Work Procedure
1. Preparation1.1 Remove spare tire.
1.2 Remove battery cover. Disconnect and cover the battery.
1.3 Remove standard amplifier and disconnect both plug connections. Fit the new amplifier onto the holding bracket of the original amplifier.
1.3.1 Only for 911 Carrera 4 (996)
Cut off the right tab (view from above) of the upper and lower holder (amplifier). Deburr cut edges and treat with corrosion protection.
1.4 Remove CD changer (if so equipped).
1.5 Remove both door panels and loudspeakers (Figure 1) (Technical Manual, Group 5, Repair Group 5751).
1.6 Remove original bass loudspeakers from both door trim panels.
1.7 Unclip loudspeaker covers from both door trim panels (Technical Manual, Group 7, Repair Group 7059).
1.8 Replace the clips (color: white) in both door panels (9 ea. per door) with the new clips.
1.9 Remove both loudspeakers from the dash panel (Figure 2) and disconnect plug connection (Technical Manual, Group 7, Repair Group 7018).
2.1 Connect both plug connections to the new amplifier.
Note:
The large 20-pin plug may have to be inserted at a 180° angle in certain circumstances.
Install amplifier back into it's original position in the luggage compartment.
Note:
Ensure adequate cooling by allowing at least 5 mm distance between the amplifier and the carpet lining.
2.2 Wrap adhesive tape around the power supply wires, RE; 6.02 and BK; 6.02 up as far as the grommet (Figure 3, Item B) on the firewall plus 5 cm beyond it.
2.3 Connect power supply.
2.3.1 Make a hole in the carpet lining next to the amplifier just large enough to accommodate the wires (Figure 3, Item A).
2.3.2 Remove grommet from the firewall, (Figure 3, Item B) and cut on the lower side.
2.3.3 Route the wire through the hole in the carpet and the grommet in the firewall. Install the grommet with the wires into the firewall. Fix wires to the firewall using a tie-wrap or adhesive tape. Seal the wire passage (Figure 3, Item B) with adhesive sealer, part number, 999 915 40040 on the battery side.
2.3.4 Wrap the support bar with 50 mm of adhesive tape as shown (Figure 4).
2.3.5 Partially assemble fuse holder and connect the side with the red positive lead 6.02, to the positive terminal of the battery.
2.3.6 Trim the positive lead 6.02; color: red, of the wiring harness to the fuse holder and secure in the gold-plated bushing (second half of the fuse holder) with the hexagon socket head bolt.
2.3.7 Screw the fuse holder together and use a tie-wrap to fit it onto the support bar that was wrapped with adhesive tape in step 2.3.4 (Figure 4).
2.3.8 Crimp the cable lug A6 to the ground lead 6.02, color: black, and secure the ground lead to the firewall at the ground point beside the battery.
3.1 Align and attach the supplied templates on the inner side of the door panels (Figure 5).
Note:
Observe the inscriptions on the templates.
3.2 Transfer the templates cut lines onto the door panels.
3.3 Trim the door panel along the mark with jig saw. Then deburr the cut edge with a file.
3.4 Put door trim panel (without loudspeaker) onto the inside of the door and check trim. There must be sufficient space for both bass loudspeakers, 160 mm.
3.5 Make a hole for the fastening clip in the small insulating mat, as shown in Figure 6, Item A.
!DANGER!
Danger (death/serious injury to driver or passenger) in the case of incorrect deployment of the side airbag.
> For vehicles with side airbags, the cut-out for the side airbag (Figure 6, Item B) must be removed before sticking on the large insulation mat.
3.6 Only vehicles with side airbag: Stick supplied insulation mats onto the inner side of each door panel (Figure 6). They are marked left and right.
3.7 Check correct seating of both sheetmetal nuts on the door (Figure 7, Item A) for fastening of the door trim panel. Clip a sheetmetal nut into the slot available in the door (Item B).
4.1 Position the door trim panel on the door, aligning the lower edges.
4.2 Bolt the front of the door trim panels (Figure 8, Item A) using 2 sheetmetal screws 4.2 x 60.
4.3 Insert the sheetmetal screw 4.2 x 70 on the bottom of the rear loudspeaker cut-out (Figure 8, Item B) and tighten hand tight only.
!WARNING!
Potential for damage to components in the door and the door trim panel from the drill chuck or drill bit while drilling.
> Mask drilling area and use a power drill with bit stop.
> Carefully carry out drilling and avoid too much pressure.
4.4 Carefully drill a 4.5 mm hole above the rear loudspeaker (Item C); using the door trim panel bore as a guide.
4.5 Fasten speaker housing to door trim panel at Item C with an M4 x 40 screw and sheetmetal nut. Tighten the screw beneath the loudspeaker cut-out (Item B).
Note:
If the cut-out in the inside of the door and the positions of the fastening points in the door trim panel overlap in an unfavorable manner, the door trim panel can alternatively be fastened at Figure 8, Item D with screws and nuts.
4.6 Check the gap dimensions of the door trim panels against the inside of the doors and retighten all screws.
5.1 Affix electric wires to the bass loudspeakers with adhesive tape or tie wraps.
5.2 Connect wires to the bass loudspeakers and fit into the door trim panel, with the connections towards the front (in the direction of travel).
5.3 Gently bend the lower tabs (Figure 10, Items A and B) on the loudspeaker grille outwards. Gently bend the side tabs (Items C and D) inwards. The grille should be gently bulge outwards overall in order to increase the contact pressure when screwing it on.
5.4 Affix plastic spacer (Item E) on the back of the loudspeaker grille or on the door trim panel using adhesive.
5.5 First clip the loudspeaker grille into the door trim panels with the lower tabs. Center loudspeaker grille and tilt towards door trim panel. While tilting, insert the side tabs into the door trim panel.
5.6 Bolt the loudspeaker grille on the top side with the door trim panel (Figure 11).
Note:
The entire surface of the loudspeaker grille should not rock when fitted.
5.7 Clean bonding surface (Figure 11, inset). Let dry, then stick on the PORSCHE logo (Do this at room temperature).
6.1 Connect wires to the new midrange loudspeakers.
6.2 Insert midrange loudrange speakers into the dash panel, tilting back as they are inserted.
6.3 Secure the midrange loudspeakers with screws, observing gap D dimensions.
7.1 Remove standard rear loudspeaker (Technical Manual, Group 7, Repair Group 7075).
7.2 For the Cabriolet, attach the crossover network to the back of the speaker using a hot glue gun (A, Figure 12). Then cover the assembly with a piece of insulating material (B, Figure 12).
7.3 For the Coupe, wrap the crossover network with the insulating material. Then insert the crossover networks into the loudspeaker cut-out and affix between the side-panel lining and the body wall so that it is protected from impacts and chafing.
7.4 Fit mid/high range loudspeakers with the standard screw
8.1 Install CD changer (if so equipped).
8.2 Connect battery and set clock.
8.3 Input radio or PCM code, if necessary.
8.4 Check the function of all the individual loudspeakers, using the balance (left/right) and fader (front/rear) controls on the radio.
8.5 Ensure the LED on the amplifier is lit during the function test.
8.6 Reinstall trim panels in the luggage compartment.
8.6.1 Only for 911 Carrera 4 (996)
It may be necessary to trim the plastic grille (above the new amplifier) as shown in Figure 13 for it to fit properly.