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Showing content with the highest reputation since 06/04/2010 in Posts

  1. 7 points
    Yes that tube goes to the resonance flap. It's probably a really long tube right? That's the one that goes to the rear of the engine (front of car). From my above post: "In the diagram link below, the tubes you are talking about is #19, which goes into #21 (another hose) which then goes into the resonance flap: http://www.autoatlan...9-05/107-10.php" Yes the DIY link I posted has the procedure you need to remove the throttle body and t-plenum so you can reach behind the rear intake crossover and reconnect a new tube from the resonance flap to the change over valve in the position you indicate (hose/tube p/n 00004320501 qty 1) You might need a extendable mirror to see it.
  2. 7 points
    :welcome: For the Cayenne S and Turbo (V8) <----- FRONT 1 - Ignition bar module, cylinder 1, bank 1 2 - Ignition bar module, cylinder 2, bank 1 3 - Ignition bar module, cylinder 3, bank 1 4 - Ignition bar module, cylinder 4, bank 1 5 - Ignition bar module, cylinder 5, bank 2 6 - Ignition bar module, cylinder 6, bank 2 7 - Ignition bar module, cylinder 7, bank 2 8 - Ignition bar module, cylinder 8, bank 2
  3. 7 points
    Which radios fitted to Porsche can have their unlock code recovered through serial number? - CR-220/CDR-220 - Becker - CR-210/CDR-210 - Becker - Traffic Pro NAV/CD - Becker Which radios can not have their unlock code recovered through serial number? - CR1 - Alpine - CDR-23/24 (or later) - Becker - PCM (Porsche Communication Management) – Siemens & Becker How to get your radio serial number? CR-220/CDR-220: Hold down the TP button for at least 10 seconds after you turn the radio on. "Becker 1" will be displayed. Rotate the right knob (slowly) and it will display the Becker model number. Then rotate it again and the serial number should be displayed on the radio. Or, if the radio is out of the car the then the serial number is on the label. CR-210/CDR-210: Press tone, then 8 and 0 simultaneously. "Becker" appears. Press station up arrow on right. "PR-VERS" appears. Press one of the numbered buttons below the display, directly below the LCD arrowheads (try a few). The model number will appear. Press station up arrow on right. "SERIAL N" will appear. Press the numbered button again. The serial number will appear. Or, if the radio is out of the car the then the serial number is on the label. CDR-23 (or later): These radios do not have a security code - that is, not that the user enters. These radios are security tested on the MOST (fiber optic bus) system to see if they are the "programmed" radio. The radios are programmed and recognized by the car’s DME and can only be replaced by a shop with a PST2 or PIWIS. These radios will not request a code when battery power is disconnected. Traffic Pro: Select the Service Menu, press NAV and multifunction key 10 simultaneously in radio mode. Use multifunction keys Nxt and Prv or turn the right control knob to select the individual items. You can move through the following items: - Model-No. - Serial-No. <-- this is what we need - Changer Reset - GAL - Radio Software - Radio Bolo - Navi Rom - Navi Flash - RTC Value To quit the service menu, press END. I get a WAIT on the display - what do I do? You have to wait at least 30 minutes before trying again. The suggested number did not work - what do I do now? Most often when the code we give you does not work it is because the serial number came from an old card in the car rather than from the procedure stated above - or a typo in the serial number submitted. Double check the serial number you submitted using the procedure above again. If that does not work then you will need to contact a dealer or Becker. Becker charges to look up your code and some dealers also charge. Our program works maybe 99.9% of the time but we have no explanation why it doesn't always work. Can you give me a code for my PCM? These units are manufactured jointly by Siemens and Becker, and the only place where you can get the codes required is from the dealer/OPC. The PCM’s require two codes, the ICS/Siemens code, and a Becker code. The ICS is the first code requested. Sorry, the only place you can get a PCM code is from a dealer/OPC. Can I post my VIN to get a code? We do NOT need your VIN - only your radio serial number. Where can I post my lost code request? Please post your request here: Lost Radio Code - post your request here Please DO NOT PM me or email me (or anyone else helping with the codes) your radio code request - we will only answer requests in that one thread.
  4. 4 points
    Air Oil Separator Replacement (AOS) EDIT: Fixed text boxes to see text better. This is an AOS DIY that walks you through the process of replacing the AOS. This is for a 2000 996 C2 Cab, six speed. I tried to be as thorough as I could in writing the DIY. If there is something left out or lesson learned from your personal experience with the AOS and or this DIY, please let me know so I can incorporate it into the document. Regards, Ken How do you eat an elephant? -- One bite at a time! Air Oil Se Author Hobbes Category Carrera (996) - Common Fixes and Repairs Submitted 03/26/2011 03:49 PM Updated 03/20/2017 06:36 AM  
  5. 4 points
    LONG STORY SHORT,,...My entry and drive system went bad one day., after almost a year of testing , replacing the battery, buying the test tool, almost brought a china piwis ,.... and bringing it to dealer and 800 dollars of dealer time., I had it fixed for 5 Dollars in parts. and one hr of soldering at first my kessy do not communicate to the darmatic tool or PIWIS at all, the dealer went ahead try to replace it , with a superseeded module, HOWEVER they wasn't able to program it for unknown reason, there is no module out there that will take my car's pin and complete the marry process because they said all the module has been superceeded. The dealer offer me to replace ALL the module in the car to an updated version for a cheapo $3000 dollars.! OF COURSE I refused,. ...,. I only lost my alarm horn , entry and drive function and its not worth $3000 dollars,. I was investigating myself trying to see what causing the problem, I came in to the touareg forum and found out those guys there have a lot of the problems with their module too. ... I was like ,hum.,,. then go under my dash and found the kessy module that is EXACTLY the same as theirs including the part number (WHICH IS A VW part number stamped on a sticker btw).... there is one guy there that took his module to a local electrician and found he has 2 fried mofset and 6 fried resistors.!!! I was like, fxxx it, why don't I give it a try, at first I couldn't found the 0.22ohm resistors (its was HARD trust me I took almost 2 months looking for them)., so I went ahead replaced the two mofset........... 15 mins and a lot of smoke later....... MAN,,,... the module can communicate with my Durametic tool...! HOWEVER,, all the antennas are reporting short to ground ERROR!!! I tried to clear it but the code come back instantly. then I went on to test the resistor value,... and found all six of the 0.22ohm resistors are SHORT (they are fusible resistor btw)....,,. sooooo I tried my best and finally able to locate those 0.22 ohm resistor .., fast forward 2 months later............ I received those resistors today.............. another 15 mins of smoke and sweat with my resoldering station... I plug the module back... run the scan tool clean the fault codes!!!!................... moment of truth,, I plug my dummy key in to the key cyclinder with the real key in my pocket!!!!!!!!!!!!! turn and the CAR STARTS!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! I have successfully fixed a $3000 dollars repair (that don't guarantee will work) with 5 dollars worth of resistors !!!!!! NOTE: IF your kessy don't communicate with the scan tool,. Its the TWO MOFSET that is Fried. if you have all antennas short to ground or not responding its the 6 resistors!
  6. 4 points
    Cayenne 2003 4.5S I needed to pressure test my coolant system to identify a leak that, when hot, could be smelt but not seen & when cold didn't leak! I wanted to buy a Coolant Pressure Test Kit but was not sure which one to buy. During my research, I noticed there was one type of generic non-branded 'universal' kit that appeared multiple times on the general market (eBay & Amazon for instance).. Most listing for this generic kit listed all the car types it would fit but of course, Porsche was not listed - however, a few VAG applications were listed so I took a punt & ordered one of these kits for UK £45.00. The good news is that one of the VAG adapters supplied (#9) fits the Cayenne the header tank & I was able to perform the test on my cold engine & immediately, the leak was apparent. The purpose of my ramblings here is to share with you the kit I bought & the adapter used so you don't have to guess & take a chance as I did. I hope this helps someone. BTW, finally my luck ran out - it was my original plastic coolant pipes that gave up the ghost (there can't be many 2003 models out there still running their original plastic pipes)
  7. 4 points
  8. 4 points
    You would need to get in line, others have been there before you. Mityvac, amongst others, have promoted this concept for years. Unfortunately, there is are a couple of major downsides: Going in through the dipstick tube, you rarely get all the old, contaminated oil out. Secondly, and perhaps more importantly, there are a lot of sharp edged things down there that can catch flexible tubes inserted down the dipstick tube. We have had more than one car flat bedded to the shop after an oil extraction unit line got stuck and could not be removed, requiring us to run up some expensive shop time getting it out. If you cannot get under the car and change the oil, or are uninclined to do so, take it to a shop and let them change the oil as the car was designed to do. In the long run, you will save yourself headaches and expense.
  9. 4 points
    The P1123 Code "Oxygen Sensing adaptation range 1 Cylinders 1-3) Lean limit" is referring to the fact that DME has reached its limit is trying to lean out that bank and the car is running too rich as the result. Usual two suspects are either high fuel pressure or a leaking injector(s) on that side. As you have not identified your year or model, in some cases is can also be a defect fuel pressure regulator on the injector fuel rail, depending upon the year, as some models do not have the external regulator. There is little probability of the MAF being involved in this issue. Step number one should be to get a fuel pressure reading off the test port on the fuel rail, should be 55+/-3 PSIG engine off; 48+/-3 PSIG engine running. If it is an early car with an external fuel pressure regulator, pull the vacuum line off the regulator and read the vacuum on the line, should be around 15 inches of vacuum. Checking the individual injectors is a bit more difficult; for a DIY, probably the easiest approach is to pull all the plugs on that bank and check their color. If one or more are overly dark, those would be your suspect injectors.
  10. 4 points
    Here's the video. Sorry for the shakiness and poor audio. I found my old 24-bit PCI soundcard isn't supported in Windows 7, and I've yet to invest in a new USB recording system. I only make these when something on my car breaks, so if anyone else in the Houston area wants to collaborate, I'll be happy to assist and film your next project.
  11. 4 points
    I did this over the weekend, so I videotaped it. My apologies for the narration. I need to not drink beer while editing. Hope this helps somebody.
  12. 3 points
    Hi, I hope someone can help. I just had my car painted and they disconnected the battery and now I have lost the radio code. this is the info I have found. I'm not sure how to go about getting it. Any help would be appreciated. Becker 1 type 4462 # Y5038582 24/99 Thanks
  13. 3 points
    I recently decided to place some bright white LED's in both the driver's side and passenger's side footwells of my '98 Boxster. The lights are super thin and come with a 3M adhesive. I placed the driver's side LED strip on the vent tube that runs horizontally and the passenger's side LED strip accross the bottom of the footwell foam cover in the natural grove channel. The foam cover is held in place by 2 screws with large heads. Both sets of lights are wired together and are joined together on the passenger side above the foam cover (and now new LED light) and connect to two (2) wires, positive and negative, that run up the passenger's side "A Pillar" trim piece, then accross the top and connect to the center interior light. The positive is soldered into the "Y" shaped copper rocker inside the light switch and the negaitve is wire tapped into the center wire entering the switch. It has the same off/on properities as the door lights with the added flair of manual on/off by turning on the center interior light. The center interior light and now footwells can be always on, always off and door and locking activated. Here is a shot of the driver's side in my darken garage.
  14. 3 points
    I had the same problem. There is a rubber coupling between the motor and window cable drive pulley. The rubber softens with age to the point where the window barely moves when the handle is operated, however when the window is fully opened or closed everything appears fine. The mechanism can be stripped very easily, I made replacement rubber coupling inserts just using a Stanley knife and 8mm rubber gasket material. The end result was a perfect cure that cost pennies.
  15. 3 points
    I recently successfully self-diagnosed and repaired the A/C on my Cayenne. Total cost for parts and refrigerant ~$65. Vent temps went from 17 C before the fix to 4 C in ~24 C / 75 F ambient temps and high humidity. I will post details on the fix and the way to diagnose this particular problem (and other HVAC issues) in a new thread. Anyways, one thing I discovered is that there is a lot of incorrect information out there regarding the HVAC system on these cars. One of the more pertinent items: The Cayenne uses a variable displacement compressor with an electronic compressor control valve for modulating the mass flow of refrigerant through the compressor. There is no compressor clutch, so to speak. This is not like the old compressors that we are all familiar with that use an electric clutch to cycle the compressor ON/OFF. Please gently slap anyone who talks about an electric clutch on the Cayenne compressor. If you are in doubt, just do a google search for "Cayenne AC compressor" and look at the pictures. There is only a single electrical connector and it routes to the back of the compressor; this is the compressor control valve. The HVAC control unit adjusts the refrigerant flow to meet the required demands. Instead of cycling a clutch on and off, a swashplate inside the compressor adjust the stroke of the compressor pistons to realize the specified refrigerant mass flow. No more ON/OFF cycling, just nice consistent cooling--in theory, at least (and when everything works). Fuse 11 that Loren mentions powers the compressor control valve. The negative lead goes to the HVAC control unit. The valve is driven by a PWM signal, likely current controlled. To the OP (Bichito): Sorry to say it, but your compressor is toast. The part that you are referring to as a clutch is actually a sacrificial break-away mechanism. The idea is that if the compressor locks up then this part will break in two and allow the pulley to spin so that your other accessories are still driven. I can think of no other scenario for your situation other than a catastrophic failure of the compressor. If you are lucky, then the compressor didn't spit it's guts throughout your refrigerant system. Either way, you will need a new compressor (and drier, at a minimum) and a very thorough cleaning of the refrigerant system (get this part wrong and you may be doing the whole job over again). Sorry... @neoplanet: Your problem may be far less serious but we need more information. You wrote that the A/C shop said that everything checked out OK. What does this mean? I'm assuming that this at least means they did a visual inspection of the A/C compressor and did not see anything obviously wrong (like what Bichito found). Did they give you any pressure numbers? Do you get any cooling whatsoever? You wrote that they said there was no voltage going to the compressor. I'm not convinced they checked this correctly. First of all, hopefully they realized that the connector they were looking at was for the compressor control valve (not a clutch, as it doesn't have one). According to the manual that I have, +12 V should be on the red/white wire. Now, if they disconnected the connector and attempted to check the voltage across both leads then they would likely run into a problem because 1) the valve is controlled by a PWM signal (you need an oscilloscope, not a multimeter) and 2) the control valve is most likely current controlled: if you take the valve (which is low impedance) out of the circuit then the computer will recognize this as a problem and probably will not drive the line low. I would totally expect them to find 0 V if they tested things this way. You can test the +12V wire by connecting one lead of a voltmeter to the red/white wire and the other lead to anywhere on the car that is grounded. To properly test that the electronic signal to the valve, you need to keep the valve in circuit and probe across both wires with an oscilloscope. Frankly, I wouldn't waste my time doing this at the moment. First thing I would do is get some pressure readings. If your high side pressure is OK then you can forget about the electrical checks on the control valve. Once I know your pressure readings I can make a suggestion as to what I would check next. Brett p.s. To address the original question, there is no A/C relay on the Cayenne and therefore no "A/C relay location". :) Edit for clarification: I should have said that there is no "A/C compressor clutch relay". I also just noticed that this thread was a year old. Oops!
  16. 3 points
    Yes. But the bolts are difficult to get from underneath. I tried bending an end wrench and ended up making one by welding a socket to a cut off end wrench and grinding some away. The mounts drop by about 3/4 of an inch with wear.
  17. 3 points
    Welcome to RennTech I can tell that your mechanic does not specialize in Porsches. This is a topic that has been discussed many times, and a good search would help you fill in the details. In a nutshell, cold air systems are a waste of time and money on these cars as it came from the factory with a very well designed one already installed. Your current fuel injectors are capable of delivering more than enough fuel, so putting in larger ones is also a general waste of time and money. They also won't add anything as the DME will step in and throttle them back to maintain the correct A/F ratios. The next big "fix" to produce more power are the aftermarket reflashes of the DME, which typically produce increases that fall with in statistical error range of the factory output on a dyno. Larger throttle bodies and trick intake plenums also add little if anything on the dyno. The best suggestion I would give to you is to remain very circumspect of performance gain claims you see in internet ads for companies that sell these mods; most are pretty much hot air. So the question becomes how to get more power; the unfortunate answer is to spend a lot of money. These engines are a system and need to be approached as such. It is very possible to generate a lot of power, nearly twice the factory output, but it comes at a stiff price: Approaching $20K for a completely redone engine out of one of the premier M96 engine builders.
  18. 3 points
    Coolant Pipe Replacement Detailed Instructions I recently replaced the coolant pipes in my car. I needed to do the job myself because there was simply no way I was going to shell out anywhere from $1500 to $3500 in labor to have it done by the dealership or an independent shop. Plus, having read about the job, I knew they would be tearing through a ton of stuff and I really feared the "oh, it also needs this" scam. I did a LOT of research on the various forums before undertaking this job. Reading and printing out anything I thought was useful information. I would highly encourage anyone reading this to do the same. Fortunately, I was not in the position that the pipes simply failed and dumped all of the coolant. I just had a semi-slow leak… dropping about a gallon of coolant every two to three weeks. So, I had time to order the parts and prepare. Prior to doing this the most complicated thing I had done myself was change the oil, replacing the brake pads and swapping out some plastic bits in the car. I had absolutely no prior mechanic experience whatsoever. However, I do work in IT, and am by nature a very technical person (I'm sure every mechanic reading this just rolled their eyes). My job is troubleshooting very complex problems on very large networks, and I think that experience probably lent itself to a successful outcome here. I'm also patient, and that is critical to getting this job done. I will say that I now have a much greater appreciation for mechanics and their skill set. This was hard. I want to caution anyone reading this that this is a BIG job and it will take a long time. My goal in writing this is so that my fellow Cayenne owners can be spared a lot of the mistakes I made and be better prepared than I was. I will say I am relieved to have this done. I feel a ton better about my car now that I don't need to worry as much about some catastrophic failure hitting me unexpectedly. One rule that I really appreciated was to only place metal on metal when working (until you actually get to removing the pipes). This prevents you from breaking plastic or tearing rubber with something metal. Trust me, pay attention to that rule. I am breaking this down into tasks, because I think it's easier to follow that way. This is how I did it. I am sure there are other ways that may even be easier, but this worked for me and my schedule. I ended up working 4-6 hours at a stretch in the garage with breaks every couple of hours. Step 1: Contribute to this forum I have absolutely no affiliation with this forum whatsoever other than I am a contributing member. The advice on this forum has personally saved me thousands of dollars, and being in IT I know the time and money it takes to run a site like this. So, contribute to the cause. However, there is a second reason to contribute, and that's to get the Porsche TSBs. The TSB for this job contains some diagrams that give you a better idea how all the replacement parts go in to place, and I thought that was handy to have. As an aside, I searched some other issues in the TSBs and found answers to some things the dealership didn't even know… such as there being a $33 replacement latch for my armrest. They wanted to sell me a whole new armrest for $750. Step 2: Obtain the Parts I looked around on the Internet and called some local sources and found a dealership that provided the parts for $550, and that included two gallons of coolant shipped to my door. To me, that was a fair price, and when I received the parts I really thought it was a fair price... there's a lot of quality stuff in there. I'm sure there may be cheaper 3rd party sources. I would just be sure they include all gaskets and such that don't necessarily need to be replaced, but should be replaced if you're tearing everything apart. Once you get the parts, pull them out of the box and examine them. Look at the pics in the forum and look at the TSBs. Get a feel for what you are replacing. Step 3: Verify you have the tools I found the following tools very handy to have, and frankly, necessary. I suggest going to your local auto parts store for most of them and get mechanic grade tools. Socket Wrench 3" Socket Extension 6" Socket Extension Metric Socket Set Torx Socket Set (think of this as a "male" Torx Socket set, you will need #27 & #40) E-Torx Socket Set (think of this a "female" Torx Socket set) Screwdriver that accepts interchangeable bits (there are times this is easier than a socket wrench) Torx Bit Set (Specifically you need a #27 and #40, I just bought a set) Locking Long Nose Pliers (6" is fine, no need for anything bigger) Regular set of pliers Wrench Set (somewhat optional) Real flat head screwdrivers Very long flat head screwdriver (this came in handy a lot) Needle Nose Pliers Small Chisel Set Hammer Tin snips Safety Glasses Mechanics Gloves One of those extension things with a magnet on the end One of those extension things with a mirror on the end WD-40 Some all-purpose grease, like White Lightning Baggies to store the screws in Masking tape/Painters Tape to cover up any exposed openings Old Bath Towels (used to protect the car) Good flashlight Lint free rags Shop Vac Two gallons of distilled water Drain pan (needs to hold 4 gallons) Shop lights A small block of wood, about 2" x 4" x ¾" A radio playing energetic music of your choice Advil and Tylenol Hope and a prayer (optional but doesn't hurt) Step 4: Book the Time I know some people say you can have this job done in less than 8 hours, but being a beginner this took me much longer. If I took out all the time running back and forth to the store for tools and such, and had a guide like the one I am writing, I still think it would have taken 10-12 hours. I ended up removing all of the engine covers on one weekend night, and then doing the actual job the following weekend. I then drove the car for a week with the new pipes and finally put all the engine covers back on over the weekend (I cleaned the covers and the engine thoroughly with a damp rag at the same time to pretty it up a bit). You don't really need to do it that way, but that split the work up a bit. I work in an office in front of a PC all day; I'm not used to working in a hot garage for 8-10 hours at a time... I'm a skinny computer geek : ) When I did the work, I draped some old bath towels over the sides and front of the car to protect it. The last thing I wanted to do was mess up the paint on a zipper or with a dropped tool/screw. Step 5: Remove the Engine Covers There are really two parts to this. You have the decorative covers over the actual engine, and then you have the covers that border the engine. You'll want to remove all of the covers around the border first. There are five of them in total. They all have these little black plastic plugs that you just turn 90 degrees. They should just pop up at that point, but you might have to give them a little lift with a screw driver. While you're removing those covers you might want to pay attention to how they go together and where they slide in to place. You'll also want to remove the windshield washing fluid cap (use the masking tape to cover up the exposed hole) before you remove the cover that surrounds it. Those little things are $4.25 each from the dealership, so try not to lose them. Now you have the three silver looking decorative covers; one on each side of the engine and one towards the front middle with the engine type on it. First, you need to unbolt the two secondary air injection units. Those are the round things with the plastic covers near the back of the engine compartment. You do not need to disconnect them from anything, just unbolt them (three screws each) and then move them off to the side. It might be a good idea to get some labeled baggies to store the screws in. Once those are removed you can get to the side engine covers a little easier. The engine cover in the front middle you just lift off, just work it back and forth a little and it should pop off. Take note that there are four little plugs that fit into holes on the cover itself, you'll need to find them again when replacing it. Now remove the one on the driver's side. It's pretty easy to remove. There are four screws towards the bottom that need to be removed, and then the cover will just come off. The one on the passenger side is a bit different. You have the engine mount right in the middle of things. Assuming you have the tools, you can unscrew the engine mount and get it out of the way. That will let you get to each of the four screws easily on the cover and remove it. I wasn't so lucky here (didn't have the right tools at the time), so I just got the four screws out of the cover and ended up wedging it out. While doing that, the piece of the cover under the engine mount snapped off. I wasn't too concerned about this, because where it snapped is hidden by the engine mount. When I put everything back together I just slid it back and screwed it in. You can't tell at all that it was ever snapped in half. Step 5a: Remove Fuel Pump Fuses You'll want to check your manual (you can also download the manual from this site), but you need to remove a couple of fuses for the fuel pump. Right in front of the driver under the hood there is a small compartment. Remove the cover, and then remove a second cover to expose the fuses. Mine were fuse 14 & 15 for the fuel pump. Store them somewhere safe. Once those are removed, start your car. It will run for a few seconds and die. Congrats, you just removed most of the fuel from the fuel line. I know some people don't disconnect the fuel rail or anything, but to me that's a bad idea. I had a lot of time to try it that way and honestly I'm glad I got it out of the way. Step 6: Disconnect the fuel line The fuel line is near the back center, it's just one tube running to the fuel rail. You'll disconnect it by using a wrench and a pair of pliers. You're unscrewing the part on the left (the thin part) from the part on the right (the wide part) which shouldn't turn as it is part of that tube. Once unscrewed, the fuel rail is only connected to the manifold. A little residual fuel might leak out, so you might want to have a rag handy to wipe it up with. Use masking tape to cover up any exposed holes. It wouldn't be a bad idea to disconnect the batteries now either. I didn't, but that was probably stupid. Step 7: Remove the Y-Pipe that goes to the Throttle Body This plastic Y-Pipe is right up front so it's very easy to get to. There are two flexible pipes on either side you need to remove first; just use a screwdriver to loosen the two clamps on each of them and you should be able to compress them enough to remove them. The Y-Pipe itself is attached to the throttle body via two long, plastic bolts. They have a screw head on them but they are not screws, they're more of a key. You just turn them a bit to line the key at the bottom (use a flashlight and you'll see it move as you turn it with the screwdriver) with the slot. When it's lined up, use a pair of needle nose pillars to lift it straight out. It's plastic and may be brittle, so be a little careful. You will need to remove an electric connection to the throttle body in order to get to one of them. There is a tube connected to the bottom of this y-pipe, so you can't just lift it out. It has some give to it, but not a lot… just enough to get your hand under there once you pull the y-pipe off the throttle body. You have to press the buttons on each side of the tube in order to get it off the y-pipe. Step 8: Remove Emission Tubes & Electrical Connections from Throttle Body There are two emission tubes crossing the throttle body, Porsche refers to them as "vent tubes." I know this because one snapped in half when I removed it, and the dang thing was $130 to replace. To remove them, you just need to press the clips at either side of the end of the tube together and then pull it straight out. I don't think mine had ever been removed, and in retrospect a bit of WD-40 used sparingly here might have been a good idea. I think I used too much force and that's why the small one snapped. I have read that some people have replaced this broken tube with a more generic tube from a hardware store. I just spent the $130 and did it right. There is a third tube connected to the throttle body, you just need to remove that one end of it. You will also have two electrical connections to remove. One you had to remove to get the y-pipe off in the previous step. Just remove the second one and then you're done. Step 9: Remove the Throttle Body The throttle body is connected to the manifold via four bolts. Remove those four bolts and it will come off. You sort of have to wiggle it out because of that thin metal bracket that's holding it there, but it will come out easy enough. Some people take this opportunity to clean it. You'll probably see some gunk on the back side of it on the inside. Step 9: Remove the Electrical Connections to the Fuel Injectors There are eight fuel injectors connected between the fuel rail and intake manifold. Mine were blue plastic, and there is an electrical connection running to each of them. There is a metal clip at the bottom that you just need to press up. I placed a flat head screwdriver between this clip and my index finger, and pushed up and pulled at the same time to disconnect it. Once you remove one you'll get the trick and the rest will come right off. Step 10: Remove the Intake Manifold with Fuel Rail Attached I know a lot of people have different ideas here, some people want to remove the fuel rail independently, and that was the first way I tried it. In retrospect, it's much easier to just leave it attached. There are four screws that hold the fuel rail to the intake manifold. I would recommend leaving these alone, especially since the one at the back on the passenger side is nearly impossible to get to. These screws are $6+ each… I know because I lost one. :P There are 10 bolts that need to be undone to remove the manifold. They don't come all the way out, they'll stay attached to the manifold. Once you loosen them enough they sort of come free and wiggle around. The one at the back on the passenger side was a bear to get to. I ended up placing the Torx Socket bit on top of it using the magnetic extension thing. I then put the 3" extension on top of it, and finally attached my socket wrench to it. I kind of built it all up I guess. I then went really, really slowly and loosened it up. Once loose, make sure to vacuum up any debris on the engine. When you pull the intake manifold off you will have eight gaping holes right down to your cylinders, you don't want anything falling in there. You can now scoot it forward a bit to get to the tubes you will need to disconnect. There are two tubes at the back of the manifold… a firm one and a flexible one. The firm one is just like the one under the y-pipe, and is easy enough to remove IF you can get enough pressure on the connector. The flexible one was just kind of stuck on mine and I left it on. You kind of have to scoot the manifold forward and angle it out, but it will come out with the fuel rail attached. You may have to remove some tubes and such from their guides or brackets. That flexible tube was long enough that I just put the whole thing on the driver's side of my engine and left it there. It didn't seem to be sitting on anything that couldn't support it. I'm sure it can be removed, but at this point in the job I was tired, hot, and just wanted to keep going. Once off, IMMEDIATELY cover up the exposed intake holes with long strips of tape. Cover them completely, and make sure they STAY COVERED. Shine a flashlight in each hole first to make sure nothing fell down there. If so, get it out as delicately as possible. Vacuum up any other debris you see. You can now see the infamous coolant pipes. Step 11: Assessment At this point, you can see the coolant pipes and should be ready for the meat of this repair. The starter is right there too… right under the leaking pipes. Brilliant, isn't it? This may not be true for you, but I had an AMAZING amount of debris in here… honestly looked like a bird had built a nest. I have no idea how it all got in there, but some where at some point tons of debris got in here, and now it was all soaked in coolant. I think my coolant leaking may have been mitigated because the wet debris probably acted as a mud and sealed everything up a bit. I vacuumed it up with a shop vac prepped for a wet cleanup. Now you need to decide if you will see this repair through or not. Once the next step is taken, there is no going back, and honestly the toughest part of this job by far is getting the old pipes out. Step 12: Drain the Remaining Coolant Your first goal is removing as much coolant from the car as you can. On the V8's, there is a drain plug at the bottom of the car, but on the turbo's you won't have one. That drain plug required an allen bit that was larger than I had on hand or could even find at a hardware store. Honestly, in retrospect I wouldn't have even bothered locating it. I'm sure there's a pipe down there you could remove, but I didn't waste time looking for. I took a tip I found on a forum, and drilled a hole right in the middle of the center coolant pipe (of three) and used a siphon with a hand pump to drain out every bit I could. I repeated this process on the larger lower pipe. DO NOT SIPHON BY USING YOUR MOUTH. Coolant is dangerous, nasty stuff. Make sure there are no animals or kids around while you are doing this. WEAR SAFETY GLASSES AT ALL TIMES! Doing it this way you're going to spill a lot of coolant, but it is what it is… they've been leaking all over everything anyway. I used my shop vac to vacuum up anything I could that escaped the siphon. I've also read of people renting professional vacuum pumps to suck it all out, but again, that's more complicated than it needs to be. I did some research, and coolant is not currently controlled by the EPA for disposal, and it can't be recycled. The unofficial advice I got was to dump it in the woods and douse the area with a hose for a bit. Do not dump it down the drain or dump it where animals could readily drink it. Don't dump it in a stream. Presumably it breaks down fast enough on the ground that there isn't a long lasting effect. Step 13: Remove the Three Upper Coolant Pipes The first pipe you need to remove is the long skinny pipe with three connectors. This one is easy enough to remove, and you should have a replacement as part of the kit. One of the connectors broke off in the hole, and I had to very carefully remove the pieces. Relatively speaking this was easy compared to the rest. There is a compression ring that needs to be removed for the connection at the back of the engine, use the locking pliers to do that. Cover up the exposed holes with masking tape. You now have to remove the three upper coolant pipes. There is a bracket at the back of the engine holding the three pipes. There are also two clips attached (you'll be looking at the back side of them) to that bracket that just support a hose at the back (just has electrical connections in it, and it's probably already split so you don't have to be super careful). Pinch the connectors with a pair of needle nose pliers and they'll come off. You now have to remove three bolts from it to remove the upper half of that bracket. I removed two of them but couldn't get to the third without snapping the thing in half. Porsche was kind enough to provide a new one in the kit so I wasn't worried about it. You will now see three rubber hoses attached to the plastic pipes. They are held on to them with compression rings. Use the locking pliers on the rings to loosen them (they need to be squeezed together to loosen) and slip them back over the pipes. I did one at a time, completely removing the ring and setting it off to the side for safety. The locking pliers really excelled here. When using them, attempt to come at the ring from the top instead of the side, the grooves on the pliers will then secure the ring quite nicely. You might have to adjust the pliers a couple of time to get the right amount of the compression for the ring to move freely. With those ends free, I used the shop vac to suck out a lot more coolant. Once done, cover up the exposed holes with masking tape. Once those three ends are free, you'll need to free up the other ends. Here's the deal, they are probably going to break when you try to remove them, and probably going to snap off at the spot where they connect to the coolant reservoir. I twisted and pulled and sure enough, they snapped off. You can remove the lid of the coolant reservoir by removing several screws, a small aluminum pipe on top, and the rubber pipes towards the front of the car. The small aluminum pipe has a single screw that needs to be removed. There is probably a lot of corrosion here so you may need to use a flat head screwdriver to pry it out. Be careful, it's flexible enough to come out and get out of the way but just barely. There is a compression ring on each of the rubber pipes that is easy enough to get to, just loosen and slide it down the pipe. Suck out any coolant and cover the exposed pipes with masking tape. Once you have that lid out, you'll see the remaining plastic bits in the holes. It's difficult to move, but those plastic bits are just in there with pressure, they aren't glued or anything. I used a small chisel and the hammer to break them out. As I got to the o-rings I pulled on those with needle nose pliers and in one instance the whole chunk came out. I also used a lot of WD-40 to work everything out. What you don't want to do is take any risk of chiseling into the metal of the lid, so be careful. This is all about removing the plastic material. Each bit you remove gets you one step closer to freeing up enough pressure to get the remaining bit out. Once it's all clean, leave it off to the side while removing the big pipe. Step 14: Removing The Big Pipe This one is tough. Make sure you're rested, well fed, and cooled down a bit. If you're aggravated already, walk away and relax a bit. You will need to break this pipe into two pieces. I used a boring bit to drill a big hole in the top, and then used tin snips to cut chunks out until I got it in two parts. Again, I used a shop vac to suck out any remaining coolant as I went along. Really, anything will work… you could even use a chisel to break it out. It's coming out one way or the other, no need to be pretty about it. Once it's in two pieces, you can probably rotate the two halves apart. Use WD-40 generously on the ends first though, and give it a bit to work in there. Regardless, when I went to pull out the two ends, they ended up snapping off… leaving their end pieces in the hole. If you read through the three forums, different people use different techniques to try and avoid this with mixed results. This is the worst case scenario though, so lucky for you I fought through it and have plenty of advice. Assuming your pipe broke off as mine did, you will see a metal ring in each end, with black plastic between it and your car. That metal ring was an inner support ring for the original pipe and needs to be removed. This is a violent procedure. IMPORTANT: I cut up some lint free cloths and stuffed one into each end as far as I could so that any material from the following procedure wouldn't go any further. Once done with the procedure below, I vacuumed up anything I could and then removed those cloths. Again, use WD40 a LOT. I sprayed and sprayed as a worked, and I think it helped. READ THIS CAREFULLY: Removing the plastic and metal ring from each end is all about removing material. You are trying to get as much plastic out as possible. If you get the ring out first, great, but it's not 100% necessary. The plastic is what needs to come out, and you need to get it out from all around it. In addition to the plastic, there are two o-rings in there, so they are just adding more friction preventing this from moving. You'll get bits of that out as you work, and that's good. Eventually, you get enough bits out that the rest will just fall out. Use a hammer and chisel to collapse the metal ring on the top and sides as much as possible. I used to the chisel to cut in to it a bit too. Once I got it that far, I switched to the long screwdriver, hammering the end of it into the plastic over, and over, and over again. I pried as much as I could and worked out bits of material. This took a long time, but sometimes you'll get a big chunk out and that will give you renewed hope. Again, this is all about material removal. Keep telling yourself that. Every bit you get out makes this easier. Once you get enough plastic out, you'll see the metal ring move a bit as you work. This is a great sign and you are almost done. Ultimately, you should be able to pry it out with the screwdriver. NOTE: When working you want to work as much towards the metal ring as possible. You want to avoid scraping the inside of the hole where your new pipes will go. I did scrape up mine a bit, it's unavoidable, but regardless my new pipes don't leak. When you go to remove the bits closest to you, you're working somewhat blind and it is hard. This part almost broke me, but I used a mirror to check and recheck my work as I went along. Bright lights help here too. Honestly, I really can't say enough how hard this part was and how long it took in comparison to everything else. It was the part that had me the most worried, but I got through it. Once it's all out, remove the cloths from inside the pipe and vacuum a lot. Now is the time to clean stuff up too, as you're about to put the new pipes in. As a best practice, you should clean up the inside of those holes. I used some steel wool; I know some people used scotch bright or even buffing pads. I didn't go overboard with this; I just want to get any grime out of there. Step 15: Install the New Big Pipe At this point you should be elated. You're through the worst. Installing these pipes are a bit difficult, but not bad. If they are not already on there, put the O-Rings on the small pipe. Use the White Lightning grease or whatever you bought and coat the inside of the hole on the engine and the outside of the pipe. Use it liberally. A bit of WD40 wouldn't hurt either. Press it into the hole at the back of the engine and do your best to get it all the way in. This is where a small block of wood and a hammer come in handy; you can use those to tap it in the rest of the way. Do not put the rubber sleeve on it. For the big pipe, install the o-rings and lube everything up good with the grease, both the hole it goes in and the pipe itself. You will also need to grease up the end the rubber part goes on and the other end of the short pipe that the rubber sleeve will slip over. Place the tightening rings over the rubber sleeve as well. Slide the rubber sleeve as far as it will go over the pipe. Push the pipe into the hole, I found a twisting action worked well. I also used my metal screwdriver against the bottom of the engine bay as a lever to slide it in the rest of the way (it required a lot of pressure). You then need to rotate it to line it up with the short end of the pipe. You'll slide the rubber sleeve over it and then tighten up the two rings. NOTE: Be sure to rotate the rings as far down as possible so that the screw does not interfere with the three pipes you're about to place on top of it. The new big pipe should be in place, and you're now done with the hardest part of this job. Step 16: Install the Three Pipes You'll want to put the lid back on the coolant reservoir (replacing the seals Porsche included with the kit), reattach the pipes and tighten up the screws. DO NOT OVERTIGHTEN THE SCREWS. I snapped one clean off. Make sure they're tight, but don't put all your muscle into it. Once on, you are ready to slide those pipes in. You do not need to put the lower bracket at the back on first; I did it after installing the pipes. Again, make sure everything is lubed up well so that any points of friction are well covered. Slide the pipes in. I used by long screwdriver again as a lever to apply the necessary pressure. On both these pipes and the big pipe it looked like I could have gone another 16th of an inch, but nothing leaks so I guess it was far enough. Put the bracket on at the back before you attach the hoses. You'll use your locking pliers again to attach the compression rings. With the bracket in place it is obvious how far up the hoses go. You'll put the upper bracket on, using the spacers for the screws and screwing it down tight. Don't forget to attach the two brackets that hold that electrical cable in place. Not a big deal if you do forget. Step 17: Install Final Pipe Now install that skinny pipe. This one is easy. Don't forget about the small compression ring that goes at the far end. Everything else just clips in. Step 18: Assess Your Work Look over everything and make sure it all looks right. At this point you should have a sealed coolant system. Check all your connections and make sure everything is solid. At this point you're home free, and you should be feeling pretty darn good. Step 19: Fill Up Coolant I use a 50/50 water to coolant ratio… so I mixed everything up with what I had and filled up the coolant tank. Once it was full, I left it overnight and checked in the morning for any fresh coolant. I was totally beat from a long day of working on it and thought putting everything back together fresh in the morning was a good idea. Step 20: Put Everything Back Together You tore it apart, now put it back together. I cleaned everything as I went, so now my engine looks great and I think that's a good idea. You don't need to go overboard, just use some lightly damp, lint free rags and wipe everything down. Porsche should have also provided new seals that go on the bottom of the intake manifold. I replaced mine dutifully, and I am glad I did. The old ones just looked worn out, no way they weren't leaking. Putting everything together is pretty straightforward once you've taken it apart. Just be careful and make sure you get all electrical connections and hoses in back on securely and in the right places (hard to mess that up). Also make sure you remove every bit of masking tape as you go. Final Thoughts I am very, very glad I did this project for two reasons. One, it saved me a ton of money and two, I now know tons more about the engine. Doing this project means I could replace my fuel injectors, spark plugs, injection coils and a host of other things when and if I have to. I know where the throttle body is, and if it's sticking I know where to go to clean it. If I need to replace the starter, I know where it is and how to get to it. I can now take my car on trips without fear of a massive coolant leak. This was the last "major" Cayenne defect for me that needed to be fixed. The water pump & drive shaft were already replaced. With 116,000 miles, I have quite a bit of faith in my car not having a catastrophic failure (knock on wood). At the end of the day, I'm pretty proud of myself for getting this all accomplished, and I hope I've saved some other poor soul a ton of time by writing all of this down. If it does help you out, please reply to this post and let me know. Author Harness Category Cayenne (9PA, 9PA1) - Common Fixes and Repairs Submitted 06/11/2011 05:39 PM Updated 03/14/2017 07:05 AM  
  19. 3 points
    Recently PCA posted attempt to accommodate 996 owners who may be frustrated with value and IMS controversy. We're aware of the class action suit won against Porsche regarding the original IMS. Also, it's recommended that we replace the original IMS anyway and don't know how to determine if it was defective to begin with. There's a company publishing on Facebook, believe called Gearheads, that put the 996's as one of 8 sports cars that, if bought, should be done with extreme caution. Some of PCA comments included that maybe 1 of 10 996's may experience IMS failure (local dealer told me maybe 1 of 100 and part of problem due to lack of mileage accumulation) and 9 of10 potential buyers have issues with IMS controversy. Not very helpful from my perspective. Another engineering problem is with pinion gear in 2d gear of manual tranny. I've replaced IMS and installed new tranny. Assume there were at least 50k of this model sold and, if so, a lot of potentially frustrated owners. Acknowledge that some non 996 owners response might be we had a choice. MY car's been for sale and can only tell prospective buyer the replacement IMS warranty was only for 30 days. I'm preparing to discuss this at future PCA meets and seeking comments.
  20. 3 points
    So, again in an effort to help others that might look for this in the future: 996 GT3, Airbag Light and Durametric fault " Code 30, ignition circuit - side airbag, passenger". Side airbag = door airbag: There was nothing wrong with it, the connector was good, and I also electrically swapped a spare airbag that I had, but the fault remained. Knowing the issue was coming from that circuit, and since I had disconnected the door and the controller when I stripped the car, I looked at both of those, looking for a bent pin, or? I expected the door connector to be the bad player since it's a bit less straightforward to connect and disconnect than the controller. While trying to identify the relevant pins on the big connector at the door jam to wring out the wires, I noticed that, with the connector off, the two pins/wires for the door airbag were shorted together (no doubt a shunt to prevent accidental airbag deployment when the connector is not connected). I also noticed that, in the connector, right next to the two pins, there was a small rectangular slot that matched a small plastic piece on the mating connector. At first I thought that it was an alignment device, but there was more to it than that, because there was a small piece of metal in the slot. While ohming the two airbag pins, I shoved a pick in the slot and suddenly, the two shorted pins/wires were no longer shorted, meaning that THE PLASTIC PIECE HAS TO BE ALL THE WAY INTO THE RECTANGULAR SLOT so that the circuit is in an acceptable state for the airbag controller. So again, even if the connector appears to be connected, you need more than just the pins to be in contact, you need the plastic tab to be all the way in to the slot. These pins and slot are part of a sub-connector within the main door connector and the sub-connector is somewhat free to move a bit. I made sure that it was all the way in and now my airbag light is gone. I'm sitting in the car with the laptop, having gone back in with the Durametric to clear the code, and decided to tell my story. Hopefully it can help someone. Case closed :)
  21. 3 points
    I hadn't driven the car lately and took it out for a spin. After it warmed up, I stretched it's legs until the speedo pegged stupid, then i eased out of it for a mile or so and exited the highway. When I got to the intersection the oil pressure lamp lit up and i noticed it was about .3 bar. I could hear my sphincter pull my Levi's into my collon. A quick blip of the throttle brought it back up to 1.5, where it mostly stays. Even cold it doesn't usually make it over 3. So I headed to the house and hit this forum to find what I thought was my best guess as to what is causing this. The top choices seemed to be switching to the hotly contested "right" oil viscosity or a collaped or improperly fitted oil filter. I considered both of these causes and the bad charma my wife continues to throw at me and this car because she just doesn't get it. The correct answer turned out to be the bad karma. She caused the low pressure piston spring to break in the middle and the movement/vibrations allow it to thread itself back together to make a half as long - twice as strong spring, and that apparently will cause low pressure pretty much all the time. I ordered the part from the stealership $8, bought a cool new hat, and once it came in I swapped the springs. It took me little more detective work to find the bolt the spring goes over but once I did it is a 60 second swap. BTW, you can let out a lot of oil in those 60 seconds so be ready. That fixed it. 5 bar at start up, 1.5 at idle, and 3-5 going running thru the gears. I'm willing to bet there are more of these worn out springs/bad wife karma combos out there so now you know. Maybe the brighter already knew.
  22. 3 points
    To anyone who is following this topic: It CAN be done and is not as nearly complex as you might think. After my initial post I received an email from another forum member. He informed me that he had done the swap successfully a couple of year ago and that while it was not bolt on/plug and play, it was by no means as difficult as the internet would have you believe. He was amazingly helpful during the process and the only reward he wanted was knowing that another 3.6 swap would be done. I am currently driving the car with no issues, it has terrific power & drivability and I could not be more happy with it. There is one tiny trick he revealed that when you hear it, it makes all of the sense on the world and it solves the programming issues between modules, the key transducer and the immobilizer which in turn solves the problem between VarioCam & VarioCam+. We are going to post a write up on the swap procedures so that others can do it with the same success. What I liked best about the process was that there were no "workarounds", aftermarket pieces or hacks needed to make it work, it is all 996 and is very straightforward. Please note: we are not doing this for any kind of reward or fee, we are just so pleased that it can be done that we will share it with the forum, and that should happen soon.
  23. 3 points
    My 996tt Key is just too badly abused to be used lol So SunCoast Porsche Dealer was kind enough to honor the PCA discount and sent me the NEW design KEY which is an easy gut swap from old to new! As this process went on you can really see and feel why they went with a new key design. New weather seal design is much better and and the construction is 100% more solid. Of course its light years more pleasing to own. Box Old Key New Key Old and New OPENed Up Remove the Transmitting Crystal Pull back this Clip and this one Pull out the Circuit Pull the woodriff key out that is sitting on a spring to release the pressure on the key blade it self Pull and you have one dirty key... Clean the Key Blade using metal polish and bronze wire brush (bronze so you don't scratch the key blade when cleaning.) LOTS of dirt from the keyblade! So fresh and clean your Key Blade will be Don't forget to clean the tract ... do it right! Plug it into the same spot but on your new Key New All rubber pad in the new key Plug things back in old & new New Key with Crest Key Chain The BEST part of it All.
  24. 3 points
    I've added a new section to the OBD II section that gives a table of Porsche System Tester(s) codes and their cross-reference to P-Codes. Useful when the service technican gives use a two or three digit code that is not a (Standardized DTC SAE J 2012) P-Code. This listing is also useful to related P-Codes, to determine fault types and whether the MIL (CEL) light on, off or flashing with a specific code.I think I transferred everything ok but let me know if you see typos or other mistakes.Porsche OBD II P-Codes Section
  25. 3 points
    So for everyone that has been discussing Porsche Cayenne ATF....AKA JW3309/LT41171.Porsche PN 000 043 205 28There has always been debate on Toyota Type IV being the same as the Cayenne ATF. So i sent in VIRGIN SAMPLES to blackstone to get the analysis on additives.The results are shown below:..........................................Cayenne ATF....................Toyota Type IVBoron.......................................73.........................................84Calcium...................................128.......................................105Phosphorous...........................292.......................................271Zinc...........................................6..........................................11SUS Viscosity @ 210F.............48.3......................................50.1cSt Viscosity @ 100C..............6.74......................................7.26FlashPoint in F........................410.......................................370Translation.....Both fluids are chemically the same as far as blackstone can see with their equipment. I attached the Porsche ATF slip for reference. VOAs cost $$, but well worth it if it saves cash down the road. I have some diff fluids coming as well for a VOA as well. The flash point requirement is >335F, which both exceed.So save yourself some $$ and buy the ATF from Toyota.
  26. 3 points
    Well thanks for the comment. I figured a way to get the Reservoir out and it indeed did leak from the seam at different locations. Received the parts and coolant within a day, and re-assembled the whole thing yesterday. The system is not leaking anymore, and the remaining task will be to find a place to get old coolant disposed before I can replace it. Overall I split the job over 2 vacation days, where-off most of the time I did spend analyzing function of components and how things are assembled and of course removing more parts then needed. Looking into these things is always interesting and entertaining to me since I normally analyze very complex systems on the nano-scale while getting hands off the computer keyboard and some physical workout hanging under the car for free. However, as a car non-expert I always wish to find more information on rather trivial looking steps, and since I could find nothing specific about the reservoir replacement , I compiled a picture documentation of how I did the 2006 CTTS coolant reservoir replacement job. Hope this might be useful for others too.
  27. 3 points
    996 owners don't hate their cars either! I love my C4S! That being said, I'm pretty excited to test drive a 991. I think my next 911 purchase will be a 991.
  28. 3 points
    There are three possible adjustments to the position of the windows: 1) inboard/outboard, 2) up and down at the front of the window and at the back of the window, and 3) forward and backward. The access holes on the underside of the door are two near the front edge of the door and two near the rear edge of the door. The ones closest to the front edge and rear edge of the door are for accessing the adjustment for 2) above. The ones furthest from the front edge and rear edge of the door are for accessing the adjustment for 1) above. To perform the adjustment for 3) above, you must remove the door panel to get access to the window regulator glass clamps. Here is a photo that will help you visualize what you are dealing with (click to enlarge): Note that this is the forward leg of the window regulator for the driver's side door (left side) from a 986, but it's the same setup for a 996. 1) The yellow arrow points to the very edge of the access hole black rubber plug for adjustment 1) [inboard/outboard]. That adjustment is accomplished by loosening the 10mm nut that is on the opposite side of the stud whose flattened head can be seen at the foot of the regulator leg. When you loosen the nut, the stud can be moved inboard and outboard and that affects the inboard/outboard position of the window when it is closed. 2) The red arrow points to the access hole black rubber plug for adjustment 2) (up and down final position of window when it is closed). To make that adjustment, pull off the rubber plug and insert a socket with an extension to turn the torx head screw to which the green arrow is pointing. Clockwise will lower that side of the window, CCW will raise that side of the window. You can raise or lower the front of the window with the torx screw in this photo, and raise or lower the rear of the window with the torx screw that is on the rear leg of the window regulator. Even though it's a torx bolt, a 5 mm socket will work. 3) The white arrow points to the screw that tightens the rubber-lined metal clamp that holds the glass window onto the window regulator. There is one metal clamp on each of the two window regulator legs. In order to perform adjustment 3) [forward/aft], you must remove the door panel to get access to that screw on each of the two clamps. Once you loosen each of the two screws, you can move the glass forward and backward, enough to fix the problem described in the first post. Be careful not to overtighten the clamp because it is squeezing the glass through the rubber pads. Here is a closeup of the window regulator torx screw and window clamp to help you get oriented: Regards, Maurice.
  29. 3 points
    Hi All, I've located the problem, quite simple really apart from the lack of space behind the dash. I located the servos, there are three I could see, and one under the dash controls the recirculation system. one nearest the shifter is the footwell, there’s one a little further up I assume that’s for the face vents or windscreen. In order to access the servos first remove the bottom panel, one torx screw nearest the seat in the centre, then drop the panel down & detach the 12v aux sockets (there’s 2 on mine). Also detach power from the footwell light. Then remove the glove box, very simple just a few screws then is drops away. Then you can see more. If you follow the wires you see the servos, all 3 are the same basic type. 3 screws hold each one on, that’s the more tricky part as they are fiddly, but once the servo is off you can test it. Mine was dead, but once I worked it a little it jumped into life, maybe it was jammed. I them popped the cover off and you can see inside, there’s a little motor in there and a few contacts, I cleaned it all up with contact cleaner lubricated it and reassembled it. Then hey presto I had a blast of air in the footwells. So that’s the first time for 4 years +, and the dash didn’t have to come out, thankfully. If it fails again I'll get a new solenoid, I think now I know I could replace it in 15 minutes. Hope this helps someone else, regards James
  30. 3 points
    After reading this forum on Saturday, I went about replacing my amber side markers with clear side markers. After partially removing the wheel well liner like this forum and the owner manual suggests I struggled to remove the first side marker. After about 20 minutes, the first amber marker was out. What a chore. Now that I could see specifically how and where the marker attached (with pressure clips) I decided to take a different approach on the second side... 1. Slip a piece of fishing line (I used 40lb test) under the front point of the side marker. You may have to put a little pressure on top or bottom of the lens to free up a gap to get the line completely under the point of the light. 2. Carefully work the line back from the point 1/2 to 3/4 inch toward the center of the light. 3. Holding both end of the fishing line, give the line a firm tug, not too hard. This will unclip the lens form front pressure clip and partially from the rear pressure clip 4. Carefully remove the lens the rest of the way from the rear pressure clip and a slight tilt will also release the safety clip as well. 5. Remove the bulb from the amber lens, replace bulb with amber bulb, align slots on bulb gasket with clear lens align tabs on clear lens with pressure clips on vehicle and press lens into place. Total time expended on first side (using the owner’s manual method) 30 minutes by the time I put everything back together. Total time expense on second side 4 minutes. I hope this helps everyone save some time so you can spend less time with your hand(s) wedged up inside the fender well and more time behind the wheel.
  31. 3 points
    Removing selector knob 1. Selector lever is in position D. Note! -- The button (inset) at the front must not be pressed down when the selector knob is pulled. 2. Pull selector knob up and off. Installing selector knob Note! -- The button must not be pressed down when the selector knob is installed. 1. Selector lever is in position D. Caution! Spring in selector knob is overstretched! - Only move the selector knob as far forward until the tool can be inserted. - Avoid any further overstretching. 2. The unlocking hook in the selector knob must retract to the button grey object . Lock the hook under the button, using short screwdriver A for example. 3. Push on the selector knob until it audibly engages in the selector support. The sleeve is then inserted in the selector lever cover. 4. Remove the tool on the handle. 5. Functional test of gear selecting system: - Will the vehicle start? - Do all the selector lever positions work?
  32. 3 points
    The famous plastic cooling pipes are indeed connected (push in) in to the thermostat housing, a small coolant leak at that spot drips into the V between both cylinder banks and evaporated before the coolant hit the floor, that could be the smoke you have seen. A leak on the water pump typically falls on the floor or the under tray.
  33. 3 points
    I change the driver side fuel pump (primary) last week end. If you need to drive the car and avoid to pay a towing, just remove the #1 pump relay in the engine compartment fuse box. You need a torx 30 because the relay is located in the hidden part right next to the firewall. If your car starts and stall in less than 30 secs... Remove the key, remove the #1 fuel pump relay, then restart the car. If the car still running after 30 secs, like me your primary fuel pump is defect. By doing this, the computer think there is no fuel on left side and run the secondary pump !!! I drove the cayenne about 60 miles with the second pump to the dealer to buy the fuel pump, small pipe and 2 seal because you need to open both side under the seat. The fuel pump have many pipe attached to it with different size and lenght to avoid bad connection. Two pipes are running from left to right. The job is not easy but you need to do it when the tank is almost empty or use a manual pump like me. Do it outside, the smell is horrible and take a tylenol. Dont forget to clean the fuel filter on the top plate driver side, I never seen so much black dirt in a small filter... I clean it 8 times in fuel bowl and reinstall it. I suspect dirt filter may cause the pump problem. To remove the bolt under the seat use M10 and they are very very tight and this is probably the biggest job to do. Then have a beer and congratulate you for saving 1,000$. I have all the pdf very helpfull if you want it, let me know.
  34. 3 points
  35. 3 points
    I have a 1997, which was the first year. It has been so long I do not remember all the details. The door lock thing I think was for model year 1998. In the US we did not even have a one touch up for the passenger window in 1997. That started in 1998. The window and top up thing started in 2002. I remember this because we took the top relay out of a 2002 and tried it on an older car. Did not work. Different control units. Live with what you have or buy a newer car..
  36. 3 points
    I know when I need technical information, I come to this board. So for all those who search the board for 997 air filter housing removal, hopefully they will find this thread...
  37. 3 points
    2003 Boxster - Purchased new in December '02 with mileage from the Port to my dealer here in So Cal (17 miles). I just changed my oil at 135,000 miles yesterday. I've only performed standard maintenance and do most of it myself: Oil and Filter (Amsoil 5W-40/Mahle Filter) every 15K Front Brakes - 60K Drive Belt - 60K Front and Rear Brakes - 120K Drive Belt - 120K Clutch as not been replaced on the vehicle. I have had to have my key reprogrammed on a couple of occasions over the years. I also had to purchase the shroud that must be removed to fill the transaxle twice due to road debris. I drive the car daily here in Southern California and drive a windy mountain road called the Ortega Highway to get from Southern California Wine Country to Orange County. I seem to replace the rear tires every 25K to 35K (I dumped the Pilots on my first tire change for a better wearing tire). Fronts about every two sets of rear tires. Best car I've every owned. It's my daily driver and runs incredible. Other than rock chips on the front from Southern California freeways, you would think the car had 20K miles on it. I just got in from the store...top is down and it's a beautiful day here today. Must be back in the 80's...heading back out to grab some carne asada for the barbecue. B) All the best, Bill_SoCal (Murrieta, CA) 2003 Boxster 2006 Cayenne 2008 Cayenne S
  38. 3 points
    Because of the demand for disassembling sun visor - here it is: 1. Unclip mirror insert 3 -- Insert a narrow screwdriver between the mirror insert 3 and the mirror housing 2 at the bottom center, and unclip the mirror insert. 2. Remove mirror insert 3 -- Pull the mirror insert 3 upwards and remove from the mirror housing 2. 3. Remove bulb 5 and contact clips 4 -- Remove the 12V /3W bulb 5 from the contact clip 4. Take the contact clips upwards out of the holder. 4. Unclip mirror housing 2 -- Insert a narrow plastic spatula between the mirror housing 2 and the sun visor 1 on the left and right and unclip the mirror housing. 5. Remove mirror housing -- Take the electric lead out of the mirror housing 2 and detach the mirror housing from the sun visor.
  39. 3 points
  40. 3 points
    I would add the following to help others attempting this ... please read the above and the below completely BEFORE starting your work. You'll thank yourself ! Getting the tank out I'd remove the air pump instead of tying it to the side as above. Its very simply and takes 30-40 seconds. It gives you room you REALLY need. Plus you won't break the air hose by bending it too much. NOTE: There are two screws that hold the air pump in place - at the bottom. In my case I found out that the nut thse screws go into had fallen off during removal. The nuts are 'suspended' in a rubber tube and age/temperature had made the rubber brittle and the nut had just fallen when I took the screw out. I simply got new speed nuts (2x : part number: 999.500.078.00 : $2) and used them to fit the air pump back again. Its worth taking the air pump off even if you now need to buy $2 more of nuts when ordering your tank - it gives you a lot of room you need ! To remove the coolant reservoir easily out of its harness, slide it towards the engine (i.e. move right) by around 1/2 to 1 inch. Then move it DOWN and out of its rail/holder. There is no need to slide it COMPLETELY (3-4") towards the engine completely as it first appears. The railings have tabs and gaps to facilitate such removal/installation. You probably won't even have that much room to slide it out completely ! When draining the coolant from below the car, you'll need a bucket to keep most of the coolant and may need to empty the tray below into the bucket. Use 2 trays so you can empty one when the other is below the car. The coolant drains fast, so you can't use just one without making a mess. Also, there is a lot of coolant, almost a bucketfull. Coolant is a corrosive liquid - keep it off the paint. If you drop some on the paint, don't panic, just wipe it off with water and a cloth. Use gloves if possible. The drain plug for the coolant is close to the rear bumper, don't search too deep inside near the transmission etc ! There is a coolant level sensor at the bottom of the coolant tank. Its deep and tough to see and you may break it manupulating the tank of get it out of the engine compartment. I'd recommend you reach down and remove it as follows. - when reachable, turn the sensor by 1/4 turn from towards you to towards the engine. - pull the sensor out from the bottom (it needs 2" to fall out, its 2.5" tall). - keep it somewhere ! If you do break it (likely), its around 10-18 bucks, so don't panic ! Lastly, be patient in getting the tank out. Its not difficult but simply time consuming. Be careful not to bend/break other hoses while you try getting the coolant tank out. Putting the new tank back in place When installing the new tank, I found it easy to first install the sensor at the bottom and then twist-lock it (1/4 turn). The electrical connection should point towards the right taillight. First try to get the entire tank in the volume reserved for it in the engine compartment. Don't try to directly fit it in. Make sure you don't leave any tubes/connectors behind the tank during installation. The last think after installation is to realise you need to get it out to rescue a forgotten tube. Now you want to get the tank back in its harness. The harness' as well as the tank's railings have gaps to ease removal/installation. What worked good for me was rotate the tank anti-clockwise by 10-20 degrees when inside the cavity/volume of engine compartment position the right most tab of the tank sticking out of the harness while keeping the other two tabs (on the tank's top) positioned to fall in the gaps between the harness' tabs. Try feeling the gaps with your finger to know where the tank's tabs should land. Slide a 1.5" diameter metal tube at the bottom (running front -> back) slightly to the left (or right?) so that the level sensor wouldn't be obstructed upon rotation. It should gently slide out of its holder. Now level the tank (i.e. rotate it clockwise by 10-20 degrees). The tank's tabs should have fallen where the harness' gaps are and the tank will be one tab sticking out (out = towards the engine) Finally move the tank gently away from the engine, in its final installed position [*] Slide the metal pipe back into its clamp [*] Connect everything else just the reverse as removal. After everything is installed Once you have the new tank in place, you will need to refill it with coolant and 'bleed' the coolant system. Fill the coolant tank with existing/new (porsche recommended) coolant to the max level and close the coolant tank lid. I simply filtered my existing coolant with a old (but clean) cotton t-shirt and poured it in using a funnel. Then, to quote Loren, "Lift the bleed valve." "Start the engine and allow it to get to full operating temperature (I also ran the air conditioning to force circulation). The coolant warning light will likely start to flash. Shut the engine off and WAIT until the engine and coolant has cooled enough to remove the coolant tank cap. Then add coolant to the tank and repeat the process. You made need to do this 2-3 times. When the coolant level fails to fall then the system is bled and you can close the bleeder valve." About bleeding the coolant system. Close the bleeder value after about 40 minutes (total) of good driving. You shouldn't ride with it open for more than this (my Porsche tech told me this). You MUST wait for the coolant to cool between your 2-3 tries, else you won't be filling the tank completely (coolant contracts as it cools). I've had to wait for over 3 hours to cool. If you try before this then the coolant will spill off when you open the cap. You may get a coolant light even with the bleeder valve closed after a few days. This is ok and doesn't mean you cracked your tank or something again. Basically there was some air trapped and the car "burped" it into the coolant reservoir, triggering off the coolant light. Wait for 4 hours for the car to cool and then top off with coolant+water (replacing a lot) or just water (replacing just a little). If even after 3-4 top offs/"burps" you need to keep adding coolant, have it checked for other leaks in the coolant system. In the end, once you've done it, please pat yourself on the back !! Great job :thumbup: !! Even my service tech. at the local dealership said its not a simple job. Its worth doing it on your own if you suspect you're losing coolant. :cheers: Sid
  41. 3 points
    For those with the horn problem, I wanted to steer you towards the black hi temp silicone repair. I tried going to Lowe's, Home Depot, and even Ace for the o-ring solution suggested by jporter, but could not find an o-ring #38 or nylon washers of the right spec. Very frustrating. When I took off the airbag, I found that my rubber bushings were all still in place! This intrigued me because everyone else's had tears or even torn all the way through. Nevertheless, the silicone fix has solved my horn problem, and I conclude that my rubber bushings, though still intact, had become exceptionally flimsy, and unable to offset the airbag's weight. Good luck to others with this problem. James
  42. 3 points
    Easier fix is to fill the rubber bushing completely with Black hi Temp silicone gasket in a tube available at all auto parts stores. It dries hard and returns the horn to normal operation.
  43. 3 points
    Removing: Lever the locking button A off with a suitable tool or finger. The locking button must be pressed so that the tool can be inserted between the selector lever B and locking button. (The ignition key must be in position 1 before the locking button can be pressed.) 2. Remove compression spring A and pull spring clip B off toward the rear. 3. Pull selector lever up and off. Installing: 1. Assemble the selector knob with spring clip, compression spring and locking button. Fit conical compression spring with the small diameter facing the guide peg.) 2. Press the complete selector knob onto the shift lever until it bottoms. The spring clip must fully engage in the slot on the selector lever. 3. Check function of locking button.
  44. 2 points
    The RENNSTANDs are the safe and efficient solution and they're in production. They even have jack pads specifically for the Macan. I purchased four but you can get away with two, using them first on the front jacking points and then conventional jack stands with polyurethane protective pads on the yokes for the rear jacking points.
  45. 2 points
    I used these and had the local Discount Tire install them for $20. No programming required and they work fine. http://www.tpms.com/Huf_IntelliSens_RDE011_Set_p/uvc0011set.htm
  46. 2 points
    Brown/Green and Borwn/Black got to the brake pad sensor. Brown/Blue and Brown/White go to the speed sensor. brown wire goes to ground (chassis) at the wheel carrier screw point.
  47. 2 points
    Cooling System (Boxster/Boxster S) (click to enlarge)
  48. 2 points
    The dual mass flywheel is the only source of harmonic dampening in the engine, removal of that capability can lead to serious issues, like cracked (or worse) crankshafts. These engines are not particularly well internally balanced from the factory, so the dual mass dampening is rather important. More than one leading Porsche engine builder has recommended against using single mass flywheels unless the entire engine components and the flywheel are properly rebalanced as a unit. A second consideration is how well the single mass itself is balanced; we have seen several that were 10 grams (and more) out as delivered. These flywheels are also difficult to have accurately balanced; only a handful of machine shops can do a proper job. And even after one is correctly rebalanced, they still can be a bit of a pain to drive on the street due to clutch chatter related issues.
  49. 2 points
    check out Dutch Treat Porsche in Lawndale, near Manhattan Beach. Rob is honest and knows his stuff.
  50. 2 points
    PCM1 used two different navigation drives. Up to 31st January 2001 it was an 8-bit drive. After that date it was a 16-bit drive. If you are lucky enough to have a 16-bit, then you can run the Vauxhall/Opel maps for their NCDR/NCDC systems. If your car is 2002 you should be OK. To check which drive you have: From A/C Screen, press bottom right knob. It will display the PCM version, and the Navigation software version. PCM/IDIS V5.43 Nav Software Ver POIE609D = 8bit Nav Software Ver PONA642D = 16bit Nav Software Ver PONA628D = 16bit The update to the software was included in the Porsche 2002-1 map update. All that you need to do to update the system is to insert the 2002-1 map, and the system updates automatically. After that, the Vauxhaull/Opel maps will run. AFAIK, the 8-bit systems cannot be updated. Porsche have released maps for PCM1 systems dated 2008/2009, and I assume these are compatible. All the above applies to European systems. I don't know what is available in the US, I'm afraid.
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