Noises In the Door/Door Trim Panel Area
Noises In The Door/Door Trim Panel Area
Vehicle Type: 911 Carrera (996) / 911 Carrera 4 (996)
Model Year: As of 1999 (X)
Concern: Noises in the door/door trim panel area
Information: The following information contains the most up to date specifications for repairing complaints of noises in the door/door panel area. Most of the following procedures were implemented during production (see notes). Before beginning the work, please road test the vehicle to isolate the area where the noise is coming from. Then refer to the technical bulletin for assistance. After completing the work, road test the vehicle again to confirm the noise was eliminated. Apart from the complaints listed and the relevant remedy, other causes of noise may occur in the door trim panels. It will be necessary to seek out these causes and systematically eliminate them on your own.
Parts Information:
Part Number Description
999 911 227 40 Sponge rubber tape (25mm wide).
999 507 505 40 Gray plastic clip for securing the door panel to the door.
999 507 582 40 White plastic clip for securing the door panel to the door.
999 507 651 40 Expanding nut.
999 911 606 40 Teflon adhesive tape (20 mm wide).
993 555 545 00 Narrow felt tape (15mm wide).
996 542 075 04 Power window, left.
996 542 076 04 Power window, right.
N 020 902 1 Tie-Wrap
D 007 000 A2 Silicone lubricant spray (VW part; soon to be available as a Porsche part).
Work Procedure: Refer to figure 1 for the parts overview. In order to remedy noises in the door/door panel, the following items must first be removed only if necessary.
Part to be removed.
Door panel (left or right)
Notes for disassembly:
1. Disconnect and cover battery terminal first. See warning.
2. CAUTION: The bowden cable can be damaged if bent in the area of the hook. On vehicles with the new style bowden cable, push the hook into the end piece of the cover after disassembly.
3. Always replace the fastening clips before reinstalling the panels. See figures 2 and 3 for the proper use of the clips.
Figure 2 - Large ribbed area. For non-leather door panels, use gray clips (999 507 505 40). For leather door panels, use white clips (999 507 582 40)
Figure 3 - Small ribbed area. Use white clips for both leather and non-leather door panels. This type of door panel was introduced into production as of 11/99.
Part to be removed.
Inner door release (left or right)
Power window (left or right)
Notes for disassembly:
1. Disengage return spring.
2. Remove the four securing screws.
3. Disengage the inner door release at the bottom and guide it out at the top.
Only if necessary! Remove according to directions in the workshop manual.
CAUTION: There is a danger of injury caused by airbag or side airbag, even after the power supply is interrupted. The airbag can be unintentionally triggered if sufficient time is not allowed after disconnection the battery.
- Wait at least one minute after disconnecting the battery before proceeding with work.
Complaint 1: Rattling and knocking noises from the entire door area (left or right side).
Cause: The door film is striking the door trim panel from the inside.
Repair: Construct 2 sets of tape strips. Cut 6 strips of sponge rubber tape 70 mm long. Stick together 3 strips so that a total thickness of approximately 10 mm is achieved. Stick both sponge rubber sets on to the door film. See arrows in figure 4.
NOTE: Before re-installation of the door panel, all eight plastic clips (I in figure 1) and the plastic expanding nut must be replaced. See door panel notes for disassembly for plastic clip application.
Make sure the allen head bolt under the plastic airbag cover (D in figure 1) is tightened to 5.9 Nm (4.5 ftlb.).
Complaint 2: Creaking noises from the front or rear of the door area (left or right side).
Cause: The fold of the artificial leather or of the leather on the door panel is rubbing on the inner door panel.
Repair: Cut a 20 mm wide piece of Teflon tape to a length of 300 mm. Then cut it in half to have two 10 x 300 mm strips. Apply these strips to the door at the front and rear area where the leather/artificial leather on the door panel contact the door. Make sure the tape is in far enough so not to be visible with the door panel installed. See arrows in figure 5.
NOTE: Before re-installation of the door panel, all eight plastic clips (I in figure 1) and the plastic expanding nut must be replaced. See door panel notes for disassembly for plastic clip application.
Make sure the allen head bolt under the plastic airbag cover (D in figure 1) is tightened to 5.9 Nm (4.5 ftlb.).
Complaint 3: Clicking/crackling from the area of the side airbag.
Cause: In some cases, barcode sticker is applied to the interior of the airbag cover on the door panel. During driving, it is possible that this sticker may detach itself from the cover and cause clicking or crackling noises.
Repair: Remove the sticker and place it on another part of the door panel. See figure 6.
NOTE: Before re-installation of the door panel, all eight plastic clips (I in figure 1) and the plastic expanding nut must be replaced. See door panel notes for disassembly for plastic clip application.
Make sure the allen head bolt under the plastic airbag cover (D in figure 1) is tightened to 5.9 Nm (4.5 ftlb.).
Complaint 4: Creaking in the area of the inner door release.
Cause: Relative movement between the inner door release and the door trim panel during driving.
Repair: Apply felt strips to the inner door release/door panel contact point. See arrow in figure 7.
Make sure the felt tape is positioned so it is not seen from the outside.
NOTE: Before re-installation of the door panel, all eight plastic clips (I in figure 1) and the plastic expanding nut must be replaced. See door panel notes for disassembly for plastic clip application.
Make sure the allen head bolt under the plastic airbag cover (D in figure 1) is tightened to 5.9 Nm (4.5 ftlb.).
Complaint 5: Grating from the door lock
Cause: The catch bar is rubbing in the door lock.
Repair: Spray the door lock with silicone lubricant spray. Spray in the inner area of the lock, in which the catch bar engages. See arrow in figure 8.
NOTE: Do not use greases or other lubricants on the door lock. They attract dirt and will cause mechanical problems.
Complaint 6: Clicking from the area of the inner door (power window).
Cause: Movement of parts against each other in the power window assembly. In early production cars, the parts were manufactured with a silver metallic finish.
Repair: As of 8-28-98, VIN numbers 99 1XS 62 3589 Coupe and 99 1XS 65 1949 Cabriolet, the power window components were powder coated (black) to reduce noise. If the vehicle is manufactured before these VINs, replacement of the entire power window assembly is necessary.
NOTE: Make sure that the vehicle was manufactured before the above mentioned VINs.
Concluding Work: After repairing the presumed noise sources, install the door panel with new clips. Connect the battery and enter the radio code if necessary. Road test the vehicle to confirm the noise was eliminated.
Literature: 911 Carrera (996) Technical Manual, Groups 5, 6, and 7:
57 51 37 - Disassembling and assembling door
69 .. .. .. - Safety regulations for airbag vehicles
69 63 19 - Removing and installing the side airbag unit
70 59 37 - Disassembling door trim panel
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 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.