Body - Stainless Steel Sill Cover Installation
Boxster (987)7/05 ENU 6807
Date Dec 15, 2005
Stainless-Steel Door Sill Cover, Illuminated
Vehicle Type:
Boxster (987)/Boxster S (987)
Model Year:
As of 2005
Situation:
Installation Instructions
Information:
The stainless-steel sill cover is installed in the entry area of the doors. When you open the door, the Boxster logo-made from electroluminescent film lights up. The door control unit ensures that the illuminated sill cover switches off automatically after approx. 10 minutes. Once the door is closed, the logo no longer lights up.
Parts Info:
Note:
The supplied abrasive pad can he used to eliminate small scratches on the surface of the stainless-steel sill cover. Be very careful not to use the abrasive pad on adjacent painted surfaces and glass areas of the logo as it is likely to damage them.
Please inform the customer of this information accordingly!
Parts list:
Note:
The description of the retrofitting procedure refers to the right side of the vehicle. The procedure is the same for the left side of the vehicle. Any deviations are described separately for the driver's and passenger's side.
WARNING
Risk of short circuit and fire due to work on vehicle electrical system.
--> Always route the electric wires without tension and so that no chafing occurs and secure to existing wires/components with tie-wraps/electrical tape.
ATTENTION
Risk of damage (scratches) to painted surfaces and illuminated surface (logo)
^ if abrasive pad is not used correctly.
--> Do not use abrasive pad on adjacent painted surfaces and illuminated areas (logo).
Materials:
Tools:
Work Procedure
1 Preparatory work.
1.1 Raise door windows.
1.2 Remove inner door sill trim. --> Workshop Manual "680519 Removing and installing inner door sill trim" - section on "Removing"
1.3 Remove cover strip. --> Workshop Manual "680719 Removing and installing cover strip" - section on "Removing"
1.4 Remove front side section trim. --> Workshop Manual "702419 Removing and installing front side section trim"- section on "Removing"
1.5 Remove bass loudspeaker. --> Workshop Manual "914119 Removing and installing front loud-speakers" - section on "Removing"
1.6 Pull back carpet lining and loosen wiring duct --> Figure 3-A-.
2 Route electric wire harness --> Figure 2-B-.
2.1 Insert wire harness into the wiring duct --> Figure 3 and position inverter --> Figure 3-B- in the first cut-out of the wiring duct.
3 Disconnect plug connection for door wire harness.
3.1 Driver's side:
3.1.1 Clip plug connection --> Figure 4-Arrow- out of bracket and slide protective hose over the plug connection.
3.1.2 Release lock --> Figure 5-A- and disconnect plug connection --> Figure 5-B-.
3.2 Passenger's side:
3.2.1 Disengage plug connection --> Figure 6-A- at the body and slide protective hose over plug connection.
3.2.2 Release lock --> Figure 5-A- and disconnect plug connection --> Figure 5-B-.
4 Route electric wire harness --> Figure 2-C-.
4.1 Push rubber sleeves --> Figure 7-A and B- out of A-pillar from the inside and carefully pull these and the door wire harness out through the openings.
4.2 Push rubber sleeve --> Figure 7-C- out of door and rubber sleeve --> Figure 7-D- out of door sub-frame and carefully pull these and the door wire harness out through the openings.
NOTE:
Observe direction of installation of electric wire harness. Open ends of wires (Figure 8, Item A) must be pointing towards the door wire harness plug connection (Figure 8, Arrow).
4.3 Guide electric wire harness carefully through the rubber sleeve using a Teflon hose.
4.4 Replace protective hose for door wire harness.
4.4.1 Slide rubber sleeve back to the end of the protective hose --> Figure 9-Arrow-. Remove electrical tape and pull protective hose --> Figure 9-A- off the door wire harness.
Note
The electric wire harness for the illuminated sill cover is not covered by the protective hose.
4.4.2 Slide rubber sleeve back slightly --> Figure 9 -Arrow-. Pull new protective hose over the door wire harness as far as the rubber sleeve and secure in this position with electrical tape. Pull protective hose tightly and wrap electrical tape along the entire length of the rubber sleeve up to the door wire harness plug connection.
ATTENTION
Risk of damage to protective hose, door wire harness and rubber sleeve
^ due to incorrect routing.
--> Route door wire harness carefully so that the protective hose, door wire harness and rubber sleeve do not become chaffed at the edges.
4.5 Route door wire harness and rubber sleeve into the passenger compartment through the opening for the door sub-frame, door and A-pillar.
Press rubber sleeves --> Figure 7-A, B, C and D- into the openings and check that the rubber sleeves fit snugly all the way round.
5 Connect electric wire harnesses --> Figure 2-C and D-.
5.1 Connect lead RD (0.5sq.) from the wire harnesses.
5.1.1 Slide shrink-fit hose over lead RD (0.5sq.) from wire harness --> Figure 2-D-.
5.1.2 Crimp lead RD (0.5sq.) from wire harnesses --> Figure 2-C and D- together using a cable connection.
5.1.3 Slide shrink-fit hose over the cable connection and shrink the hose with a hot-air gun.
5.2 Attach lead BN (0.5sq.) from wire harnesses --> Figure 2-C and D- as described in Step 5.1.
5.3 Wrap electrical tape around leads RD (0.5sq.) and BN (0.5sq.).
5.4 Connect plug connection from wire harnesses --> Figure 2-B and 0-.
5.5 Secure wire harness to the vehicle wire harness with electrical tape.
6 Connect plug connection for door wire harness.
6.1 Passenger's side:
6.1.1 Stick a 40-mm length of adhesive sealing strip --> Figure 11 -A-, Part No.000.043.129.00, to the back of the connector housing.
6.1.2 Push back protective hose around the plug connection and then connect and lock the plug connection.
6.1.3 Pull the protective hose as far as possible over the plug connection and press down firmly on the adhesive strip.
6.1.4 Engage plug connection at the body --> Figure 6.
6.2 Driver's side:
6.2.1 Push back protective hose around the plug connection and then connect and lock the plug connection.
6.2.2 Pull the protective hose as far as possible over the plug connection and clip onto the fuse carrier --> Figure 4.
7 Connect and route electric wire harness --> Figure 2 -E-.
7.1 Disassemble 32-pin door control unit connector.
7.1.1 Remove tie.wrap --> Figure 12-A-.
7.1.2 Release lock --> Figure 12-B-.
7.1.3 Pull plug carrier --> Figure 12-C- out of the connector housing.
7.2 Press socket contact of lead BK/RD (0.75sq.), chamber 20 --> Figure 13-A- and socket contact of lead BN (0.75sq.), chamber 21 --> Figure 13-B- out of the 32-pin door control unit connector.
7.3 Connect lead RD (0.5sq.) from the wire harness --> Figure 2-E-.
7.3.1 Remove approx. 15 mm of insulation on lead BK/RD (0.75sq.) --> Figure 14-A-.
7.3.2 Crimp lead RD (0.5sq.) and lead BK/RD (0.75sq.) together using a cable connection --> Figure 14 -B-.
7.3.3 Slide shrink-fit hose over the cable connection and shrink the hose with a hot-air gun.
7.4 Attach lead BN (0.5sq.) from wire harness --> Figure 2-E- and lead BN (0.75sq.) of the 32-pin door control unit connector --> Figure 74-C- as described in Step 7.3.
7.5 Wrap electrical tape around wires.
Note
Make sure the socket contacts are seated securely.
7.6 Insert socket contact of lead BK/RD (0.75sq.) in chamber 20 --> Figure 13-A- and socket contact of lead BN (0.75sq.) in chamber 21 --> Figure 13-B- of the 32-pin door control unit connector.
7.7 Assemble 32-pin door control unit connector.
7.7.1 Push plug carrier --> Figure 12-C- into the connector housing.
7.7.2 Press in lock --> Figure 12-B-.
7.7.3 Secure wire harness to connector with a tie-wrap --> Figure 12-A-.
7.8 Route wire harness along the door trim panel --> Figure 15 and secure to standard door wire harness with electrical tape.
8 Install sill cover.
8.1 Remove residual adhesive from door sill and clean bonding surface to remove any dust and grease.
8.2 Pull protective film off the bonding area of the sill cover.
Note
Center the notch in the sill cover at bead height (Figure 16, Arrow).
8.3 Position sill cover at the contour of the door sill, stick it on and press down firmly.
8.4 Connect plug connection for sill cover --> Figure 17 -A-.
8.5 Lay flat belt lead over sheetmetal flange --> Figure 17-Arrow- and attach rubber seal for door. --> Workshop Manual "576379 Removing and installing rubber seal for door" - section on "Installing"
9 Concluding work:
9.1 Secure wiring duct and position carpet lining.
9.2 install front side section trim. --> Workshop Manual "702419 Removing and installing front side section trim" - section on "Installing"
9.3 Install inner door sill trim. --> Workshop Manual" 680519 Removing and installing inner doorsill trim" - section on "Installing"
9.4 Install bass loudspeaker. --> Workshop Manual "974719 Removing and installing front loud-speakers" - section on "Installing"
9.5 Position door trim panel, connect plug connection from wire harnesses --> Figure 2-C and E- and wind foam strips --> Figure 2-F- around it --> Figure 18-A-.
9.6 Secure door trim panel. --> Workshop Manual "705979 Removing and installing door trim panel" - section on "Installing".
9.7 Carry out a function test.
9.7.1 Close both doors and then open them again.
9.7.2 Both sill covers must light up for approx. 10 minutes.
Working Time:
References:
--> Workshop Manual "576319 Removing and installing rubber seal for door"
--> Workshop Manual "680579 Removing and installing inner door sill trim"
--> Workshop Manual "680779 Removing and installing cover strip"
--> Workshop Manual "702479 Removing and installing front side section trim"
--> Workshop Manual "705919 Removing and installing door trim panel"
--> Workshop Manual "914779 Removing and installing front loudspeakers"
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