Convertible - Rear Cover
Boxster8/00 6154
Binder - Group 6, Body Equipment
This bulletin replaces bulletin of the same name dated 12-22-2000.
Speedster Rear End (Rear Cover)
8-10-01
Vehicle Type:
Boxster / Boxster S
Model Year:
MY '97 (V)
Concerns:
Retrofitting
Information:
A Speedster rear end can be mounted onto the convertible top compartment lid when the convertible top is fully opened. (Figure 1). It is fastened with two belts on the roll-over bar and with two outer locks in the holders for the hardtop mount. Mounting the Speedster rear end is therefore only possible on vehicles without a hardtop and with the convertible top open!
The center section of the windstop can no longer be mounted due to the belts in the middle area of the roll-over bar (poly glass window).
After removal, the centrally divided Speedster rear end can be inserted into the special fabric cases and stored in the rear luggage compartment of the vehicle.
DANGER!
Danger of accident (death / danger to yourself and / or other road users) as a result of losing the Speedster rear end.
> Regularly check the Speedster rear end before each journey and during an extended journey to ensure that it is seated securely on the vehicle.
WARNING!
Damage can be caused to the mounted Speedster rear end, convertible-top compartment lid or to the pivot pin locks (Hardtop mounts) as a result of opening the convertible top.
> Do not activate the convertible top when mounting the Speedster rear end under any circumstances.
> Insert red deactivation clip into the mount for the locking hook of the convertible top lock (above the interior mirror).
WARNING!
Damage can be caused to the Speedster rear end or accessories as a result of incorrect and improper use.
> The vehicle must never be pushed at the mounted Speedster rear end.
> The Speedster rear end must not be used for seating purposes!
Parts Information
Tools:
Torque wrench up to 10 Nm (7.5 ft.lb.)
Torx wrench T20
Socket wrench a/f 10
Installation:
1.0 Paint the Speedster rear end in accordance with the instructions for the painting of plastics DCPD contained in the Paint Manual. Mask the threaded pins before painting.
Information:
WARNING!
Damage or warping can occur on the Speedster rear end as a result of improper painting and drying processes.
> Observe the specifications and instructions for the painting of plastics as found in the Paint Manual.
> During the painting and drying process, place the parts without tension on the painting fixtures / masks provided for this purpose (included in the packages).
2.0 Check whether the holders (Figure 2, Pos. A) are already installed in the area of the B-pillar for mounting the hardtop or the Speedster rear end. If not, they must be installed according to the Technical Information, Group 6, No. 1/97 (Figure 2).
3.0 Complete the Speedster rear end and adapt to the vehicle.
3.1 Front fastening points.
3.2 Place contact surface (Figure 3, Pos. A) onto the thread bolts at the front side of the Speedster rear end.
3.3 If necessary place a spacer 40 x 28 x 2 (Pos. B) between the contact surface and the studs.
3.4 Screw contact surface hand tight to the Speedster rear end with a spacer sleeve 6.1 x 1.0 (Pos. C) and an M6 hexagon nut (Pos. D).
3.5 Rear fastening points.
Information:
The locks levers are marked with the letters L for Left and R for Right (Figure 4) for allocating the locks to the corresponding Speedster cover. Levelling out of the height between the Speedster rear end and the convertible top compartment lid to produce a uniform gap occurs by inserting spacers 60 x 23 x 1 between the lock and the mounting bearer.
3.6 Position and align the lock on the mounting bearer on the underside of the corresponding Speedster cover as far as possible outward.
3.7 Loosely prefit the lock with respectively 2 screws 5 x 20 and 2 plates 5.5 x 12 x 1.0 into the bores provided on the mounting bearer.
3.8 If height levelling is necessary, a self-adhesive rubber buffer 8.0 mm, height 2.8 mm, can be adhered to the underside of the respective Speedster cover in accordance with Figure 4, Item B.
4.0 Mount Speedster rear end.
4.1 Open cover until the convertible top compartment lid is completely closed again and the indicator light in the instrument mount is no longer illuminated.
4.2 Dismantle the center section of the windstop (poly glass window) and place into the storage case.
Fitting:
4.3 Mount the left Speedster cover.
4.4 Remove left Speedster cover from the case.
4.5 Remove red deactivation clip from the case and clip onto the mount for the locking hook of the convertible-top latch (above the interior mirror) (Figure 5).
WARNING!
Risk of damage to paint on the Speedster rear end and / or on the rear lid due to incorrect mounting.
> Observe angle when inserting the Speedster cover into the edge of the convertible4op compartment lid.
> Set down the Speedster cover slowly and carefully.
Fitting:
4.6 Insert the profile edge at the underside of the Speedster cover into the surrounding edge of the convertible top compartment lid from the front to the back (Figure 6 arrow A) with the Speedster cover slightly tilted.
4.7 Set down the Speedster cover onto the convertible top compartment lid (Figure 6 arrow B) and insert the lock into the holder. Do not lock however!
4.8 Lead the belt of the contact surface under the rollover bar and route the contact surface past the roll-over bar (Figure 7).
4.9 Align the Speedster cover roughly according to the contours of the convertible top compartment lid and to the left vehicle side.
4.10 Mount the right Speedster cover.
4.11 Remove right Speedster cover from the case.
4.12 Insert the profile edge at the underside of Figure 7 the Speedster cover into the edge of the convertible top compartment lid from the front to the back with the Speedster cover slightly tilted. In doing ensure that the connection side of the left Speedster cover is seated correctly in the U-Profile.
4.13 Set down the Speedster cover onto the convertible-top compartment lid and insert the lock into the holder. However do not lock!
4.14 Lead the belt of the contact surface under the roll-over bar and press the contact surface past the roll-over bar.
4.15 Align complete Speedster rear end symmetrically to the vehicle and lock locks. (Figure 8, Pos. B=locked; Pos. A=unlocked).
4.16 Close Velcro fastening of the belt around the roll-over bar (Pos. C).
4.17 Check that the door frame seal of the Speedster rear end is seated correctly. Correct Speedster rear end if necessary.
4.18 Check the clearance between the side windows and Speedster rear end. If they come into contact with the Speedster cover, shift the lock further outward.
5.0 Dismantle Speedster rear end.
5.1 The Speedster rear end is dismantled according to points 4.3 to 4.16 in reverse order.
5.2 Finally tighten the locks and contact surfaces on the Speedster rear end.
5.3 Tighten screws 5 x 20 on the locks using a torx wrench.
5.4 M6 hexagon nuts on the contact surfaces. Tightening torque: 7.2 Nm (5 ft.lb.).
Fitting:
5.5 To avoid damage to paint, insert the Speedster cover into the corresponding cases.
6.0 Transport the Speedster rear end in the vehicle.
6.1 The Speedster rear end parts can only be stored in the vehicle if the rear luggage compartment is empty.
WARNING!
Damage can be caused to the Speedster rear end and / or the rear end lid during transport of the Speedster rear end in the car due to improper loading.
> Always store the Speedster rear end in the cases when not in use.
> Ensure that the distance between the rear lid and the Speedster rear end positioned on top is sufficient and carefully lock the rear lid.
> Secure the Speedster rear end to prevent it from shifting in the rear luggage compartment.
Fitting:
6.2 First, place the right Speedster cover in the case into the rear luggage compartment in accordance with Figure 9.
6.3 Set the left Speedster cover down laterally reversed onto the right Speedster cover
Working Time
References:
Boxster Technical Manual, Group 6: > Repair: 61 02 19 - "Removing and installing hardtop"
> Technical Information: Group 6, No. 1/97, "Installation of the Holders for Fastening of Hardtop or Speedster Rear End"
> Paint Manual, 4/6/8 cylinder plastic painting
Invalid:
Technical Information, Group 6, No. 12/97, "Installation of a Speedster Rear End (Rear Cover)"
DISCLAIMER