicle.
6.1.6 Install and adjusting the front spoiler.
6.2 Install the spoiler lip.
NOTE: Clean the bonding surface for the spoiler lip. Cleaning agent - see "Spare part" Gr. 8/11/01 Parts Catalog.
6.2.1 Place the spoiler lip (A) (Figure 15), secure with 3 plastic expanding rivets, remove adhesive film and press on with roller.
6.2.2 Insert all plastic expanding rivets (Figure 16).
7. Concluding work.
7.1 Mount wheels.
Tightening torque: 130 Nm (96 ftlb.).
7.2 Connect the diagnostic tester (Figure 17).
7.3 Read out fault codes, record, remedy any faults and delete fault codes.
7.4 Perform a light test.
Literature: 911 Carrera Technical Manual, Groups 5/6/9:
Repairs:
51 90 19 - Removing and installing underside panel
53 69 19 - Removing and installing wheel housing liners and wheel housing trim
55 90 37 - Disassembling and assembling rear lid
63 15 19 - Removing and installing front spoiler
94 15 19 - Removing and installing main headlights
94 33 19 - Removing and installing bulb for tail light
Paint Manual, 4/6/8 cylinder - plastic painting
Important Notice: Porsche Cars N.A Technical Bulletins are intended for use by professional technicians, not a "Do-it-yourselfer." They are written to inform these technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Special tools may be required to perform certain operations identified in these bulletins. Use of tools and procedures other than those recommended in these bulletins may be detrimental to the safe operation of your vehicle. Properly trained technicians have the equipment, tools, safety instructions and know-how to do a job properly and safely. If a condition is described, do not assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See your Porsche Dealer for information on whether your vehicle may benefit from the information. Part numbers listed in these bulletins are for reference only. Always check with your authorized Porsche dealer to verify correct part numbers.