Interior - Noises from the Dashboard Area
911 (996)1/00
7018
Binder - 7, Body Interior
6-30-00
Noises In The Dashboard Area
Vehicle Type:
911 Carrera (996) /911 Carrera 4 (996)
Model Year:
As of 1999 (X)
Concern:
Noises in the dashboard area.
Information:
The following information contains the most up to date specifications for repairing complaints of noises in the dashboard 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.
Parts information
Work Procedure:
Refer to figure 1 for the listed numbers associated with the noises. In order to remedy noises in the dashboard, the following covers and components should be removed only if necessary.
Passenger footwell bulkhead:
Undo the 2 slotted screws and pull down.
Right and left side vents:
Right:
Pull off the lower collar and unscrew the torx screw on the left in the depression. Unscrew the 2 torx screws on the outside. Pull the side vent to the rear.
Left:
Pull out the button for the light switch as far as it will go. Then press in the locking element on the lower side with a small screwdriver. Unscrew the 3 torx screws (one is hidden where the light switch knob goes) and pull the vent to the rear. Unplug the light switch.
Air ducts to the side vents:
Unscrew the crosshead sheetmetal screw in the plug-in area of the side vent on the side are duct. Pull off the two part air duct.
Passenger's airbag:
Remove ignition key. Disconnect the battery and wait one minute before airbag removal. Unscrew the airbag unit from below (2 hexagon head bolts). Pull the unit out towards the passenger seat. Pull off the electrical lead. Lay the removed airbag unit aside with the airbag opening facing upward.
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.
Dashboard speakers:
Unscrew the Torx screws, lift out the speaker and unplug the connector.
Alarm readiness cover:
Lift up the cover and unclip it to the rear.
Defroster covers:
Remove A-pillar trim. Lift and unclip defroster covers.
Instrument cluster:
Remove the hazard warning light switch button. Remove the hazard warning light switch. Remove the cover on the right side. Unscrew the torx screws that are behind the removed cover and emergency flasher switch. Lift the instrument cluster up and unplug the electrical connections.
Complaint:
Noise in areas 1 and 2 - Rattling and or crackling noises from the dashboard.
Cause # 1:
Loose electrical leads under the dashboard, e.g. leads to the passenger compartment temperature sensor, light switch and/or the loud speakers. The leads are touching the surrounding accessories, e.g. heater blower, air duct, or the dashboard itself.
Repair:
Wrap the loose electrical leads with foam or sponge rubber tape, then tie-wrap the wires back. See figure 2.
Cause # 2:
Air duct to the side vent is in contact with the heater blower or the rivets of the knee protection reinforcement bar.
Repair:
Stick felt/sponge rubber strips on the contact points between the air duct and the heater blower or other components (See arrow on figure 3). Stick felt or sponge rubber strips (approx. 35x25 mm) over all the rivets of the knee protection reinforcement bar (See figure 4. A - rivet covered, B - rivet not covered).
Note:
On leather covered dashboards, the leather covers the rivets, therefore insulation strips are not necessary.
Complaint:
Noise in area 3 - Clicking and/or crackling noises in the area of the air ducts & side vents.
Cause:
Foam seal on the plug-in areas of the air duct and the side vents has shifted (See arrow in figure 5).
Repair:
Stick felt tape over the existing foam seal in the plug-in areas, overlapping the bottom edge by approx. 2 to -mm (See arrow in figure 6). Make sure the operation of the air flap is not restricted.
Note:
Introduced 10-01-99 in production.
Complaint:
Noise in area 4 (A) - Clicking and/or crackling noise in the side vents.
Cause:
Side vents loose between upper and lower section. Clip connections are loose.
Repair:
Press the upper and lower sections of the side vent together and stick the clips together with a hot glue gun. Ensure that only a little adhesive is applied, as otherwise noise from chafing is possible (see arrow in figure 7). Stick felt strips over the adhered points in the inner connection area, which touch the dashboard.
Note:
Introduced 10-01-99 in production
Complaint:
Noise in area 4 (B) - Clicking and/or crackling noise in the side vents at the top.
Cause:
The upper edge of the upper securing clip is chafing on the installed side vent.
Repair:
Replace old style clip (999 507 533 02), with new style clip (999 507 476 01). The new style clip has narrower contact areas. See figure 8.
Note:
Introduced 10-01-99 in production.
Complaint:
Noise in area 5 - Creaking and/or rattling noises on the panel for passenger's airbag.
Cause:
The contact surface of the dashboard where the passenger rests is rubbing. (missing or damaged felt strips). Pretension of the panel is too low against the dashboard opening.
Repair:
Check the Contact surface for the airbag panel (see arrow in figure 9). If the insulation strips are missing, loose, or have slipped out of position, apply new narrow felt tape strips. See figure 9. While tightening the fastening screws for the airbag unit, have the panel of the passenger's airbag pressed forward evenly by a second person. This will ensure that the panel is under even tension after tightening the bolts.
Notes:
1. Do not stick the felt strips to the airbag unit.
2. Do not twist the pivot axis of the airbag panel. Slight even pressure must be applied to the airbag when installing it.
3. Lightening torque of the airbag bolts is 20 Nm (15 ftlb.)
Complaint:
Noise in area 6 - Creaking and/or rattling noises on the "defroster cover" cover.
Cause:
Contact surfaces of the defroster cover rubbing where it meets the A-pillar trim and the dashboard.
Repair:
Apply felt strips to the contact surface of the defroster cover touching the A-pillar trim. If the felt strips are already present, check them for correct positioning (see arrows in figure 10) and correct if necessary. Check contact points on the under side of the defroster covers. If necessary apply new felt strips. See figure 11.
Complaint:
Noise in area 7 - Creaking and/or crackling noises in the loudspeakers.
Cause:
The alarm readiness cover, at its front bevel, is in contact with the windscreen.
Repair:
Stick a felt strip approx. 5mm wide on the lower edge of the front bevel. Make sure it's low enough So it can't be seen. See figure 12.
Complaint:
Noise in area 8 - Clicking and/or crackling noise in the loudspeakers.
Cause:
Loose connection between the upper and lower speaker housing sections.
Repair:
Glue the upper and lower sections together at the joint with the hot glue gun. See figure 13.
Compliant:
Noise in area 9 - Leather equipment - Creeking noises caused by installed components rubbing on the leather. Example; side vents, passenger's airbag, speakers, and instrument cluster.
Cause:
Creaking noises are caused by the movement of the leather components. The leather trim is cut too long and overhangs in the openings.
Repair:
Check the leather trim in the areas of the cut-outs for the individual components. The contact surfaces of the fastening points (plastic plug-in nuts) and the lateral passage must be free of leather. If necessary, cut back the leather in the shaded area indicated in figure 14.
Note:
1. The contact areas for the accessories must not be trimmed. Take note of the field of vision.
2. Figure 14 shows the view for the right side vent.
Complaint:
Noise from area 10 - Creaking noises due to relative movements of individual installed components. Example; side vents, passenger's airbag, speakers, instrument cluster mounting, and center console.
Cause:
Loose fastening screws due to the settling behavior of the plastic plug-in nuts in the dashboard.
Repair:
Tighten the fastening screws, if necessary replace plastic plug-in nuts. See figure 15.
Notes:
Plug-in nut, pink - 999 920 015 40
Plug-in nut, blue - 999 920 012 40
Work Procedure:
After repairing the presumed noise sources, install all removed parts, e.g. instrument mount, defroster covers, alarm readimess cover, passenger's airbag, air ducts, side vents and speakers. Connect the battery and enter the radio code if necessary. Road test the vehicle.
Note for reassembly of panels. If the interior panels have to be removed, make sure the clips that hold on the interior panels (A-pillar, C-pillar, etc.) are replaced before reinstalling them. Reusing the old clips on the vehicle may lead to new noises. Install a new yellow clip (A) part number 999 507 479 09 on the interior panel. Then install the Tricot insulating tape (B) part number 999 551 134 40 over the clip. See figure 16.
Labor:
Reworking cut-outs (trimming leather back) for components in area 9.
Literature:
911 Carrera (996) Technical Manual, Groups 6 and 7.
69 Safety regulations for airbag vehicles.
69 59 19 Removing and installing the passenger's airbag unit.
70 18 37 Disassembling and assembling dashboard.
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