Sliding Roof - Noises
911 (996)12/98 6040
Binder - 6/7 Body
Date: 10-15-98
Work on the Sliding Roof
Vehicle Type:
911 Carrera (996)
Model Year:
as of '99 (X)
Equipment:
Vehicles with sliding roof - M 650.
Concerns:
Work on the sliding roof.
Situation:
Noise problems and elimination.
Information:
This Technical Information provides extended specifications for work on the sliding roof and recommendations for eliminating noise problems. New text about "Work on the sliding roof", as well as text which has been revised from previous publications, is marked on the side.
General:
Before beginning the work a test drive should be carried out, with the customer if possible, in order to locate the noise problems and to determine the type of noises. While doing this, move the sliding roof into different positions (closed and open in several positions).
Required Materials:
Part Number Description
964 555 565 OO Felt strips - piece goods, enough for several vehicles.
Procedure:
Removing sliding roof panel, sliding/tilting roof trim and inner panels:
Remove and install sliding roof panel (Figure Item A), sliding/tilting roof trim (headliner flap, Figure Item C) and inner panels as described below (see also Technical Manual "911 Carrera 996" Group 6, from Page 60 2).
Warning:
Damage to rear water drainage channel or to the sliding roof mechanism when the sliding roof panel is removed and when moving the trim of the sliding/tilting roof. The sliding roof frame must not be moved to the "Open" position when the sliding roof panel has been removed. The trim of the sliding/tilting roof must be shifted without the use of force.
Removing sliding roof panel:
- Open sliding roof panel approx. 80 mm.
- Disengage trim of sliding/tilting roof out of the left and right- hand mounting brackets (drivers) by pressing it towards the rear, and push back by approx. 30 mm.
- Close the sliding roof panel and move to tilting position. Push trim of sliding/tilting roof evenly as far as it will go without tilting it.
- Move the sliding roof panel to zero position (closed).
- Unscrew the four fastening screws T25 M5 x 8 from the sliding roof panel and remove the sliding roof panel.
Removing sliding/tilting roof trim:
- Pull trim of sliding/tilting roof forward until the front edge (Figure 2, Dimension X) stands approx. 30 mm behind the front roof cut-out edge.
- Disengage left and right inner side panels (Figure 2, arrow).
- Pull out the connector springs (Figure 3, arrow d) on the gate at one side and pull out the sliding/tilting roof trim upwards on this side.
Removing left and right inner panels:
- Push the sides of the inner panels out of the sliding roof frame inwards to the center of the vehicle (Figure 4, arrows). Note: Only necessary if inner panels are being replaced!
Check the bottom of the removed sliding roof panel for pressure marks or chafing damage. If there are pressure marks or chafing damage, check the top side of the removed sliding/tilting roof trim for projecting threaded pins, missing felt strips or loose pieces of foam rubber.
Possible causes may include:
- Threaded parts - Figure 5, arrows 1: Threaded pins too long, touching the sliding roof panel.
- Support points - Figure 5, arrows 2 + 3: Felt strips missing or damaged.
- Insulation - Figure 5, arrows 4: Pieces of foam rubber loose or missing. There are nine pieces of foam rubber altogether on the top side of the sliding/tilting roof trim.
Remedy:
- File down threaded pins 3.0 mm, Figure 5a) so that they are flush with the nuts (a/f 5.5 mm). In most cases, only threaded pins in the front area (left/right) on the inside touch (Figure 5a) the sliding roof panel and must be reworked.
- Replace felt strips part number, 964 555 565 OO Dimensions: Items 2 and 3, 15 x 15 mm.
- Stick back on loose pieces of foam rubber.
Note:
The pieces of foam rubber are not available from Porsche Parts. Replace missing parts with commercially available pieces of foam rubber (triangle profile) if necessary. Dimensions: height 7.0 mm, length approx. 80 mm.
Possible causes may include:
- Side clearance of the sliding/tilting roof trim too small making it difficult to move - Figure 6, arrows 5.
Remedy:
- In order to allow sufficient clearance (smooth operation) for the sliding/tilting roof trim, file down the mounting tabs (left/right, Figure 6, arrows 5) to the rib width of 2.0 mm (see Figure 6a).
- Support points - Figure 7, arrows 6 + 7:
Felt strips on the mounting brackets (left/right) missing or damaged.
- Noise insulation - Figure 7, arrow 8:
Sleeve (hose) of mounting bracket (left/right)
moved, damaged or missing.
- Support points - Figure 7, arrows 2 + 3:
- Replace felt strips part number,
964 555 565 OO Dimensions: Item 6, 20 x 15 mm, and Item 7, 20 x 6 mm.
- Fit sleeve correctly (Figure 7, arrow 8).
- Replace missing or damaged sleeve with commercially available shrink-fit hose (inner diameter 4.0 mm, length 20 mm).
- See description, Figure 5.
Possible causes may include:
- Noise insulation - without diagram: Sleeve (hose) of the gate - connector springs for installation (left/right) damaged or missing.
Remedy:
- Fit sleeve correctly. Replace missing or damaged sleeve with commercially available shrink-fit hose (inner diameter 3.0 mm, length 20 mm).
- Support points - Figure 8, arrow:
Felt strips as support (left/right) for the wind deflector which is set down (sliding roof panel closed) are missing.
- Stick felt strips part number,
964 555 565 00 (dimensions 20 x 12 mm) on left and right (Figure 8, arrows).
Note:
The felt strips must project at the sides by approx. 2.0 mm over the support edge of the wind deflector (F) when the wind deflector is set down.
- Rear water drain - Figure 9, arrows 10+11: Water drain (left/right) touching roof.
- Affix felt strips part number, 964 555 565 00 (dimensions 25 x 25 mm) to the left and right hand sides between the roof and the attached water drainage hose (Figure 9, arrow 10).
- In order to do this, the C-pillar trim on the left and/or right side must be removed (see Technical Manual "Repair" Group 7, from Page 70 - 51), and the inner roof trim (headliner) in the area of the rear window upper edge must be removed by pushing it backwards.
- Rear water drain - Figure 9, arrows 11: Water drain edge (left/right) touching roof.
- File the side edge on the rear water drain (left/right - Figure 9, arrow 11) into an angle with a narrow flat file.
Installation:
Installing left and right inner panels:
- Push the sides of the inner panel into the groove of the sliding roof frame. You should now be able to move the inner panel smoothly. If not, the inner panel is not correctly engaged.
Installing sliding/tilting roof trim:
- Insert the sliding/tilting roof trim into the roof cut-out from above tilted to one side, and thread the inner panel into the trim on this side. The other side of the sliding/tilting roof trim lies on the gate. Pull out the connector spring on this side of the gate (Figure 11, arrow d) and insert the sliding/tilting roof trim downwards by the side of the spring. Thread the inner panel and lower the trim.
^ Position the sliding/tilting roof trim with the front edge approx. 80 mm (Figure 12, dimension X) behind the front roof cut-out edge.
- Engage the inner panel at the left and right sides into the support tab of the sliding/tilting roof trim (Figure 13, arrow).
- Push trim of sliding/tilting roof evenly as far as it will go to the rear without tilting it.
Installing sliding roof panel:
Note:
Install sliding roof panel in the sliding roof frame in zero position (closed).
- Push the gate (Figure 14, arrow D, left/right) backward (clearance compensation approx 2.0 mm).
- Put on sliding roof panel and push forward. Position T25 MS x 8 fastening screws and tighten the screws slightly.
- Adjust sliding roof panel in line with the roof contour (Figure 15).
Front dimension A = 0 to -1.0 mm lower.
Rear dimension B = 0 to +1.0 mm higher.
DV Front roof contour.
DH = Rear roof contour.
- Tighten fastening screws T25 M5 x 8. Tightening torque: 6 Nm (4.5 ft lb.)
- Move sliding roof to lifting position. Pull sliding/tilting roof trim forward evenly until a distance of approx. 40 mm to the roof cut-out edge is reached.
- Check that the side inner panels (left/right) are engaged.
Note:
The following procedure must be carried out for inner panels which are damaged or have disengaged from the groove of the sliding roof frame: Remove sliding roof panel and sliding/tilting roof trim again. Press inner panel concerned back into the groove of the sliding roof frame or replace damaged panels. Install sliding roof panel and sliding/tilting roof trim again.
- Close the sliding roof panel (zero position).
- Push sliding/tilting roof trim forward as far as the roof cut-out edge. While doing so take care not to push trim of sliding/tilting roof upwards. This could disengage and/or damage the inner panels.
- Open sliding roof panel approx. 80 mm. Pull trim of sliding/tilting roof forward until the left and righthand mounting brackets (drivers) engage. Close sliding roof panel.
Function test:
- Move sliding roof panel to lifting position. The rear edge of the sliding/tilting roof trim must now lie slightly against the sliding roof panel.
- Close the sliding roof panel (zero position). The trim of the sliding/tilting roof must lie against the clamping frame of the roof lining on the front, right and left with a slight degree of pre4ension. The trim of the sliding/tilting roof must not lie against the rear cross bar of the roof lining. A gap of approx. 0.5 mm (check card thickness) must be left, otherwise rattling noises can occur. Pull the clamping frame of the roof lining slightly downward at the back if possible.
Do not leave a gap between the rear cross member and the sliding/tilting roof trim in vehicles with a fully coated (flocked) clamping frame.
- Carry out a test drive with the vehicle.
Working Time:
Labor Operation Description Time Units
60 40 19 06 Removing and installing sliding roof 80 TU
panel, sliding/tilting roof trim and inner
panels:
Includes: Adjusting sliding roof panel.
References:
911 Carrera (996) Technical Manual, Group 6:
Technical Information:
Group 6, No. 1/97, Pages 6 - 3/ 6 - 4.
Repair: 60 40 19 - Removing and installing sliding roof panel.
You will receive the most up-to-date revised text with the next supplement.