® AfterSales Training “Soft” Roof & Body Systems 911 Carrera (996/997) & Boxster (986/987) P60 Porsche AfterSales Training Student Name: Training Center Location: Instructor Name: Date: _ Important Notice:The contents of this AfterSales Training brochure was originally written by Porsche AG for its rest-of-world English speaking market The electronic text and graphic files were then imported by Porsche Cars N.A, Inc and edited for content Some equipment and technical data listed in this publication may not be applicable for our market Specifications are subject to change without notice We have attempted to render the text within this publication to American English as best as we could We reserve the right to make changes without notice © 2007 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®, CaymanTM, Tiptronic®, VarioCam®, PCM®, 911®, 4S®, and the model numbers and distinctive shapes of Porsche’s automobiles such as, the federally registered 911 automobile The third party trademarks contained herein are the properties of their respective owners Porsche Cars North America, Inc., believes the specifications to be correct at the time of printing However, specifications, standard equipment and options are subject to change without notice Part Number - PNA P60 004 Edition - 5/07 Table of Contents Description Section 911 Carrera (996) Cabriolet Body Equipment 911 Carrera (997) Cabriolet Body Equipment Boxster (986) Body Equipment Boxster (987) Body Equipment Conversion Charts “Soft” Roof & Body Systems “Soft” Roof & Body Systems 911 (996) Cabriolet Body Equipment Subject Page Excerpts From Owner’s Manual Key Functions Central Locking Rollover Protection Convertilble Top Operation 10 Convertilble Emergency Operation 12 General Information – 911 Carrera (996) 29 General Information – 911 Carrera 4S (996) 30 Convertible Top 32 Top Operation 32 Top Construction 32 Top Sectional Views 34 Flaps In Side Trim 41 Secondary Flaps 42 Top Compartment Lid 43 Convertible Fixed Glass Rear Window As Of 2002 45 Hardtop 47 Cabriolet Windows 51 Accessories 52 Electrical System 56 Rollover Protection 66 “Soft” Roof & Body Systems Page 1.1 911 (996) Cabriolet Body Equipment Notes: Page 1.2 “Soft” Roof & Body Systems 911 (996) Cabriolet – Owner’s Manual “Soft” Roof & Body Systems Page 1.3 911 (996) Cabriolet – Owner’s Manual Page 1.4 “Soft” Roof & Body Systems 911 (996) Cabriolet – Owner’s Manual “Soft” Roof & Body Systems Page 1.5 911 (996) Cabriolet – Owner’s Manual Page 1.6 “Soft” Roof & Body Systems Boxster (987) Body Equipment The redesigned air inlet in the rear quarter panel takes up the graceful geometric lines of the Carrera GT The positioning and the opening cross section of the air inlet have been carefully optimized to ensure the maximum possible increase in air flow rate combined with the minimum possible effects on lift and resistance This way, it has been possible to improve the flow of air through the engine compartment, to lower the temperature in the engine compartment and to optimize the intake of combustion air Body Structure The purpose of redesigning the body structure of the new Boxster/S (987) series was to increase torsional and flexural rigidity in comparison with the previous Boxster/S (986) and also to further improve crash safety in a frontal or offset crash (frontal crash with head-on collision on one side of the vehicle) Additional objectives were improved body seams and an increase in the space available to the vehicle’s occupants, particularly taller persons These improvements have been achieved by means of seven main changes: • Use of the spot welding/bonding method • Redesigning of the joint areas (A-pillar, sills) • Use of a new bulkhead cross member made of boron steel • Repositioning of the pedals towards the front • Use of “tailored blanks” for the front side members • Integration of an additional load path at the level of the upper door trims Mild Steel Tailored Blanks High Strengh Steel Boron Steel High Strength Stainless Steel Aluminum Page 4.4 “Soft” Roof & Body Systems Boxster (987) Body Equipment At the same time, the precision of the production process has been further improved by way of the Porsche fixing concept, whereby special reference points define the relative positioning of the body components with a very high level of precision The attendant very high process reliability ensures uniform joint lines throughout all areas of the body The Porsche body structure is still executed as a light weight design with high strength and ultra high strength steels This concept ensures very good passive safety The torsional and flexural rigidity of the body structure has been further increased by using the spot welding/bonding method to join the side sections and the floor assembly Torsional rigidity has increased by %, flexural rigidity by 14 % The redesigned joint areas (A-pillar / sills) have also contributed to these excellent results The bulkhead cross member in the front of the vehicle has been completely reengineered It now consists of high strength steel (boron 02) and is produced by a new process This has allowed the cross section to be matched to the package conditions and optimization of the available footwell space The strength of the cross member has also been increased The increased rigidity of the cross member and the improved anchorage have significantly reduced footwell intrusion in the event of a crash The reduction in the cross section has also allowed the anchorage for the pedals and the pedals themselves to be moved forwards by 10 mm In order to improve ergonomics, the clutch pedal has been moved forward by 15 mm This provides taller drivers with more legroom and allows them to find an optimum seat position Door The doors have been modified in the following areas in relation to the predecessor with the objective of further improving crash safety: In order to reinforce the passenger cell in the event of a frontal or offset crash, the upper load path has been optimized The upper load path distributes the energy acting on the body in the event of a frontal crash very effectively between the front and rear parts of the car via the door To accomplish this, the upper part of the door has been strengthened by the high strength steel door channel reinforcement (1) In the event of a crash, this reinforcement transmits the attendant forces via a support on the rear side section to the rear part of the car This has further improved the deformation behavior and the integrity of the passenger cell (important for protecting passengers) Door reinforcement (2) consists of high strength steel profiles and is also integrated into the door construction In conjunction with the rigid side structure, it provides for increased penetration resistance and improved side protection The door arrester has been equipped with an additional, third index position for more precise positioning of the doors during opening The new seats featuring comprehensive improvements, such as higher headrests, increased shoulder width and markedly improved lateral support also afford tall persons substantial benefits in the interior The tailored blanks employed in the rear side members on the previous Boxster/S (986) models are also used in the front side members on the Boxster/S (987) These blanks consist of fine panels made of different types of steel in various thicknesses which are welded together by way of laser technology This enables the vehicle’s weight to be reduced and crash zones to be defined In conjunction with the front side members, the bulkhead cross member in the upper tier ensures an extremely robust structure - Door channel reinforcement - Door reinforcement “Soft” Roof & Body Systems Page 4.5 Boxster (987) Body Equipment Cabrio Top The glass rear window, which is the only component to be adapted from the previous Boxster/S (986) model, is heated to ensure clear visibility in all weather conditions The lines of the cabrio top have been modified in the area of the side windows It now presents an impression of increased tension when viewed from the side The resultant benefits take the form of increased headroom when entering and exiting the car with the top closed and better visibility to the sides and the rear The cabrio top is a totally new development featuring a magnesium structure The tension bows and center spars of the corner and main arches are produced in aluminum This has resulted in a further weight reduction for the cabrio top/roll-over bar unit in comparison to the previous Boxster/S (986) models, which already offered an exceptionally lightweight unit Similar to the previous Boxster/S (986) models, the front area of the top consists of a solid cast magnesium structure This offers enhanced passenger protection in particular in the event of the car rolling over with the top closed, since it improves the strength and stability of the top in this area The electric operating system for the top can be used at vehicle speeds of up to 31 mph (50 km/h) After releasing the top, the opening process must be started by way of a one touch button The one touch function is available at speeds between - 31 mph (10 - 50 km/h) At speeds below mph (10 km/h), the button must be held The closing process functions in the same manner The basic principle of the cabrio top, with mechanical release, electric drive and zig-zag folding, has been retained The quality has been further enhanced with extensive modification efforts This improved quality is reflected in the fact that the top cover now for the first time consists of layers of material In addition to the top’s outer fabric and the roof liner, an additional new intermediate layer of fleece has been incorporated under the outer fabric, resulting in a substantial reduction in interior noise when the top is closed Page 4.6 “Soft” Roof & Body Systems Boxster (987) Body Equipment At 12 s, the opening and closing time for the top on the new Boxsters again sets the standards in the area of cabrio tops with a top compartment lid and leads the competition Notes: “Soft” Roof & Body Systems Page 4.7 Boxster (987) Body Equipment The pre-assembled cabrio top unit consists of the top frame with top cover (1), the roll-over bar (2) and the water collecting pan (3), and is mounted into the body as a complete unit and connected to the top drive Water management in the area of the top has also been improved A further water outlet has been added to the water channel at the front This outlet serves to discharge the rain water which collects in the front header bow when the vehicle is stationary into the seal of the A-pillar via the corner piece of the seal This results in improved water drainage, in particular markedly reducing the likelihood of rain water dripping into the vehicle after entering a car with a wet top In order to take into account the higher roll-over bar, the top’s opening curve, the complete kinematics of the top frame have been redesigned This way it was possible to accommodate the higher roll-over bar without changing the lowered position of the roof frame Wind Deflector The principle for the top drive has been adopted from the previous Boxster/S (986) models The drive power is transmitted from the centrally located electric motor via the flexible drive shafts to the two side mounted top operating mechanisms On the axles of this mechanism are the steering arms which move the top via the push rods and the top compartment lid via the push rod springs The top movement is smooth and harmonious The top is lowered smoothly towards the rear without leaving the vehicle’s contours The harmonious impression is further enhanced by the fact that the top compartment lid is opened and closed simultaneously with the movement of the top The basic principle of the optional three part wind deflector has been adopted from the Boxster/S (986) models The 25 mm higher roll-over bars enable a larger surface area for the middle element made of acrylic glass The locking system on the fixing elements provided on the roll-over bar has also been redesigned for increased simplicity and substantially improved user friendliness The wind deflector has been provided with a camber for increased stability, thereby effectively reducing possible fluttering effects at high speeds In order to release the wind deflector, it is now sufficient to press one of the two release buttons The wind deflector can then be removed Installing the wind deflector has also been simplified The wind deflector is placed on the central guide and then slid back into the two locking attachments The two outer parts of the wind deflector (fine-meshed plastic screen inserts) retain the same installation procedure and are held in place with vibration free clips Page 4.8 “Soft” Roof & Body Systems Boxster (987) Body Equipment Hardtop Notes: The optional hardtop has essentially been adopted from the previous Boxster/S (986) models The easy to install lightweight hardtop weighing 51 lbs (23 kg) is manufactured out of aluminum by the punch riveting method and incorporates a heated rear window The aluminum side parts with sealing system have been adapted to the new contours of the door windows “Soft” Roof & Body Systems Page 4.9 Boxster (987) Body Equipment Convertible Top Operation Conditions for operating the convertible top: The following operating instructions are from the vehicle owner’s manual – The ignition must be switched on (engine running or off) – Maximum speed 30 mph (50 km/h) The opening/closing process of the convertible top will be interrupted if the maximum speed is exceeded > Reduce speed Press button again The opening/closing process is ended Brief operating instructions can be found on the back side of the driver side sun visor Warning! When opening or closing the convertible top, serious personal injury may occur if a person’s body parts are near or in the way of the convertible top mechanism’s moving parts Opening Convertible Top > Make absolutely sure that nobody can be injured by the convertible top mechanism or the convertible top compartment lid Do not operate convertible top: – At temperatures below 32° F (0° C) – When one side of the car is on a curb, a hoist or a jack – When items of luggage or other objects hinder the convertible top movement or are in abrasive contact with the convertible top or rear window Items of luggage or objects on the luggage tray above the engine compartment lid must be put in the storage box or be secured under the net to prevent their sliding out – Drive only with the convertible top fully open or closed > Avoid frequent operation of the convertible top with the engine off; the vehicle battery would be unintentionally discharged rapidly > The convertible top must be operated only when the car is stationary Make sure there is sufficient clearance above the convertible top (e.g in the garage) > To prevent damp stains and abrasions, only open the convertible top in a dry, clean state > Park your car in the shade whenever possible, as the fabric, rubber material and color can be harmed by long exposure to sunlight Door Windows Releasing the latching lever – Press on the release plate A Latching lever B pops into engaging position Releasing Convertible Top Caution! Risk of damage by the locking hooks on the roof frame when the latching lever is not engaged correctly > Make sure that the latching lever is felt to engage when opening > Swivel latching lever B to the rear until it is felt to engage If the door windows are closed, they will automatically be lowered a few centimeters before the convertible top is opened or closed The door windows close automatically when the convertible top is locked with the latching lever on the windshield frame Page 4.10 “Soft” Roof & Body Systems Boxster (987) Body Equipment Opening The Convertible Top With The Button Warning! Closing The Convertible Top With The Button Warning! Risk of injury > When opening the convertible top, make sure that nobody can be injured by the convertible top mechanism or the convertible top compartment lid > In order to abort convertible top operation in the event of danger: up to mph (10 km/h), release the button immediately, over mph (10 km/h), activate the button briefly > Up to mph (10 km/h): Pull the button back and hold without interruption until the convertible top is in the final position and the message on the on-board computer goes out In case of danger, release the button Convertible top operation stops > From mph (10 km/h) to 30 mph (50 km/h): Pull button back briefly, the convertible top opens automatically The message in on-board computer goes out In case of danger, pull the button back again, the convertible top operation stops Danger of injury and damage > When closing the convertible top, make sure that nobody can be injured by the convertible top mechanism or the convertible top compartment lid > In order to abort convertible top operation in the event of danger: up to mph (10 km/h), release the button immediately, over mph (10 km/h), activate the button briefly > Keep the lids of the make-up mirrors in the sun visors closed when closing the convertible top > Lock the convertible top with the latching lever after automatic closing > Up to mph (10 km/h): Push the button forward and hold without interruption until the convertible top is in the final position and the message on the on-board computer goes out In case of danger, release the button Convertible top operation stops > From mph (10 km/h) to 30 mph (50 km/h): Push button forward briefly, the convertible top closes automatically The message in on-board computer goes out In case of danger, push the button forward again, the convertible top operation stops > Lock convertible top with the latching lever “Soft” Roof & Body Systems Page 4.11 Boxster (987) Body Equipment Locking The Convertible Top Emergency Operation > Before performing emergency operation, please check: Was the ignition switched on and the handbrake applied? Are the electrical fuses defective? Warning! > Swivel latching lever B to the front until it is felt to engage The locking hook must engage in the receptacle on the windshield frame C Note If the convertible top has been opened for a longer period, it could be necessary to assist the locking hook engage C There is a danger of injury and risk of damage during emergency operation There is a danger of crushing or pinching body parts at all moveable convertible top parts which could cause serious personal injury > Take great care when performing emergency operation > Do not operate the convertible top during and after emergency operation > Lever off joint rods only with the greatest care > If the convertible top is not in the rearward final position, the convertible top compartment lid or the convertible top could fall down when the joint rods are levered off For this reason, hold convertible top or convertible top compartment lid firmly before levering off the second joint rod > During emergency operation, ensure that the paint is not damaged > With the vehicle stationary, press and hold the button for convertible top operation and pull the convertible top to the windshield using the handle recess D Remove the ignition key so that the convertible top is not operated unintentionally On both sides of the car, unclip the black rod cover A and pull it up and out Page 4.12 “Soft” Roof & Body Systems Boxster (987) Body Equipment When levering off joint rod D on the other side of the vehicle, the convertible top compartment cover must be held so that it does not fall down in an uncontrolled manner to protect against injury from a fallen cover Take lever of the wheel-bolt spanner B out of the tool kit Warning! Danger of crushing or pinching > Lever off joint rods only with the greatest care > If the convertible top is not in the rearward final position, the convertible top compartment lid or the convertible top could fall down when the joint rods are levered off For this reason, hold convertible top or convertible top compartment lid firmly before levering off the second joint rod Grasp convertible top compartment cover in the center and set up completely (arrow) Lever joint rod E (white fastening) off the ball head with blade of lever B A corresponding amount of force is required to lever off the ball head, creating danger of crushing and pinching When levering off joint rod E on the other side of the vehicle, the convertible top must be held so that it does not fall down in an uncontrolled manner to protect against injury from a fallen cover Example: Convertible top in rearward final position D - Joint rod for convertible top compartment cover (black ball Lift convertible top with both hands (arrow) and close head fastening) E - Joint rod for convertible top (white ball head fastening) 10 Lock convertible top The position and accessibility of the joint rods change depending on the position of the convertible top It can be helpful to fold up the rear part of the convertible top 11 Carefully lower convertible top compartment cover Lever joint rod D (black fastening) off the ball head with blade of lever B As the connection is under spring tension, a corresponding amount of force is required to lever off the ball head, creating danger of crushing and pinching Danger of damage at the convertible top > After emergency operation, not operate the convertible top with the rocker switch > Drive slowly to an authorized Porsche dealer in order to have the fault remedied Caution! “Soft” Roof & Body Systems Page 4.13 Boxster (987) Body Equipment Rear Spoiler Notes: The integrated electrically extendable rear spoiler has also been restyled and as before is executed as a plastic construction with aluminum support The spoiler extends at approx 75 mph (120 km/h) to reduce lift coefficients at the rear axle, thereby increasing driving stability Since aerodynamic forces are rather less important at low speeds, it retracts at speeds below approx 50 mph (80 km/h) to show off the classic lines of the Boxster/S to their best advantage Page 4.14 “Soft” Roof & Body Systems Conversion Charts Temperature Conversion Metric Conversion Formulas INCH X MM X MILE X KM(KILOMETER) X OUNCE X GRAM X POUND(lb) X kg(KILOGRAM) X CUBIC INCH X cc(CUBIC CENTIMETER) X FOOTPOUND(ft lb) X Nm(NEWTON METER) X HORSEPOWER(SAE) X HORSEPOWER(DIN) X Kw(KILOWATT) X HORSEPOWER(SAE) X MPG(MILES PER GALLON) X BAR X PSI(POUND SQUARE INCH) X GALLON X LITER X FAHRENHEIT CELSIUS X 25.4 0394 1.609 621 28.35 0352 454 2.2046 16.387 061 1.3558 7376 746 9861 1.34 1.014 4251 14.5 0689 3.7854 2642 32÷1.8 1.8+32 “Soft” Roof & Body Systems = = = = = = = = = = = = = = = = = = = = = = = MM INCH KILOMETER(KM) MILE GRAM OUNCE KILOGRAM(kg) lb(POUND) CUBIC CENTIMETER(cc) CUBIC INCH NEWTON METER(Nm) ft lb(FOOT POUND) KILOWATT(Kw) HORSEPOWER(SAE) HORSEPOWER(SAE) HORSEPOWER(DIN) Km/l(KILOMETER PER LITER) POUND/SQ INCH(PSI) BAR LITER GALLON CELSIUS FAHRENHEIT Page 5.1 Conversion Charts Notes: Page 5.2 “Soft” Roof & Body Systems Part Number - PNA P60 004 ... 66 Soft Roof & Body Systems Page 1.1 911 (996) Cabriolet Body Equipment Notes: Page 1.2 Soft Roof & Body Systems 911 (996) Cabriolet – Owner’s Manual Soft Roof & Body Systems Page... Manual Page 1.4 Soft Roof & Body Systems 911 (996) Cabriolet – Owner’s Manual Soft Roof & Body Systems Page 1.5 911 (996) Cabriolet – Owner’s Manual Page 1.6 Soft Roof & Body Systems 911 (996)... Owner’s Manual Soft Roof & Body Systems Page 1.7 911 (996) Cabriolet – Owner’s Manual Page 1.8 Soft Roof & Body Systems 911 (996) Cabriolet – Owner’s Manual Soft Roof & Body Systems Page 1.9