Overhaul
Disassembling And Assembling Door
Disassembling door
WARNING: Danger of injury if side airbag units in the door are triggered while ignition key is not removed!
- Always remove ignition key during body work, and do not commence adjustment work until a waiting period of at least 1 minute has elapsed!
- The ground strap of the battery must be disconnected during work on the airbag system and alignment bench work within the framework of body repair!
CAUTION:
- Damage to the bowden cable when removing door trim panel! Damage by bending the bowden cable at the hook!
- Pull the hook out of the end piece only after installation in the inner door release!
- Damage to plug connection lugs during door removal! Damage to lugs when pulling the plug connection out of the A-pillar!
- The locking element at the bottom part of the plug connection must be pulled out before the plug connection is disconnected!
- Danger of material damage if the door lock is installed incorrectly! Malfunctions in the alarm system!
- The door lock should be installed only when the actuating lever is in basic position!
NOTE:
- The door trim parts must be removed before removing the parts inside the door!
- Follow the special instructions on installation and adjustment for assembly of the door.
1. Remove mount
1.1. Undo the M6 x16 hexagon-head bolt and remove the mount.
2. Unclip and disengage the bowden cable
2.1. Disengage support frame -arrow D- upwards.
2.2. Unclip bowden cable -arrow B- from the door lock.
2.3. Swivel bowden cable by 90 ° -arrow B- and pull it out of the actuating lever -arrow A-.
3. Disconnect connection piece
3.1. Move connection piece -A-.
3.2. Press -C- downwards.
3.3. Press the connection piece -B- upwards and separate from each other.
4. Remove door handle and bottom part of door
4.1. Remove collar nuts M6.
4.2. Separate bottom part of door handle from door handle and remove.
4.3. Press electrical plug connection off microswitch -A- and disconnect.
4.4. Unclip on the base of the electrical lead -B-.
5. Remove door lock
5.1. Undo micro-encapsulated Torx screws T40 M8 x 14.
5.2. Disconnect the electrical plug connection. To do this, press the locking lug -A- on the plug connection and separate in the direction of the arrow -B-.
5.3. Pull door lock with actuating motor unit out of the door.
6. Remove door window
6.1. Undo Torx screws T 30 on the clamping pieces of the power window unit.
6.2. Pull door window out of the door channel.
7. Remove power window unit
7.1. Disconnect the electrical plug connection.
7.2. Undo collar nuts M6 from the power window unit.
7.3. Pull the power window unit downward out of the door opening.
8. Remove door brake
8.1. Unscrew Torx screw M8 -A- from the A-pillar.
8.2. Remove collar nuts from the door brake.
8.3. Pull out the door brake towards the inside.
8.4. Remove the seal.
9. Remove door seal on outside
9.1. Press out clip -A- with a plastic spatula.
9.2. Pull off door seal on the outside.
9.3. Carefully pull the seal out of the clips along the door contour.
10. Remove window guide rail
10.1. Unscrew the B3.5 x 9.5 sheetmetal screw from the window guide rail.
10.2. Pull off the B 3.5 sheetmetal nut.
11. Remove door channel seal on inside
11.1. Pull the door channel seal on the inside off the bead of the door channel.
12. Remove lid
12.1. Press out the 24 x 40 lid -A- and the 20 x 28 lid -B- with a plastic spatula.
13. Remove wiring harness
13.1. Unclip the electrical wiring along the inner door panel.
13.2. Pull wiring harness out of the door in the -direction of the arrow-.
14. Remove angle piece
14.1. Unscrew T 45 M8 x 33 Torx screw from the angle piece and the 12 x 8 x 7 centering sleeve.
Assembling door
NOTE:
- The bottom edge of the window must rest on the screw during adjustment!
- Observe additional instructions for adjusting the door window!
WARNING: Danger of injury if side airbag units in the door are triggered while ignition key is not removed!
- Always remove ignition key during body work, and do not commence adjustment work until a waiting period of at least 1 minute has elapsed!
- The ground strap of the battery must be disconnected during work on the airbag system and alignment bench work within the framework of body repair!
NOTE:
- Follow the special instructions on installation and adjustment for assembly of the door!
- In order to achieve better adhesion, heat the insulation using a hot-air gun! Note
1. Stick in the insulation
1.1. Peel off the backing and stick the insulation into the door below the side-impact bar.
2. Fit angle piece
2.1. Position the angle piece with the 12 x 8 x 7 centering sleeve on the door and fasten with the T 45 M8 x 33 Torx screw.
2.2 Tightening torque: 23 Nm (17 ftlb.)
3. Fit wiring harness
3.1. Insert wiring harness into the door in the -direction of the arrow-.
3.2. Clip in the electrical wiring along the inner door panel.
4. Fit lid
4.1. Press in the 24 x 40 lid -A- and the 20 x 28 lid -B-.
5. Fit door channel seal on inside
5.1. Position the door channel seal on the inside -arrow- in the bead of the door channel and press it on.
6. Fit window guide rail
6.1. Push on the B 3.5 sheetmetal nut.
6.2. Position the window guide rail and fasten it with the B3.5 x 9.5 sheetmetal screw.
6.3. Tightening torque: 1.4 Nm (1 ftlb.)
7. Fit door seal on outside
7.1. Position door seal on the outside at the top edge of the door and push it on.
7.2. Clip in the seal along the door contour.
7.3. Fasten the door seal on the inner door panel with the clip -A-.
8. Fit door brake
8.1. Position the seal.
8.2. Insert door brake from the inside and fasten it with the collar nuts.
8.3. Tightening torque: 10 Nm (7.5 ftlb.)
8.4. Screw Torx screw M8 -A- onto the A-pillar.
8.5. Tightening torque: 23 Nm (17 ftlb.)
9. Fit power window unit
9.1. Insert power window unit into the door opening from below.
9.2. Fasten the power window unit with the M6 collar nuts.
9.3. Tightening torque: 10 Nm (7.5 ftlb.)
9.4. Refer to Additional adjustment instructions for the power window.
9.5. Plug in the electrical plug connection.
10. Fit door window
10.1. Insert door window into the door channel and position it in the front and rear clamping pieces of the power window unit.
10.2. Tighten the T 30 Torx screw.
10.3. Tightening torque: 8.5 ± 1.5 Nm (6.0 ± 1.0 ftlb.)
NOTE:
- The actuating lever must be locked in basic position before installation!
- Observe additional instructions for adjusting the door lock!
11. Fit door lock
11.1. Insert door lock with actuating motor unit into the door and fasten with the micro-encapsulated T40 M8 x 14 Torx screw.
11.2. Tightening torque: 20 + 2 Nm (15 + 1.5 ftlb.)
11.3. Plug in the electrical plug connection.
12. Fit connection piece
12.1. Clip in the electrical lead -B- on the base.
12.2. Insert door handle and position the bottom part of the door handle on the door handle from inside. Tighten with the collar nuts M 6.
12.3. Tightening torque: 10 Nm (7.5 ftlb.)
12.4. Connect electrical plug connection -A-.
13. Disconnect connection piece
13.1. Insert the connection piece into the actuating shaft -arrow A- without play.
13.2. Push out the sliding piece -arrow B- until it can be heard to engage.
13.3. Actuate the handle -arrow C- to ensure that the handle and door lock function without play.
14. Fit bowden cable
14.1. Insert bowden cable into the actuating lever -arrow D- and rotate by 90° -arrow C-.
14.2. Clip bowden cable into the door lock -arrow B-.
14.3. Engage support frame -arrow A- on the door lock.
15. Fit mount
15.1. Position the mount in the door and fasten it with the M6 x 16 hexagon-head bolt.
15.2. Tightening torque: 10 Nm (7.5 ftlb.)
Basic setting of door lock
WARNING:
Danger of injury if side airbag units in the door are triggered while ignition key is not removed!
- Always remove ignition key during body work, and do not commence adjustment work until a waiting period of at least 1 minute has elapsed!
- The ground strap of the battery must be disconnected during work on the airbag system and alignment bench work within the framework of body repair!
Basic setting of the door lock before installation
CAUTION:
To prevent locking or unlocking actuation, or incorrect installation of the door lock! Malfunctions in the alarm system!
- The door lock should be installed only when the actuating lever is in basic position!
1. Swivel out the actuating lever -A- in an upward direction.
2. Lift the spring and simultaneously lower the spring hook of the actuating lever until it engages in the locking spring -B-.
NOTE:
- Greater force is necessary to actuate the door handle after installation of the door lock as the locking spring audibly disengages.
- Make sure that the lugs of the support frame are correctly locked when assembling the door lock to protect against theft -arrows: D-.
Standardising the system
Standardising the power windows
The system must be re-standardised after an interruption in the power supply to the power window electronics in the door. The position values for the short-stroke lowering function, position-controlled lowering function in the case of convertible top actuation and enabling for "automatic start-up of window closing" (one-touch function) are redefined. The standardisation process is initiated by continuous actuation of the operating button Raise window.
- Hold down the button Raise window until the window is closed and is switched off by the blockage detection function of the power windows.
Blockage detection function
NOTE: If the window drive encounters resistance during the door window movement, the motor is switched off after a delay of 500 ms.
Precondition for operation of the power windows
Ignition switched on.
Ignition key should not be removed from the steering lock with the ignition switched off.
The door is opened for the first time after switching off the ignition.
Door opened.
Fitting the door window in the clamping jaws
1. Insert the door window through the door channel into the clamping jaws of the front and rear drivers.
2. Position the door window corner flush with the driver at front.
NOTE: The bottom edge of the window must rest on the screw during adjustment.
3. Tighten the clamping jaws after completing the adjustment.
Tightening torque: 8.5 Nm (6 ftlb.)
Adjusting the door window angle in the vehicle's longitudinal direction
1. Adjust to equalise the angle of the door window on the clamping jaws of the driver (upwards or downwards).
Adjustment range 10 mm
2. Tighten the clamping jaw after completing the adjustment
Adjusting the door window height
1. Adjust the upper limit stops of the drivers by screwing the Torx screw T30 in or out with socket E6 in or against the direction of travel.
Adjustment range approx. 15 mm
2. Adjust the drivers so that they meet the upper limit stops at the same time.
NOTE: The adjusting screws of the drivers for the upper limit stops for the door window height are accessible through 2 holes at the bottom of the door.
Adjustment procedure:
1. Open the doors
2. Lock door lock with a screwdriver.
3. Move the power window regulator into its upper position.
4. Adjust door window height at the drivers so that the door window evenly projects approx. 2 mm above the roof strip.
Checking the adjustment
1. Close the doors.
2. Use a wax marker to mark the door window along the roof strip.
3. Actuate the door handle until the window lowering function is activated.
Adjustment valve for window lowering function approx. 13 mm
NOTE: The wax marking along the door window should be uniformly approx. 4 mm.
Adjustment of the door window pressing force on the door seal at the top and sides
1. Move the power window unit rails by approx. 10 mm outwards or inwards.
NOTE: The adjusting nuts of the power window unit rails for the pressing force of the door window upper edge against the convertible top are accessible through two holes at the bottom of the door.
Adjustment procedure:
1. Open the doors.
2. Move the power window regulator into its upper position and undo the combination nuts M 6 of the power window rails.
3. Adjust the power window unit so that the upper edge of the door window is sufficiently pressed against the door seal at the side
Tightening torque: 10 Nm (7.5 ftlb.)
Checking the adjustment:
- Clamp a sheet of paper between the door window and door seal.
NOTE: It must not be possible to pull out the sheet of paper.
Adjusting the lower stop of the power window unit
NOTE:
- When replacing the power window unit, make sure that the correct position of the lower limit stop is selected for the respective model.
- There are two bores lying one above the other with the screwed-on limit stops in the front power window unit rail.
- The upper limit stop must be removed for the 911 Carrera (996) model.