Installation
1.0 Work before painting:1.1 Set the new trunk lid carefully on the spoiler, remove the hexagon-head bolts M6 x 18 (10 x) from the cover trim (underside of the trunk lid) and remove the cover trim.
1.2 Remove the 4 cheese-head screws which fasten the spoiler to the trunk lid and carefully lift the trunk lid away from the spoiler.
1.3 Mask all threads (if necessary also on the spoiler supporting plates) on the trunk lid and the spoiler.
Information:
The supporting plates for the spoiler may not be removed from the new trunk lid, as the fastening screws are securely attached.
Furthermore, the supporting plates are positioned on the trunk lid to provide optimum gap dimensions.
The bracket for the 3rd brake light can also remain attached to the trunk lid.
CAUTION!
Damage or warping can occur to the trunk lid and the spoiler - in the event of improper painting and drying processes.
> Observe the specifications and instructions for the painting of plastics as contained in the Paint Manual.
> During the painting and drying process, place the parts without tension on the painting fixtures provided for this purpose (included in the packages).
1.4 Paint the spoiler lip and trunk lid with spoiler in compliance with material specifications according to the Paint Manual.
2.0 Fit the new spoiler lip (Figure 2, shaded grey) to the front spoiler.
2.1 Remove the crosshead screws from the wheel arch area of the standard spoiler lip.
2.2 Beginning at the middle, and working from the inner to the outer side of the spoiler lip, unclip the locking lugs using a slotted screwdriver.
2.3 Beginning with the middle locking lug, carefully clip the new spoiler lip to the front spoiler.
2.4 Fasten the spoiler lip to the front spoiler using the two crosshead screws at the sides.
3.0 Fit the spoiler to the trunk lid.
3.1 Check the threads of the painted parts for paint impurities and, if necessary, recut using an M6 tap.
3.2 Remove right taillight (Technical Manual, Group 9, Serv. No. 9433).
3.3 Using a pointed-nose pliers, unclip the cable clip, situated at the right in the engine compartment, for the wiring harness of the luggage compartment lid (hereafter referred to as trunk lid) and disconnect the electric plug connection X23.
3.4 Remove the trunk lid without the hinge with the help of a second person (Technical Manual, Group 5, Serv. No. 5590).
3.5 Fit right tail light (Technical Manual, Group 9, Serv. No. 9433).
3.6 Lay the new trunk lid (Item A) carefully on the underside of the spoiler (Item B), position and securely fasten to the spoiler using the microencapsulated cheese head screws M6 x 18 (Item C, see also parts scope).
Tightening torque: 10 Nm (7.4 ftlb.).
4.0 Complete the rear lid and mount it on the vehicle.
4.1 Fit the 3rd brake light.
4.1.1 Feed the 2-pole connector for the 3rd brake light in through the mounting point towards the innerside of the trunk lid and connect to the 2-pole connector of the new wiring harness.
4.1.2 Carefully fit the 3rd brake light on the trunk lid. Ensure that the 3rd brake light is positioned evenly on the gap and that the seal is correctly positioned on the trunk lid. If necessary loosen the bracket for the 3rd brake light and position the 3rd brake light together with the bracket into the slot in the trunk lid.
4.1.3 Fasten the hexagon-head bolts M6 x 18 to the bracket of the 3rd brake light.
Tightening torque: 10 Nm (7.4 ftlbs.).
4.1.4 Position the remaining connectors in the wiring harness at the other connection points on the underside of the trunk lid (see Figure 5).
4.2 Complete the trunk lid.
4.2.1 Fit the new cover trim (Figure 5) to the underside of the trunk lid using the hexagon-head bolts M6 x 18 (10 x) (Technical Manual, Group 5, Serv. No. 5590).
Tightening torque: 10 Nm (7.4 ftlb.).
4.2.2 Remove fan and fan housing (Figure 6, Item A) and the engine compartment light from the old trunk lid and fit in the new trunk lid (Technical Manual, Group 5, Serv. No. 5590).
4.2.3 Remove the air duct (Item B) for the air cleaner from the old trunk lid and fit in the new trunk lid (Technical Manual, Group 5, Serv. No. 5590).
4.2.4 Attach both collars (Item C) for the rubber buffer (Item D) to the bores in the trunk lid.
NOTE
While doing so, be careful not to damage the wedge incorporated into the bores, as this serves as a locking device for the collar! Remove paint runs, if any, from the bores using a pocket knife or a triangular scraper. De-burr the bores if necessary.
4.2.5 After positioning the collar, carefully drive it into the bore using a plastic hammer.
4.2.6 Carefully remove the rubber seal from the old trunk lid and fit in the new trunk lid.
4.3 Mount the new trunk lid on the vehicle.
4.3.1 With the help of a second person, place the trunk lid on the lid hinges and loosely position the old hexagon-head bolts (4 x).
4.3.2 Clip the electric wiring assembly into the cable guide at the right shock absorber and feed in to the engine compartment, to the connector on the right-hand side.
4.3.3. Create a 12-pole electric plug connection.
4.3.4 Position the trunk lid on the trunk lid hinges corresponding to the areas stripped of paint by the screw heads and check the joint dimensions according to the Technical Manual, Group 5.
4.3.5 Fasten the hexagon-head bolts to the trunk lid hinges.
Tightening torque: 10 Nm (7.4 ftlb.).
4.3.6 Remove the upper part of the lock from the old trunk lid and loosely prefit in the new trunk lid.
4.3.7 Adjust the upper part of the lock and fasten securely.
Tightening torque: 10 Nm (7.4 ftlb.).
5.0 Function tests.
5.1 Perform a closing test on the new trunk lid and, if necessary, re-adjust the upper part of the lock.
5.2 Test that the 3rd brake light is functioning. Ensure that all bulbs in the brake light light up.
If it is functioning correctly, clip in the side cap of the 3rd brake light (Technical Manual, Group 5, Serv. No. 5590).
5.3 Switch on the car ignition, connect and switch on the PST2.
5.4 Select vehicle type "911 (996)", read out the error log and, if necessary, delete.
5.5 Function test "Engine compartment purge fan".
5.5.1 Select the menu item "DME control module" and confirm with the >> key.
5.5.2 After reading out the DME control module, select the menu item "Engine compartment purge fan" and start with the F8 key.
5.5.3. Hold a sheet of paper between the spoiler and the engine compartment lid in the area of the ventilation slots.
5.5.4 If the fan is functioning correctly, the sheet should be sucked on to the trunk lid.
5.5.5 Return to the main menu of the PST2, switch off the PST2 and disconnect it from the diagnostic socket.
Working Time
References:
911 Turbo Technical Manual Groups 5/6/9:
> Repair: 5 - Rear body joint dimensions
55 90 19 - Removing and installing rear lid
55 90 37 - Disassembling and assembling rear lid
63 15 37 - Disassembling and assembling front spoiler
94 33 19 - Removing and fitting bulb for taillight
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