Tonneau Cover - Installation
Boxster8/97
6157
Binder - Group 6
10/16/97
Installation of Tonneau Cover
Vehicle Type:
Boxster
Model Year:
As of 1997 (V)
Concern:
Installation of Tonneau Cover
Information:
Tonneau covers may now be retrofitted on to Boxster vehicles. The cover can be used as a complete cover (parked car) or fitted only to the passenger's side (driving vehicle).
Safety Tips:
The cabriolet top must not be operated with the tonneau cover installed. A deactivation clip can be installed in the top lock latching assembly to ensure the cabrio top is not operated unintentionally.
The driver's and passenger's doors must not be opened with the tonneau cover installed. The Tenax fasteners or tonneau cover could be damaged. Locking the driver's and passenger's door will help ensure this does not happen.
Installation:
Mounting Tenax fasteners to the vehicle and to the dashboard.
E�CW:
- Copy the templates included in this bulletin and cut them out. Templates # 3 and # 4 are used on both the left and right sides. They should be mounted according to the contour of the vehicle.
- Open the cabrio top fully and remove the existing Torx screws (closest to the seats) from the dashboard speaker grills. Replace them with Tenax fasteners (B4.2 X 20).
- Apply the template (1) as shown in figure 2. Mark and drill a 3 mm hole using a suitable angle drill at the point marked on the template.
- Carefully install a Tenax fastener (B4.2 X 20) at this point.
Mounting the Tenax fasteners to the backside of the seat backrest.
- Bring both seats to their most forward position and fold the seatback forward.
- Cut out template (2) for the clothing hook and hang the template over the clothing hook. Make sure the template is hanging vertical. Mark and drill a 3 mm hole in the area marked on the template. Carefully install a Tenax fastener (B4.2 X 20).
Mounting Tenax fasteners below the outside mirrors.
- Cut out template (3). Fold back the outside mirrors and mount the template as shown in figure 3.
Note:
Protect all holes drilled in body panels with corrosion inhibiting paint.
- Mark and drill a 3 mm hole in the area marked on the template. Apply sealer to the Tenax fastener (B4.2 X 20) and carefully install.
Mounting Tenax fasteners to the Cabrio Cover
- Cut out and apply template (4) as shown in figure 4. Mark and drill a 3 mm hole in the area marked on the template. Install Tenax fastener (B4.2 X 10) half way, then remove the fastener and shorten the threaded part of the fastener by approximately 3 mm. Apply sealant to the fastener and reinstall fully.
Mounting velcro fasteners to the under side of the Cabrio Cover
- Open the cabrio cover until it is at a 450 angle. Protect the cabrio top fabric at this time.
- Make 8 hole markings at equal increments on the - underside of the top cover. The marks must be 35 mm from the outside edge of the top cover and must start at the area shown by the white arrow in figure 5.
- Using a 3.2 mm drill bit, drill the 8 holes for the velcro fasteners. Caution:
Restrict the depth of the drill bit to 5 mm to avoid damaging the outer skin of the Top Cover.
- Mount the velcro fasteners using a 3.2 mm pop L rivet.
Fitting the Tonneau Cover
- When fitting the tonneau cover proceed as follows:
Cabrio top in the open position.
Cabrio top cover open at a 45° angle. Windstops between the seats removed. Both seat forward with the seat backs in normal position.
- Fit the tonneau cover over the passenger compartment. The metal hooks of the tonneau cover are situated at the underside of the cabrio top cover (figure 6, black arrow). Any excess material is folded and secured to the velcro fasteners (figure 6, white arrow).
- Close the cabrio top cover and straighten the tonneau cover for a smooth fit.
- Open the velcro and zippered panels in the area of the roll bar and slide the tonneau cover over, then close the velcro and zipper panels.
Mounting the Tenax fasteners to the tonneau cover
- Stretch the tonneau cover forward towards the Tenax fasteners at the speaker grills. Mark the position on the tonneau cover make a 10 mm hole with a suitable punch. Install the companion Tenax fastener to the tonneau cover and fasten it to the Tenax at the speaker grill. Repeat this procedure for the other side.
- Fasten the safety belt with hook to the underside of the dashboard and close the zipper between the Driver's and Passenger's side (figure 7).
- Stretch the tonneau cover forward towards the center of the dashboard and mark the position of the Tenax fastener near the passenger compartment monitor. Make a 10 mm hole with a suitable punch. Install the companion Tenax fastener to the tonneau cover and fasten it to the Tenax fastener.
- Mount the remaining Tenax fasteners in the following order:
Outside mirrors, left and right.
Cabrio Top Cover, always mount one side first before completing the other side. Close all remaining velcro and zipper openings. Insert deactivation clip at the top latch mechanism (figure 8).
Lock the doors.
Note:
To allow for proper fit Porsche recommends leaving the tonneau cover installed on the vehicle for several hours. Please inform your customers accordingly and provide them with this information.
Driving with the Tonneau Cover installed
- The passenger side can be opened or closed. Open the zipper that separates Driver's and Passenger's side. Unlatch the Tenax fasteners at the dashboard and outside mirrors.
- Open the velcro and zipper part of the tonneau cover in the area of the rollbar and place the velcro cover between the rollbar and cabrio cover in such a manner that the windstop can be snapped in place (figure 9).
- Bring the seat backrest forward and fold the tonneau cover so it can be fastened to the Tenax fastener on the backside of the seat backrest (figure 10). If the vehicle is driven with the Tonneau cover partially installed be sure the safety belt is left installed.
Tonneau Cover removal
- Removal is reverse of installation. Fold the tonneau cover and store it, along with the deactivation clip in the provided storage bag. Install caps on the Tenax fasteners.
Parts:
986 561 985 00 Tonneau Cover with storage bag and installation kit.
Spare parts:
986 561 983 00 Cover with velcro fasteners.
986 561 984 00 Storage bag.
999 591 597 02 Tenax fasteners B4.2 X 10 (Qty 6).
999 591 608 17 Tenax fasteners B4.2 X 20 (Qty 3).
911 561 529 00 Tenax caps(Qty 9).
986 504 986 00 Deactivation clip.
N/A 3.2 mm pop rivets.
Installation Time:
180 T.U. Labor Operation Number 61 57 23 00