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Showing content with the highest reputation since 08/13/2025 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. Welcome to RennTech If you do not have access to a wiring diagram for the vehicle, probably the easiest way to check the ground is to pull the bulb in the light and use a multimeter to check the condition of the ground at the bulb socket.
    2 points
  4. We have used them here in the US for years at MUCH colder temperature's than you get without ANY issues. Put on the adaptor, add external magnets such as the Filter Mag, and enjoy both better filtration and peace of mind.......
    2 points
  5. Welcome to RennTech The factory radio had a ground wire that had to be attached to the car's chassis under the dash as a simple anti theft device. If that ground is not there, the immobilizer will prevent the car from starting.
    2 points
  6. 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
  7. My 2001 C2 top has not worked the entire five years I've owned the car, full saga below.* Without all the back story, here's where I am today. When I click "Calibrate," nothing happens and PIWIS 3 returns "Function inactive, end position not reached." The front latch is reset per the service manual, and the clamshell potentiometer was installed at as close to 6.2k ohms as I can get it (about 6.24-6.26). [I rebuilt this engine in my dining room with my cat, 12,000 miles ago—I may not know what I'm doing, but I can follow directions.] Top is in service position. Actual Values / Input Signals Latch locked Catch not locked Latched unlocked Catch not unlocked (can't be both, right, has to be one or the other?) EDIT: RESOLVED, please see follow up post. Convertible top Convertible top raised Convertible top compartment Convertible top compartment lid unlocked Right side flap up Right side flap not up Right side flap down Right side flap down Left side flap up Left Side flap not up Left side flap down Left side flap down Speed Speed >5 km/h (3 mph) (that's not correct) Handbrake Applied Latching hook Latch hook not actuated Engine-compartment lid Engine-compartment lid closed Convertible top button Close convertible top button actuated Supply voltage 14.45 v Warning light on 36044.3 min (!) Actuation counter 1 1746 Actuation counter 2 65536 Calibration counter 2 Pot 1, convertible top 0.92 v Pot 2 (conv. top compartment. lid) 2.51 v Calibration: Pot 1 val 1 0.80 v Calibration: Pot 1 val 2 1.27 v Calibration: Pot 1 val 3 1.88 v Calibration: Pot 1 val 4 2.29 v Calibration: Pot 1 val 5 2.96 v Calibration: Pot 1 val 6 3.22 v Calibration: Pot 2 val 1 1.55 v Calibration: Pot 2 val 2 1.82 v Calibration: Pot 2 val 3 2.00 Calibration: Pot 2 val 4 2.71 These aren't even actual calibration values, are they, they're stored values from the last time it successfully calibrated. It's my latch isn't it. There's a microswitch I've overlooked, a stupid simple on off switch, and because of that, it never starts the calibration process. Guess I'm going out there one more time this weekend and taking that off again. Insight invited, thanks for letting me ramble. 😄 Keith *The Complete Saga I bought the car like this in January of 2001. Tip cab with a top that had been manually put up via emergency procedure. Dash light for the top was on. I found a matching hardtop an hour away that same week, manually put the top down, slapped the hardtop on, and drove it. Turns out, the left rear window regulator had failed and someone had manually pulled it up (the motor was missing) and then drove a drywall screw through the regulator frame close enough under the bottom of the window bracket that the window stayed up. I rebuilt both rear window regulators and in October of 2021, started working on the top. I probably didn't reset the latch correctly at that time, or the clamshell pot. Still, I told Durametric to calibrate and it started to. When the top moved doubt 1/2 way up, I could hear the pump motor straining and—since the rear interior panels were still off—I took a look: both hydraulic pistons were jetting fluid down the rain drains. I put the hard top back on. Then the engine failed, then (unrelated) I moved, and I spent all of 2023 rebuilding it. July, 2024, I sent two cores to Cab Hydraulics in Sarasota to rebuild. Put them in, new hoses too, and this time I reset the latch and the clamshell pot correctly. I think. But there was no longer a top warning light on on the cluster. I told Durametric to calibrate it, and it wouldn't. Opened a dialogue with the developers, sent them logs they asked for, did everything the guy said, and the last I heard was that maybe their software wouldn't calibrate it unless it was in an error state. Then (not their fault) I took a job and started the process of moving. Hard top went back on. July 2026, time to get back to it. I knew I was going to have to have access to PIWIS, so I followed that thread on some other forum ("under $75") and got the image running on my shop computer. Which, I understand, isn't the same as pulling up to the dealer, so I'm aware that's a possible failure point. I 100% believe the latch and clamshell pot to be correctly reset now. No dash light. When I click "Calibrate," nothing happens and PIWIS 3 returns "Function inactive, end position not reached."
    1 point
  8. Must not be seeing one of the microswitches (dirty, misaligned, or broken).
    1 point
  9. 1 point
  10. 1 point
  11. 1 point
  12. 1 point
  13. Porsche only - find a donor car to get them from.
    1 point
  14. 1 point
  15. It that a plug or plastic pop rivet? I am only finding the plastic rivet.
    1 point
  16. 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
  17. 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
  18. 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
  19. 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
  20. 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
  21. Sometimes these systems store a lot of secondary codes that confuse what is really going on. I would start by clearing all the codes and then see what comes back.
    1 point
  22. You should be comparing the voltages for the O2 sensor ahead of the TWC to those after the TWC: The voltage curve for the senor after the TWC should be a relatively straight line, the one ahead the should be a sine wave like pulse; if the voltage curves are both sine waves, the cat is toast.............
    1 point
  23. Non, push down with one hand, squeeze the ribbed bottom ring with the other hand and pull up, this is not as easy as it looks, succes.
    1 point
  24. Your alternator is not functioning, running you should have 14.5V DC. Pull the alternator, check the wiring connections to be sure they are tight and seated, if they are you are in the market for a voltage regulator..........
    1 point
  25. I'd start with checking the alternator, is it putting out 14.5 V DC at idle? If not, I would check to make sure you properly reconnected the wiring.
    1 point
  26. 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
  27. Do this someplace safe... Put in Neutral and see if the noise continues or not. If it does not continue then it is likely in the drivetrain (transmission, transfer case, driveshaft, rear end}. If it does continue then it is likely in the running gear (wheel bearing, axle shaft, or even warped brake discs).
    1 point
  28. Sorry I have not replied. I did not buy the Cayenne it belongs to a friend of mine and I enjoy working on them when I have time so I spend a few days a week fixing stuff. It been fund and I love finding something that is bad from either age or the last repairman messed something up. so far I have replaced both valve cover seals with the cam actuator seals and spark plug tube seals and new spark plugs. I also replaced the vacuum pump and fixed the power brake vacuum hose that was cracked on both ends, I also replaced the purge valve. I also made a new vacuum line from the oil air separator to front timing chain cover out of copper pipe with rubber ends. I was very pleased to see how nice the motor runs now. I also replace the rear hatch actuator to unlock the rear hatch before you would hit the button but it would not unlock you had to use your finger to manually unlock it from the inside. that's fixed now. Right now I have the head liner and the sunshade off and getting ready to clean the old headliner before I put in the headliner but, before I put back the headliner I'm going to replace both struts for the rear hatch, the glass does not stay up at all and the hatch does stay up but it slams when its closing. I also fixed the drivers seat back cover that kept coming off, I ran a screws 1/4 through bottom of the back cover to hold it to the seat. I have to do the same thing to the passenger side seat too. once I have everything fixed inside the car I need to see what the oil leak it has/had is coming from it could be from old valvecover seals that I replaced or the transmission is leaking. when he first dropped off the car the oil leak was massive and now after the work I have done to the car the oil stain is a drop so that may be fixed, but I need to see and make sure. Oh I'm having a problem finding the struts for the hatch the car has the power liftgate, I find the struts for the glass but I can't find for the power lift gate, does it now use struts for the hatch on the power lift get?
    1 point
  29. If you get a honk it means you have at least one zone open or one (or more) fault codes. You will need a Porsche compatible scanner to get the fault code and report it here. It should narrow down exactly where the problem(s) are.
    1 point
  30. The engine serial number would have been built in late 2005 or early 2006. Porsche rebuilt engines always get the latest parts and a warranty. To be sure you would have to open the engine to get the IMD diameter. If you want insurance then you can install one of the 3rd party IMS oiler solutions. IMS Solution: Oil Fed Plain IMS Bearing - No Ball or Roller Intermediate Shaft Bearings LNENGINEERING.COM IMS bearing failures are expensive. The IMS Solution is the only permanent solution to the IMS problem. Proven protection and the industry’s best warranty.
    1 point
  31. 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
  32. Found the solution, the circuit board inside to control unit was corroded at the power input, cleaned resoldered and now working! That’s saved a fair few pounds, just all the trim to put back
    1 point
  33. 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
  34. Today I did front final drive gear oil change. This DIY will show you how I did it. Since I had a hard time to access the drain plug, I removed fill plug and used a pump to suck out the final drive oil. Worked really well, and helped avoid messy drain, which puts oil onto the lower axle carrier frame too. FSM calls for change quantity of 0.42L, and I managed to remove about that much from the drive, so I feel confident I got it all. Used empty oil can go suck old oil into it, and another empty oil can to put same amount of new oil it, making sure I fill with what I removed. I actually filled the new oil can with maybe 1/4" more oil, to accommodate for some oil that pump cannot take out of can, and some oil left in tubing. Oil used for change: Mobil Delvac 1 full synthetic gear oil 75W-90 (direct cross reference to Shell TF0951 - factory fill oil) Oil refill quantity: 0.42L (bit less than half a quart) New fill plug part number: N 902 818 02 Fill plug tighten torque: 25.8 ft/lbs Fill plug removal tool: ratchet, extensions (at least 6"), 5mm hex socket, shop towels Look at this DIY before you do the change. Make sure you have all materials and time to do it. Expect about an hour to hour and a half to complete. Let us know if you have comments. Thank you.
    1 point
  35. Osunick, Your GPS antenna is located behind the rearview mirror. Hope this helps.
    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. 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
  38. 2001 C4 Cab. 58k miles. I have this exact problem, ticking that happens at idle, but slightest depression of clutch pedal makes it stop. Got new clutch 4 months 4 k miles ago. The noise started a few weeks ago,. Any idea how in the world the clutch master could be making that noise? Reluctant to replace without seeing how it could be the problem. Thanks.
    1 point
  39. I think this will do it. Good luck. DC Porsche 997 PCM Removal.pdf
    1 point
  40. Changed the master clutch cylinder and the noise is gone. Thanks for all of your comments. Carrera3.2, When I did the clutch/flywheel, I also replaced the: - IMS bearing and flange with LN Engineering upgrade - All 3 cam chain tensioners - RMS - AOS - Water pump - LN engineering Low Temp thermostat - Slave cylinder - Clutch master cylinder - Sparkplugs and all 6 coil packs - Cardan Shaft (the rubber guibo on my original shaft was cracked) - Coolant reservoir tank and cap - Changed Trans and front diff fluid - Changed oil and filter Hope this helps. If I can think of anything else I did, I'll add to the list. My car drives amazingly well now. Britt
    1 point
  41. I could not disagree more. You want the TB to be dry as only air passes over it.
    1 point
  42. 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.
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  43. They "pop" off, you can use two flat screwdrivers, a door trim clip disposer fork, or similar tool.
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