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Showing content with the highest reputation since 10/07/2025 in all areas

  1. If the oil cap is hard to remove, you have a high vacuum level in the sump, which is bad for a variety of reasons, including lean stalling. The correct way to access the AOS is to fully warm up the engine by driving the car for 10-15 min, then replace the oil cap with the one in the picture above with a hose that connects to the digital manometer. If the vacuum level exceeds 6-7 inches of water vacuum, the AOS is leaking air into the intake system, causing the lean stall conditions. The normal level of vacuum is typically 4-5 inches of water, which is a really weak vacuum level, so it doesn't take much of a leak to cause problems, which is why we always checked every car that passed thru the shop with the manometer.
    3 points
  2. The AOS can either be pin pointed or eliminated by having the car's sump vacuum level checked with a digital manometer (most quality shops have them as the AOS is a perpetual issue; surprise the dealer didn't do this).
    2 points
  3. 1 point
  4. 1 point
  5. My convertible top has never worked so today I started testing all systems. I reset the lid potentiometer to 6.2k, manually opened the front latch and told the PIWIS to perform a calibration. The windows begin to lower but they stop moving after a second, triggering the dreaded "Function inactive, end position not reached" error. I tested all of the microswitches and got good results. I moved on to the "Drive links checks" and can move everything (except for the side flaps) but not for more than a second before receiving "Function inactive...etc" errors every time. For some reason the convertible top ECU is receiving an actual speed value of "Speed >5km/h (3mph)". (Highlighted in yellow on the attached screen grab). Is that enough to halt every attempt to perform calibration or drive links checks? I found a DIY from Loren (see below) that said to cut the GREY/ PINK wire leading to the top ECU if you want to eliminate the speed check for top operation. I checked it against the 2000 wiring diagram and made sure it was pin 13 on connector 1. CUT! And there was no change in the Speed value. Still reading above 5km/h - 3mph with the car standing still, parking brake on. Is there something else that will cause "drive link checks" or calibration to last only a moment before returning a "Function inactive, end position not reached" error? Thanks! )
    1 point
  6. Thanks, Loren—I had not noticed there are three microswitches in the latch, I'll look at that 3rd one next.
    1 point
  7. Must not be seeing one of the microswitches (dirty, misaligned, or broken).
    1 point
  8. 1 point
  9. The easiest and probably cheapest way as well is to add a small amount of coolant compatible UV dye to the system and run the engine for a bit. The dye will leave a highly visible (with a UV light source) trail to exactly where it is coming from. We use this technique regularly in the shop to trace difficult leak sources.
    1 point
  10. Many times the servo is not bad but the foam from the flaps has deteriorated and jammed their movement. I would check that first then rest the codes and test before actually replacing any servos.
    1 point
  11. 1 point
  12. 1 point
  13. At the end of the day, it is your car and your money. Just be aware that there always has been a limit as to how cold an automotive AC can be allowed to get; some manufacturers actually set a minimum permissible temperature for their system in order to prevent some rather strange problems. We actually had a customer that complained his system seemed to be cooling fine and then would just shut off for no apparent reason during a rather warm and humid period. After some intense diagnostics, we discovered that his system was getting so cold (very low 30F air temps), that under some humidity conditions, the car was actually freezing over the inside heat exchanger, blocking air low until it defrosted, giving the appearance that the AC had quit. We traced the problem to an AC compressor replacement prior to his purchase of the vehicle, where the wrong part number compressor was installed that had a higher capacity rating than the factory unit. We evacuated the system, replace the compressor with the correct part number, recharged the system and found the air temps inside the car's ductwork now stayed at around 41F, one degree above the manufacture's minimum allowable internal air temp. The car never froze up again. While getting you system's AC temps as low as possible seems like a worth goal, sometimes the law of unintended consequences rears its ugly head............
    1 point
  14. Item 13 is the radial shaft seal. (click the image to enlarge it)
    1 point
  15. 2006 CAYENNE 955 4.5 V8 DRIVER SIDE PRIMARY CAT REPLACEMENT Full size pictures can be found HERE Writing this down hoping it can help out another pepper owner. SKip to the bottom if you want the short version. Had to replace the drivers side (LHD) primary catalytic converter as the flex pipe had completely corroded away and was flopping loose in the wind. I got lucky and found an aftermarket one on eBay for significantly less than what the dealer would charge me. You’ll need an assortment of tools for the job: Jack Jack stands Ramps for rear 10mm sockets 12mm sockets 13mm sockets Numerous extensions Wrenches in above sizes and flex head ratcheting are awesome 22mm O2 sensor wrench or crowfoot Straight ⅜” and ¼” ratchets and breaker bars for extra leverage as needed. Flex head ⅜” ratchet Long flathead screwdriver to open up the clip holding the O2 sensor wire T25 screwdriver or bit for your screwgun for trim pieces #2 screwdriver or bit for your screwgun for trim pieces Total actual work time was about 8 hours. I could have done it in about 5 or even less if I was truly ambitious, but was taking my time and making sure I didn’t break anything in the tight space. The time also included jacking up the car, removing the underneath skid panels, engine compartment plastics, drivers tire and wheel well liner as well as reinstalling them. See Pelican Parts for the skinny on accomplishing all of those tasks. I’ll skip those tasks here. https://www.pelicanparts.com/techarticles/Porsche_Cayenne_Tech.htm Also crack open the rear hatch and block it from locking as you’ll want to disconnect the battery ground. Here is a video that shows how. Super easy and never knew myself. No need to flip the seat. How to disconnect battery ground in Porsche Cayenne (955) I will preface my replacement with the added bonus of the car having the secondary CAT delete already done. So no fighting with those. So under the car, first things first was loosening up the connection between the tailpipe section and the straight pipe, which was connected to the primary CAT. As the existing bolts on the CAT were rusted and frozen, I just snapped them off knowing they would be replaced anyways. Don’t waste your time on PB Blaster or heat. Just break them off and be done with it. So with the easy work complete now it’s time to dive into the fun part. Move up under the car so you’re looking straight up where the CAT meets the exhaust manifold. You’ve got 3 bolts above you that you’re wondering how you’ll ever get to them without taking out the front O2 sensor and even then how. Give them a spray of PB Blaster or your choice of penetrant. Now move to the front of the car in front of the sway bar, there is an opening where you can see the 3 nuts on the exhaust manifold. With a combination of extensions you can reach the nuts with a 12mm socket. You can let them soak for a little while as you have another cup of coffee or beverage of choice. At this point you may be wondering why I haven’t mentioned the O2 sensor on the top of the CAT pipe. Well, because I drove myself crazy trying to figure out how to get it out. I went after it 8 ways to Sunday. From the top with swivels and extensions and the same from underneath. I could barely get a finger over it and did manage to get the socket on it but then couldn’t get it broken free as the leverage just wasn’t there, or the socket/crowfoot slipped off. Needless to say, I wasted about an hour or so on this and questioned my seemingly foolish decision to approach this project. In the process of doing all of this, I figured out I needed to remove the middle skid plate support bracket for more room to reach up in the small area. Working by myself created new opportunities to be resourceful, or stupid depending on point of view. Since I was already committed to this endeavour by already removing, AKA breaking, the lower sections of exhaust piping, **** the torpedoes and full steam ahead. I ended up just unbolting the CAT from the exhaust manifold, dropping it down and slightly rotating it. At that point I had a good view of the O2 sensor and slipped the O2 sensor socket right over it with a breaker bar attachment. With the room to get leverage and a straight shot at it, it came loose with a marginal amount of effort. Unscrewed the sensor by hand and pushed it behind the steering column. Now for the next problem. The CAT was just big enough to not slide out with the heat shield of the steering column shaft in place. So, prop the CAT in place and remove the heat shield (2-10mm bolts), giving that extra ¾ of an inch. And so with a small amount of finagling, out she came. Could I have worked a little more on it and fought it out? Maybe. But for two 10mm bolts, easy choice. At this point in time, I called it for the day as I was now about 5 hours into the whole job. Sunday morning - here we go for part 2. Now knowing how it came out, it should make it easy to go back in. And yes, it was. Reverse the process of the removal. Slide the new slimmer CAT up into the general position it needs to be, let it rest on the other parts while the O2 sensor is installed. I did unclip the connector up in the engine bay and hang it from the hood so it would spin freely while installing it. A tip I saw elsewhere, thank you. Now push the CAT up into position and viola!. NO! WAIT! The mounting bracket is farther forward than on a stock CAT by about a ½ inch and slightly rotated off the axis of alignment from the engine bracket. The CAT won’t go all the way forward to mate with the exhaust manifold. So… Now it’s pushing, rotating and mild cursing to get it around the engine bracket. In the end, I got it together. Final decision on the bracket, it’s staying unbolted. Not the preferred method, but that’s how we’re rolling since I don't have a welder anymore to move the bracket on the CAT. At this point I was able to get my hand up to get the nuts on the ends of the bolts and finger tight them. Slide around to the front with the long extension and reach in to tighten them up. Now, if you’re lucky, you may have an air ratchet or a battery operated ratchet, which I did, to tighten them up. Do so at this point. Back to the middle of the car to reinstall the short pipe piece to the flex end of the CAT and to the tailpipe. Reinstall the middle skid plate support bracket and you’re just about complete. I hope for all of you who lasted this far have good luck getting around the secondaries if you still have them or figure an alternate plan for that. Time to start the car before I put everything back on and drop it to the ground. Hook up the battery (sparky, sparky), key in the ignition, hand pushing the brake AND… nothing. PANIC!!! I know there’s power. The interior lights come on, chime is going ding-ding. Again.. Nothing. Hold on, let’s breathe a second. Oh lord, the wife will kill me if I killed her car. 3rd time, small prayer to Stuttgart and… SHE LIVES AND BREATHES!!! And much quieter too. Do a couple of start-stop operations to double check it’s all working and then off to reinstall all the plastics and drop her to the ground. I will say, fighting to get the wheel liner on, is an extraordinary test of patience and will power. I think I fought that alone for over 30 minutes. If anyone has tips for that process, I’d be eternally grateful. Couple of side comments on this. The CAT I purchased was an aftermarket unit I got off of eBay and have no idea who manufactured it. There were no studs in the flanges, just 3 bolts and nuts per flange. I was worried they were going to fall out during the install, but the new gaskets held them in place as the holes were the right size to screw the bolts through them by hand. I know this helped during the reinstall and not having to bend or cut off the bracket on the CAT. For the heat shield, some places had said to unbolt the steering shaft and move out of the way entirely. I did not want that headache to do a realignment of the shaft/steering wheel. So I just did the minimum I thought would work. Now that you’ve gotten to the end of my story, I hope it will give someone else the courage to take on the project. Take your time, step back, breathe from time to time and don’t rush it. It will happen. Please make sure to tip your waitress. SHORT VERSION Put car on jackstands or at least front end Put rear of car on ramps if only jackstands in front Disconnect battery Remove front left tire Remove wheel well liner Remove underbody skidplates/plastics up to bumper Remove heat shield from steering shaft Remove middle skidplate support bracket Unbolt/snap off bolts from primary CAT flex pipe to tailpipe/secondary CAT Remove short tailpipe section if secondary delete performed From front of car, reach in and unbolt the 3 nuts holding primary CAT to exhaust manifold Drop CAT down and rest it on car Using O2 sensor socket, reach up into area and remove sensor Pull CAT out of car Push new CAT up into the void and rest on car Install O2 sensor Push CAT up to exhaust manifold and bolt together Install engine support bracket (if applicable) Install tailpipe section to flex pipe end of CAT Install skidplate support bracket Install skidplates Install wheel well liner Install tire Lower car to ground Install engine compartment plastics Reconnect battery Start car CELEBRATE Now if someone can share an easy way to do the passenger side......
    1 point
  16. It that a plug or plastic pop rivet? I am only finding the plastic rivet.
    1 point
  17. Remember the new ride height will be 10 mm lower than the stock height - plus the springs, struts and swaybars will all be firmer than the stock items. As I said before another option PSS-9 (adjustable) Coilovers - likely easier to find as either OEM or aftermarket.
    1 point
  18. Having spent months chasing down my very heavy steering (yes I know some like it like that) I have finally managed to over come the heavy steering by bypassing the servotronic system and locking it into 75% assistance effort. Here's how I did it, but I would appreciate any thoughts on why it wasn't working if anyone has any constructive comment about the acceleration sensor readings - which is what I think the main culprit is.
    1 point
  19. Chances are your 20 plus year springs have softened and are already sagging a bit. Springs, swaybars and struts are a matched set - I would not mix them as you could produce unstable handling. Especially if you track the car. RoW 030 is fine for street and most track driving - you just have to be careful of large speed bumps on the street. PSS-9 (adjustable) Coilovers can supply suspension tuning and even lower for track days - but you would definitely want to raise it up for street.
    1 point
  20. Blue/white marking are stock springs. For factory Sport Suspension you will need new springs, stuts, and swaybars. RoW Sport Suspension Package for 3.2S 6 speed - Carnewal WWW.CARNEWAL.COM
    1 point
  21. I waited until I could confirm my problem is solved. After asking the dealer multiple time about vacuum level measured with a digital manometer and never getting a straight answer, I spent some time talking to the tech before proceeding. According to him, the reason the car would start when cold is it was still going through the 90ish second startup sequence with secondary air injection, coupled with the vacuum leak caused by the AOS. Which, to my not-very-Porsche-tech brain kind of made sense. After getting the AOS replaced, along with a cracked brittle oil fill tube and one or two other related minor bits that were also old, cracked and or worn out, the car seems to run fine, was actually quieter than I ever remember, and the stalling problem is resolved. And no CEL since the repair. There was never any big clouds of smoke usually associated with a failing / failed AOS.
    1 point
  22. I put it in my 2004 Turbo Cab and it works great. plug and play though playing content through your iphone is not as loud as the normal stereo... you don't have to purchase the NAV card; you can use apple carplay... works a treat. Hope that helps.
    1 point
  23. See if any of the fault codes have changed. If not, then I would still go the path based on the FRAU readings.
    1 point
  24. P2189 Lambda control adaptation FRAU (lower load range) (FRAU > 0.7) - below limit value Possible fault causes - Incorrect main filling signal from hot-film mass air flow meter - Fuel pressure too high - Injection valve faulty (dripping) - Tank vent faulty (does not close completely) P2189 Lambda control adaptation FRAU (lower load range) (FRAU > 1.3) - above limit value Possible fault causes - Intake system leaking (secondary air) - Incorrect main filling signal from hot-film mass air flow meter - Leak in exhaust system - Fuel pressure too low - Fuel injector faulty (stuck) - Fuel pump delivery too low P2187 Lambda control adaptation FRAU (lower load range) (FRAU > 0.7) - below limit value Possible fault causes - Incorrect main filling signal from hot-film mass air flow meter - Fuel pressure too high - Injection valve faulty (dripping) - Tank vent faulty (does not close completely) P2187 Lambda control adaptation FRAU (lower load range) (FRAU > 1.3) - below limit value Possible fault causes - Intake system leaking (secondary air) - Incorrect main filling signal from hot-film mass air flow meter - Leak in exhaust system - Fuel pressure too low - Fuel injector faulty (stuck) - Fuel pump delivery too low
    1 point
  25. Still Fighting the misfire, local shop checked some things and found that my battery cable, the bolt that goes through the fire wall and starter / alternator cable needs to be replaced ( starter also ) before they go farther with diagnostics. $720 for diagnostics and $4000 to replace above parts (parts included) Payed for diagnostics and did all work myself. Still same problem - misfire on cyl-1 and sometimes on 3 ( misfire on 4 was just loose coil from my sloppy install ) work in progress 😞
    1 point
  26. I replaced the crankshaft position sensor and so far, seems to have fixed the problem. The engine has started a lot quicker when cold and when warm. One of the easier jobs I have done on this vehicle. Although I do have one of these lifts I purchased about 8 years ago, it sure helps a lot (made in Germany): Scissor lifts WWW.TWINBUSCH.DE Scissor lifts
    1 point
  27. Just to close this thread. The alternator died sitting on a shelf for 6 weeks while other work was being done. A new alternator fixed my issues. I hate when something goes wrong simultaneous with other issues.
    1 point
  28. Manual is a huge component of my attraction to Porsche. Where I live, 2 similar spec 997.1 vs .2, the price difference is $15,000. i chose a .1 four and years ago. That 15k delta was left in the stock market (S&P 500) and has atleast doubled. Meanwhile my cars only trip to a shop has been a gashed tire caused by road debris. I’ve done all small repairs and major maintenance. (Although I have new issue today) Do you see yourself keeping this car for a year or 2? Or 10 years or more? If you plan on keeping a .1 I’d recommend the following: Swap to a low temp thermostat X51 baffle upgrade in the sump. consider upgrading AOS to aftermarket Ultimate AOS. 50 weight oil instead of factory 40 add 3rd radiator. ignore ALL internet boogeyman stories about the IMS. 2008 era, it is just another moving part. However if you ever drop engine for a clutch or rear main seal then have a seal removed such that IMS is no longer sealed and engine oil will splash in to lubricate it.
    1 point
  29. Thanks for the heads up! Maybe they meant litres. I fixed my lack of bass with gutting the stock cabriolet subwoofer enclosure and sealing it for a proper 8" DVC subwoofer install. Super happy that I did and only cost me my rear speakers since running 5 channel amp. Cut a hole in the box and flipped it over and cut to epoxy the old speaker hole closed. Added more foam to the "bass tube" after trimming to seal the whole enclosure.
    1 point
  30. Look, diagnostics is all about isolating the problem(s) so they can be addressed. With the sensor disconnected, you are only looking at the sensor, everything else is out of the equation. Same thing when you disconnect the sensor and the connector at the DME, then you are only looking at the harness. With the sensor connected to the harness, but the harness disconnected from the DME, you are looking at what the DME is seeing. You need to go one step at a time, there are no short cuts. Porsche tends to collect various grounds to specific ground points, mostly as a matter of convenience and reducing wire runs rather than running them all to one point. All the cars have a multitude of grounding points in them as noted in the wiring diagrams.
    1 point
  31. In case someone searches for vacuum line routing in the future
    1 point
  32. P0441 code is EVAP purge valve, alongside the drive side intake manifold tubes. P2281 Code is most likely an air leak between the MAF and the throttle body, the code generally means that the powertrain control module (PCM) has detected a degree of airflow at the mass airflow (MAF) sensor which does not exist at the throttle body.
    1 point
  33. On my 2000 C4 I was lucky enough to have nylon screws. They broke of course, but drilling and tapping was easy with a few tricks and observations: Using a soldiering iron to melt a hole through the center of the nylon screw makes drilling MUCH easier Used a 3/16" drill bit to remove the majority of the nylon then used a 6mm x 1.0 to clean the threads Plunge depth is 3/4" Use a "bottom" tap rather than a "tapered" tap so you clean threads quickly and without significant insertion.
    1 point
  34. Osunick, Your GPS antenna is located behind the rearview mirror. Hope this helps.
    1 point
  35. I had the same problem. I found a thread,not too long ago, mentioning to take driver side sill plate off and look under seat memory pushbuttons to check for a disconnected plug. Yup, mine was unplugged. Whole thing took me 20 minutes to do with an ipad to display the dyi instructions, flat screw driver and hex heads. Now my keys and seats work flawlessly. Might be worth a try. Happy hunting!
    1 point
  36. P0455 Leakage in fuel tank system Diagnostic conditions D Vehicle speed = 0 km/h D Engine speed = 0 rpm D Correction factor, height > 0.73 D Coolant temperature upon starting the engine may be no more than 6.8 K above ambient temperature D Coolant temperature when engine starts > 3.8 °C D Period for which the engine needs to have been running before ignition is switched off > 20 minutes D Ignition has been switched off for at least 10 seconds. D Ambient temperature 4 … 35.3 °C D Active charcoal filter load < 3 for minor leak D Fuel tank fuel level 10 … 54 litres D Battery positive voltage 11.02 ... 14.5 V D No fuel tank filling D No faults detected for ambient pressure sensor, coolant temperature sensor, vehicle speed sensor D No output stage faults detected for DMTL pump motor, DMTL switch-over valves and tank vent D No fault detected for tank vent (flow) E The diagnostic conditions can also be established using the PIWIS Tester via the short test "tank leakage test". After the test has begun, the ignition must be switched off. F NOTE E In this context, please also observe the function description. Possible fault causes E Tank cap not closed correctly, leaking or missing E Purge air line leaking E Tank vent leaking E DMTL (Tank Leakage Diagnostics Module) leaking E Leakage in fuel tank system Page 140 of 398 07/20/2006 Function description Tank leakage test/DMTL – Tank Leakage Diagnostics Module F Note E The tank leakage test is performed only on USA vehicles. Construction of the tank leakage diagnostics module: The diagnostics module consists of an electric motor with a small air pump, switch-over valves and a reference nozzle. In addition, the modul is heated so as to prevent the forming of condensation and ice. Procedure of the function: E The pump is operated via an electric motor and conveys air through the reference leak. The power consumed during this process is determined. E The switch-over valve switches and the air current is now directed into the fuel tank. The power consumed during this process is also determined. After a waiting period dependent on the fuel tank fuel level, it must be at least as high as the power consumption was during the reference leak test if the tank system is leak-free. E The system is identified to by leaking if the power consumption is lower during the actual leakage test as it was during the reference leak test. E An evaluation of the power consumption levels when the pump is started and after the switch-over valve has switched serves to identify faults within the tank leakage diagnostic module (e.g. pump blocked, motor spins at idle speed, valve does not switch etc.). E The diagnosis of heating, motor and switch-over valve is performed via the output stage of the DME control module. P0456 Leakage in fuel tank system Diagnostic conditions D Vehicle speed = 0 km/h D Engine speed = 0 rpm D Correction factor, height > 0.73 D Coolant temperature upon starting the engine may be no more than 6.8 K above ambient temperature D Coolant temperature when engine starts > 3.8 °C D Period for which the engine needs to have been running before ignition is switched off > 20 minutes D Ignition has been switched off for at least 10 seconds. D Ambient temperature 4 … 35.3 °C D Active charcoal filter load < 3 for minor leak D Fuel tank fuel level 10 … 54 litres D Battery positive voltage 11.02 ... 14.5 V D No fuel tank filling D No faults detected for ambient pressure sensor, coolant temperature sensor, vehicle speed sensor D No output stage faults detected for DMTL pump motor, DMTL switch-over valves and tank vent D No fault detected for tank vent (flow) E The diagnostic conditions can also be established using the PIWIS Tester via the short test "tank leakage test". After the test has begun, the ignition must be switched off. F NOTE E In this context, please also observe the function description. Possible fault causes E Tank cap not closed correctly, leaking or missing E Purge air line leaking E Tank vent leaking E DMTL (Tank Leakage Diagnostics Module) leaking E Leakage in fuel tank system Function description Tank leakage test/DMTL – Tank Leakage Diagnostics Module F Note E The tank leakage test is performed only on USA vehicles. Construction of the tank leakage diagnostics module: The diagnostics module consists of an electric motor with a small air pump, switch-over valves and a reference nozzle. In addition, the modul is heated so as to prevent the forming of condensation and ice. Procedure of the function: E The pump is operated via an electric motor and conveys air through the reference leak. The power consumed during this process is determined. E The switch-over valve switches and the air current is now directed into the fuel tank. The power consumed during this process is also determined. After a waiting period dependent on the fuel tank fuel level, it must be at least as high as the power consumption was during the reference leak test if the tank system is leak-free. E The system is identified to by leaking if the power consumption is lower during the actual leakage test as it was during the reference leak test. E An evaluation of the power consumption levels when the pump is started and after the switch-over valve has switched serves to identify faults within the tank leakage diagnostic module (e.g. pump blocked, motor spins at idle speed, valve does not switch etc.). E The diagnosis of heating, motor and switch-over valve is performed via the output stage of the DME control module.
    1 point
  37. About 3 weeks back I started getting a CEL with a Code 0335 Crankshaft Position Sensor "A" Circuit. Upper Limit Exceeded. After clearing the code it kept coming back within a day or two and the car stalled on two occasions. Based on research on the forums, this seemed very much in line with sensor failures on 955's and a DIY existed for these model years, but not the 957. My 957 now has around 120k miles, and the engine runs incredibly well, aside from this one recent anomaly. I ordered a replacement sensor, from Pelican Parts which arrived the next day (very impressive service) :lowdown: thanks Pelican Crankshaft Sensor Brand: Bosch Note: Engine Type: 4.8L 4806cc V8 (3.78x3.27; 96.0x83.0) (2008 Porsche Cayenne S Sport Utility) Part #: 0-261-210-292-INT As there was no info available on this DIY for a 957 so I'm hoping the following will help others get this done easily when needed, and in particular so you can save the 2 hours extra it took me to figure out where and how everything was located, as well as how to get to it. Which I did while I was waiting for the new part to arrive However once that research was done, the actual job of replacing the sensor took about 45 minutes. The main challenge is that the connector is difficult to access as it is behind and below the fuel pump on the right hand side as you face the front of the car. Even with an inspection scope it was difficult to locate. It was only once I looked from under the car that I could see where it was located. Also the connector plug is attached to a rectangular section of plastic tubing/conduit on the wiring harness, by a clip which is very rigid. After multiple attempts to release this clip it broke off. I think give the location it gets very hot and over the years becomes brittle. You should remove the engine compartment trim at the rear of the engine for better access. I also borrowed a few pics of an engine on the web to mark the location: I also found that removing the harness from the engine made it easier to get my hands around the connector to get the two ends separated. Once you have the old sensor disconnected, attach the new one and and tape the end of the new sensor tip with some painters tape just for protection and slowly lower it down into the engine compartment. It will end up either side of the primary cat where it is easily accessible from below. Also let the old sensor cable drop into the engine bay as you will then extract it from below. Now move to underneath the vehicle. I only needed to jack up the front left of the vehicle (jack stand + jack for extra safety). No wheels need to be removed. Do not jack up the car before dealing with the connector at the top of the engine bay as it will make it difficult to reach. Between the connector and the sensor, the cable is secured at 3 locations. See pictures below. The cable is pretty easy to remove and secure from below the vehicle and it can be seen and accessed without removing any of the under trays (depending on your level of flexibility). The lowest retaining clip is a push in type retaining clip where you simply press the cable into the tensioned clip. The two upper retaining clips are circular in shape and hinge open and closed. With a built of gentle persuasion you can pull them open and the cable comes out easily. I could not get the uppermost one in the pics but it is similar to the 2nd one shown in the pics. The sensor is held in place with a single torx T5 screw. Once you have the old sensor off you can pull it out and put it aside and attach the new one. I suggest attaching the sensor first and the attaching the cable to the retaining clips. Very rewarding and inexpensive fix, and everything is back to normal. No more codes and the car runs beautifully!
    1 point
  38. Although embarrassing to air my mistake, I thought I would post this in hopes I might save someone else from the same problem: If you have adjustable coilover shocks, do not attempt to change your car's ride height unless you are doing it while corner balancing with scales. I rationalized that if I set the ride height using the factory measuring method (documented in multiple places on this site) I would get "close enough" to a balanced car for a 996 that isn't tracked. Wrong. I worked on a level floor, with a full tank of gas (per spec), new tires with factory-recommended tire pressures, using the factory-recommended ride height measurement points, drove the car a few yards after each change to settle the suspension, and after a lot of hard work I was dead on with each of the four measurements. A local indie shop, not really performance oriented, vetted my approach and said it should be fine, it's what they would do. Even after a perfect-to-the-spec alignment this morning the car pulls to the right, enough at 40 mph with hands off the wheel to change lanes in less than 50 yards. My effort was wasted and I'm out the cost of that alignment. The car goes in for a pro corner balance to correct the issue and I'll end up paying for another alignment. Lesson learned. In truth, the effort wasn't entirely wasted because I learned about the stiffness of the chassis, how even a minute change of 1mm in shock adjustment can affect all four wheels, and how each of the wheels is affected. Dialing in the ride height was a PITA but a learning experience that I believe transfers to doing a corner balance. If you install height-adjustable shocks, you must corner balance for optimal handling even if your car is a daily driver and not tracked. Bless you suspension techs who do corner balancing for a living!
    1 point
  39. Latest: Faultless starting, hot or cold, during past 2-3 months.
    1 point
  40. Well... I replaced the hinge on the center console today. After reading all that was available, I went with doing it without removing a lot of stuff like the TSB. All done sitting in the back. Not hard to do. You will have to take a hack saw blade and cut off the unbroken hinge collar, then file both spots till they are flat. The U shaped rivet supports take a needle nose plier to put in place. Knock the shaft out from right to left. Vacuum the aluminum curlies out after you do the drilling.
    1 point
  41. My Porsche is a 1999 996 C2 Cabriolet. The convertible top compartment lid (the “lid”) is attached to the body via two hinges which each have two arms. The front arm on the left hinge was broken, so I replaced the entire hinge, as replacement arms are not available. Here is the step by step process of how I did it :(I had a bunch of great photos with this article, but for some reason they did not copy and paste with the article) (I'm what you might call "format impaired".) : Tools needed: Flat Head Screw Driver 10mm Box Wrench T-30 Torx Bit 13mm Socket Short Socket Extension Electrical Tape Parts Needed: Replacement Hinge Part #996-561-907-02 (Left side) Replacement Seal Part#996-561-904-00 (“Cabrio Plate” in Porsche terminology) 1. Open the top partially so that the top is open about half way and the lid is in the fully open position. 2. Disconnect the cables that keep the rear-most part of the top secure to the car. There is one cable per side. Push the cable inward (toward the center line of the car) to release it from the ball connection. Release both cables. 3. Let the top move forward toward the closed position and push the window section up and out of the way. 4. Use the flat-head screw driver to remove the 4 plugs that keep the rear carpet in place. Remove the carpet, starting at the top and working it around the trim. 5. Once the carpet is out, follow the lid stop light wire down and disconnect it. It simply unplugs. 6. Release the wire from fastening elements (Porsche terminology) on the rear arm of the left hinge. 7. Mark the location of both left and right hinges in relation to the lid, then use the 10mm wrench to remove the 2 nuts securing each hinge to the lid. Prior to removing any parts, cover the drain hole below the hinge with a paper towel to prevent any small bits from falling into it. Once broken loose, they can be turned by finger. (This is probably better done with the assistance of a helper to support the lid, but can be accomplished by one person working alone by removing the rear nuts first and supporting the lid in place with one hand while removing the front nut on each side with the other hand.) Remove the lid from the car by lifting it up off the hinge. 8. (For the left hinge, only.) Remove the plastic fasteners for the lid stop light wire from the hinge for reuse on the replacement hinge. These both just clip on and can be easily remove with needle nosed pliers. 9. Remove the additional flap for reuse with the replacement hinge. The flap is removed by pushing the locking lever forward, then pulling the flap backwards and pulling downwards out from the underside of the hinge top. 10. Undo the motor drive from the hinge rear arm by removing the 2 Torx screws with the T-30 Torx bit. 11. Disconnect the motor drive push rod from the front locking hook at the front of the hinge by releasing the small clip retaining it. It should come off by releasing the locking tab slightly and pushing down at the same time. 12. Remove the motor drive body from the body of the hinge by removing the 2 Torx screws with the T-30 Torx bit. It’s not necessary to remove the pin with the flat head slot on it in order to remove the motor drive from the hinge. It may take a little rocking, but the part should come right off without much effort. 13. To give more play in the hydraulic line to the motor drive to be able to get it well out of the way, with the flat head screwdriver release the tie securing the line to the bottom of the compartment. This just pops off and presses back onto a threaded retainer. 14. Move the motor drive out of the way and with the 13mm socket remove the 2 nuts and 1 bolt attaching the body of the hinge to the body of the car. The 2 nuts are clearly visible, but the bolt is concealed behind a plug in the trim piece covering the front of the hinge. To access the bolt, remove the plug with the flathead screwdriver. (Be careful not to drop the socket or the bolt behind the trim piece as fishing them back out may be a challenge.) Once the nuts and bolt are removed, the hinge can be gently removed from behind the trim piece by pulling up on the back of the hinge and rotating the entire hinge about 90 degrees counter clockwise and pulling up and back while gently prying up on the trim pice with the other hand. (This is probably the hardest part of the entire procedure.) 15. Adhere the seal to the back of the new hinge replicating the position of the old seal on the old hinge. Clean up around the openings in the body panel to remove debris left behind from the old seal. Remove the backing film from the seal before installing the hinge. Make sure the contact surfaces of the hinge and body are not adhered over by the seal. Installing the new hinge is the reverse of the removal procedure: Work the front of the hinge back behind the trim piece; Attach the hinge to the car body with the 2 13mm nuts and the 13mm bolt and torque to 7.5 ftlb.(I used the electrical tape to temporarily secure the bolt to the socket and the socket to the extension to ensure I didn’t drop either down behind the trim piece.); Attach the motor drive to the hinge body with the 2 long T-30 Torx screws and torque to 7.5 ftlb.; Attach the motor drive to the rear hinge arm with the 2 short T-30 Torx screws and torque to 7.5 ftlb.; Reconnect the motor drive pushrod to the lock hook at the front of the hinge with the small clip; Re-secure the hydraulic line tie in the bottom of the compartment; Attach the brake light wire fasteners to the rear arm of the new hinge; Reattach the additional flap by inserting it onto the pins on the underside of the hinge and pulling it forward then pulling the locking lever backward until it locks; Install the lid, leaving the 10 mm nuts slightly loose and press the stop light wire into the plastic fasteners and plug it back into the connection; Reinstall the carpet; Reattach the rear roof cables; Next align the lid, so it will close properly aligned with the body. Using the marks made at the beginning of the process should make this a bit easier.
    1 point
  42. They "pop" off, you can use two flat screwdrivers, a door trim clip disposer fork, or similar tool.
    1 point
  43. Posted this on the 986 forum, thought I'd share it here... here's the link to the 986forum.com post in case there might be any relevant discussions 986 forum DIY
    1 point
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