Campaign - XE Relay Socket Receptacle Replacement
Boxster6/04 W423
Date: 9-3-04
Binder - 9, Electrics
W423 - Flat Receptacle of XE Relay Socket
(Workshop Service Action)
Vehicle Type:
Boxster (986) / Boxster S (986)
Model Year:
M.Y. 2004 (4)
Concern:
Flat Receptacle of XE relay socket.
Information:
This is to inform you of a voluntary Workshop Service Action on certain 2004 model year Boxster (986) and Boxster S (986) vehicles. Wiring Harnesses with a faulty flat receptacle were installed in the relay socket of the "terminal XE" relay on the Porsche Boxster and Boxster S for model Year 2004. This can lead to a loose contact which can cause malfunctions in fog lights, seat heating and cigarette lighters.
Therefore, we ask that the flat receptacle on the affected vehicles listed below be replaced during the Porsche Owner's next visit to your workshop.
Affected Vehicles:
A total of 97 U.S. and 11 Canadian vehicles fall within the scope of this Service Action.
Very Important!
Not every vehicle in the below listed range may be affected. Use the ranges below as a general guideline. Refer to Attachment "A" to determine if a particular vehicle is eligible for this service action. Alternatively, the VIN can be checked in the Porsche e-DCS/WWS for confirmation of an open service action.
The affected Vehicle Identification Numbers are contained in the VIN Ranges shown.
Work Procedure:
See Attachment "B"
Time Allowance:
Parts Information:
Tools:
Flat screwdriver (medium)
Torque wrench 0-30 Nm (0-22 ft-lb.)
1/4" ratchet with extension
A/f 10 socket
Shop light
Wiring harness repair kit, Porsche Set No. 960000 and pliers No. 960011
Side cutters
PIWIS Tester
Attachment "A" VIN List
Attachment "B"
Work Procedure:
Replace flat receptacle in relay socket of relay carrier.
1. Disconnect battery as described in the Technical Manual, Group 2, Chapter 27 06.
2. Remove cover from fuse box in driver's footwell.
3. Remove trim under the dashboard on the driver's side (Figure 1, Item B), to do this, undo 4 screws (Figure 1, Item A) and remove from the fuse box.
4. Undo fastening nut of relay carrier (Figure 2, Item A) using a/f 10 socket and remove.
5. Unlock relay carrier on holder (Figure 3, Item A) using a flat screwdriver, unclip, and set aside.
6. Pull off time relay from relay socket No.8 (Figure 4, Item A) and unit relay from relay socket No. 9 (Figure 4, Item B).
7. Turn relay carrier as shown in Figure 5, set aside, and cut through the 3 tie-wraps of the wiring harness (Figure 5, Item A) with side cutters and remove.
8. Turn relay carrier as is shown in Figure 6 and set aside.
9. Unlock relay socket No. 8 (Figure 6, Item A) and remove from the relay carrier, then mark relay socket No. 9 (Figure 6, Item B) with a colored mark or adhesive tape, unlock, and also remove from the relay carrier.
10. Uncover relay socket No. 9 (Figure 6, Item B) from the wiring harness of relay carrier. fig 6
11. Press out plug contact (Figure 7, Item A) of chamber 3 (terminal 30) of relay socket No.9 out of the relay socket using press-out tool.
12. Cut off flat receptacle (Figure 8, Item A) of plug contact of chamber 3 (terminal 30) using side cutters.
13. Strip approx. 5 mm from the wire.
14. Crimp new flat receptacle part No. 000.043.206.10 (Figure 8, Item A) to the wire with pliers No. 96 0 011 from the wiring harness repair kit, Porsche Set No. 96 0 000.
15. Engage plug contact (Figure 9, Item A) into relay socket No. 9 chamber 3.
16. Turn relay carrier and set aside as is shown in Figure 10.
17. Clip in marked or labeled relay socket No. 9 (Figure 10, Item B) in relay carrier, then clip in relay socket No.8 (Figure 10, Item A) in relay carrier.
18. Turn relay carrier, set aside as shown in Figure 11 and fasten the wiring harness to the cable guides of the relay carrier using 3 tie-wraps (Figure 11, Item A).
19. Turn relay carrier.
20. Connect time relay to relay socket No. 8 (Figure 12, Item A) and unit relay to relay socket No.9 (Figure 12, Item B).
21. Clip in relay carrier to holder (Figure 13, Item A).
22. Fasten relay carrier using fastening nut (Figure 14, Item A).
23. Fasten trim under dashboard on the driver's side (Figure 15, Item B) using 4 screws (Figure 15, Item A).
24. Attach cover from fuse box in driver's footwell.
25. Reconnect battery as described in the Technical Manual, Group 2, Chapter 27 06.
26. Carry out work instruction after disconnecting the battery as described in the Technical Manual, Group 9.
27. Carry out function test for fog lights, seat heating, cigarette lighter, and headlight washer.
28. Enter the service action into the Warranty Maintenance Booklet
Warranty Info:
Parts Information:
Labor Operation:
Will automatically be inserted along with the part number when the damage code is entered.
Damage Code:
W423 066 000 2
Reference:
Boxster Technical Manual
> Group 2, Chapter 27 06 - Battery R & R
Disclaimer