Spoiler - Retrofit Procedure
911(996)4/00 6658
Binder - Group 6 - Body
10-6-00
"Carrera" Rear Spoiler
Vehicle Type:
911 Carrera (996) /911 Carrera 4 (996)
Model Year:
As of '99 (X)
Concerns:
Retrofitting
Information
The rigid rear spoiler consists of an upper (wing) and a lower section (grille) and may be fitted on the standard rear lid. A brake light in the wing replaces the two standard third brake lights.
Assembly is possible for coupe and cabriolet. Opening and closing the convertible top is not affected. The rear spoiler has been developed, tested and approved for the following combinations:
Carrera rear spoiler with standard front spoiler;
Carrera rear spoiler with standard front spoiler and side member trim of the aerokit Cup;
Carrera rear spoiler with front spoiler (without lip) of the aerokit Cup;
Carrera rear spoiler with front spoiler (without lip) and side member trim of the aerokit Cup.
Other combinations are not permissible!
The Carrera rear spoiler is also available ex-works for new vehicles under Exclusive option No. XAE.
Information:
The Porsche logo and the part number are visible on the underside of the spoiler after disassembly of the new third brake light.
! WARNING
Damage to the rear spoiler is possible.
> Avoid automatic car washes, wash by hand.
> Do not push vehicle by the rear spoiler.
Part Information:
Materials:
Tools:
Socket wrench, hexagon socket a/f 5
T-wrench, hexagon socket a/f 4
Shop light
Various slotted and crosshead screwdrivers
Hexagon socket wrench a/f 10
Work Procedure:
1. Work before painting.
1.1 Disassemble the Carrera rear spoiler and remove all fittings.
1.2 Mask all threads on the spoiler wing and grille. Mask and tie both plugs of the electrical wiring harness in the spoiler wing.
! WARNING
Damage or warping can occur on the spoiler wing and grille in the event of improper painting and drying processes.
> Observe the specifications and instructions for the painting of plastics as outlined in the Paint Manual.
> During the painting and drying process, properly place the parts (without stress) on the painting fixtures that are provided in the kit.
1.3 Note:
The two-component HS filler must be sanded before the top paint is applied. The paint surface must not be touched without using protective gloves! The cover with Porsche logo is supplied pre-primed (AKZ0 primer 01-69004). Some areas (logo) cannot be sanded, the cover must be treated with a wet-on-wet filler (e.g. Standox non-stop filler-primer) before the top paint is applied. Paint the spoiler wing, grille and cover with the Porsche logo in accordance with the Paint Manual.
2. Preparatory work.
2.1 Remove battery cover, disconnect and cover the battery.
2.2 Remove the lid at the rear (hereafter referred to as rear lid).
2.3 Remove the retractable spoiler with actuating element (Technical Manual, Group 5, Serv. No. 5590).
Note:
The fan and fan housing may remain on the lid. Figure 2
2.4 Remove the standard third brake light from under the rear window. Wrap the 2-pin plug with Styrofoam and fasten it in the cut-out with adhesive tape.
2.5 Engage the cover with the Porsche logo in the cut-out (Figure 2).
3. Assemble the Carrera rear spoiler.
3.1 Connect the 2-pin plug in the spoiler wing cut-out to the new third brake light and fasten the plug connection in the installation slot with adhesive tape. Fasten the brake light in the cutout with the two sheetmetal screws 5 x 16.
Tightening torque: 2 Nm (1.5 ftlb.).
3.2 Stick Terostat tape in the center along the rear edge of the underside of the grille (Figure 3, Item A).
Note:
The tape acts as rattle protection for the grille against the rear lid.
3.3 Feed the electrical wiring harness of the spoiler wing through the large central bore in the spoiler grille and position the spoiler grille on the underside of the spoiler wing (Figure 3).
3.4 Align the spoiler grille with the spoiler wing. Place the right holder (Figure 4, Item A) on the right under- side of the spoiler grille according to Figure 4. Insert the grommet of the electrical wiring harness from the outside into the slot of the holder.
3.5 Position and align the left holder on the underside in the same way. Smear the thread of the M8 x 16 hexagon-head bolts with Loctite, allow to dry for approx. 1 mm. and position on the left holder.
Note:
For assembly after repair work, clean the thread of the M6 x 16 hexagon-head bolts with a wire brush and apply Loctite Green (Type 270) screw locking agent before installation. Screw both holders and the spoiler grille to the spoiler wing with the 4 M8 x 16 hexagon-head bolts.
Tightening torque: 23 Nm (17 ftlb.).
3.6 Clip the electrical lead into two of the self-adhesive wire retainers.
3.7 Stick the wire retainer into the right corner of the spoiler grille.
3.8 Adhere the second wire retainer flush to the edge of the spoiler grille approx. 260 mm from the right corner (Figure 5).
4. Mount the Carrera rear spoiler on the rear lid.
4.1 Insert the oval rubber sleeve of the 2nd electrical wiring harness into the bore of the rear lid.
4.2 Adhere the 3rd self-adhesive wire retainer to the right of the slot (Figure 6, Item A) on the upper side of the rear lid.
4.3 Position the rear spoiler and the rear lid in relation to each other connect the 2-pin plug connection Figure 5 Item B) and push the Styrofoam rattle protection over the plug connection. Clip the electrical lead into the 3rd wire retainer.
4.4 Position and align the Carrera rear spoiler on the rear lid.
Note: Ensure that the electrical wiring harness is not trapped and is fixed in the depression (Item B) of the rear lid by the position of the plug connection with the rattle protection.
4.5 Smear the thread of the 2 x M6 x 12 hexagon-head bolts (Figure 6, Item F) with Loctite. Use the M6 x 12 hexagon-head bolts to pre-mount both flanges (Item E) loosely to the right and left of the rear lid with the depression pointing towards the inside of the lid.
4.6 Smear the M8 stud of both holders with Loctite, insert into the bores of the flange (Item E) and position the M8 hexagon nut (Item G).
4.7 Smear the thread of the 2 x M8 x 35 hexagon-head bolts (Figure 6, Item D) with Loctite and position loosely on the rear lid with the washers 8.4 (Item C).
4.8 Align the rear lid and the rear spoiler with each other and tighten all screws while observing the following tightening torques.
Tightening torques: 8 Nm (6 ftlb.) for the M8 x 35 hexagon-head bolt (Figure 6, Item D)!
9.7 Nm (7 ftlb.) for the M6 x 12 hexagon-head bolts (Item F)
23 Nm (17 ftlb.) for the M8 hexagon nut (Item G).
4.9 Check the gap dimension at the rear side face between the rear spoiler and the rear lid. If necessary, press the rear spoiler gently on to the rear lid and remove the I emerging Terostat tape.
5. Complete the rear lid and mount it on the vehicle.
5.1 Clip 3 cable clamps into the slots on the underside of the rear lid by twisting (Figure 7).
5.2 Lay the electrical lead into the cable clamps towards the fan housing and the right hinge (Figure 8).
5.3 Mount the cover trim (Figure 8, Item C) with 4 of the Figure 7 standard combination screws M6 x 16 (Item A), the spacer sleeve 6.1 x 1.0 (Item B) and the disc A6.4 (Item D) on the underside of the rear lid (Figure 8).
Tightening torque: 5 Nm (3.5 ftlb.)
5.4 Install the engine compartment light.
5.5 Install the rear lid on the vehicle and set the body gap dimensions according to the Technical Manual, Group 5.
6. Function test.
6.1 Connect the battery, install the battery cover and switch Figure 8 on ignition.
6.2 Actuate the brake pedal and have a second person �~ Y check the functioning of the raised brake light.
6.3 Cabriolet only: Open and close the convertible top gradually and have a second person check the clearance (Figure 9, Item A) between the convertible- top compartment lid and the Carrera rear spoiler.The dimension should be at least 5 mm.
Note:
Check the functioning of the microswitch for the engine-compartment lid. To do so, open the rear lid; it must be impossible to open and close the convertible top electrically.
6.4 Read out the control modules with the PST2, if necessary delete the Figure fault memory, enter the radio code and set the time in the instrument cluster.
Working Time:
References:
911 Carrera Technical Manual, Group 5:
Repair: 5 - Body gap dimensions
55 90 37 - Disassembling and assembling rear lid
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