AfterSales Training “Soft” Roof & Body Systems Sports Cars (9x1) P60 Porsche AfterSales Training Student Name: Training Center Location: Instructor Name: Date: _ Important Notice: Some of the contents of this AfterSales Training brochure was originally written by Porsche AG for its rest-ofworld English speaking market The electronic text and graphic files were then imported by Porsche Cars N.A, Inc and edited for content Some equipment and technical data listed in this publication may not be applicable for our market Specifications are subject to change without notice We have attempted to render the text within this publication to American English as best as we could We reserve the right to make changes without notice © 2015 Porsche Cars North America, Inc All Rights Reserved Reproduction or translation in whole or in part is not permitted without written authorization from publisher AfterSales Training Publications Dr Ing h.c F Porsche AG is the owner of numerous trademarks, both registered and unregistered, including without limitation the Porsche Crest®, Porsche®, Boxster®, Carrera®, Cayenne®, Cayman®, Macan®, Panamera®, Speedster®, Spyder®, 918 Spyder®, Tiptronic®, VarioCam®, PCM®, PDK®, 911®, RS®, 4S®, FOUR, UNCOMPROMISED®, and the model numbers and the distinctive shapes of the Porsche automobiles such as, the federally registered 911 and Boxster automobiles The third party trademarks contained herein are the properties of their respective owners Porsche Cars North America, Inc believes the specifications to be correct at the time of printing Specifications, performance standards, standard equipment, options, and other elements shown are subject to change without notice Some options may be unavailable when a car is built Some vehicles may be shown with non-U.S equipment The information contained herein is for internal authorized Porsche dealer use only and cannot be copied or distributed Porsche recommends seat belt usage and observance of traffic laws at all times Printed in the USA Part Number - PNA P60 005 Edition - 5/15 Table of Contents Description Section Boxster (981) Convertible Top 911 Carrera (991) Convertible Top Reference “Soft” Roof & Body Systems “Soft” Roof & Body Systems Boxster (981) Subject Page Convertible Top Convertible Top Operating Concept Convertible Top Fabric Convertible Top Insulating Materials Convertible Top Roofliner Convertible Top Frame Convertible Top Drive Convertible Top Sensors Convertible Top Locking Mechanism Convertible Top Sealing System Convertible Top Covers Convertible Top Emergency Operation Convertible Top Service Position Wind Deflector Roll-over Protection “Soft” Roof & Body Systems Page 1.1 Boxster (981) Convertible Top Operating Concept General Information The following development goals were realized in development of the 981 Boxster convertible top: • Roofline with significantly reduced sag points for a highquality appearance • Small stowage package above the engine compartment without convertible top compartment lid • Opening and closing while driving up to 31 mph (50 km/h) • Reduction in interior noise from 74 dB to 71 dB at 62 mph (100 km/h) "Open convertible top" switch Due to omission of the convertible top compartment lid (weight savings of 26.5 lbs/12 kg), it was necessary to stabilize the convertible top in the stowage position A passive stowage lock was developed for this purpose in the 981 Boxster "Close convertible top" switch When in stowed position, the convertible top is pressed onto the support surfaces of the centering pins with an increased counter-force of approx 140 N per side by way of subsequent tensioning of the kinematic system Page 1.2 The 981 Boxster convertible top is fully-automatic In other words, manual unlocking and locking of the front locking hook on the window frame when opening and closing the convertible top is no longer necessary The top is operated by way of two one-way switches in the area of the center console, one each for opening and closing, or optionally by way of the vehicle key A corresponding display with information text is shown on the multi-function display on the instrument cluster The entire opening or closing operation is completed in only approx seconds, which represents an absolute top value “Soft” Roof & Body Systems Boxster (981) Convertible Top Frame Convertible Top Fabric In order to enhance driving comfort, the convertible top is designed using an improved “soundproofing fabric” The material thickness was increased by 0.5 mm for this purpose The convertible top fabric features a “lap seam” that is additionally welded on the rear This guarantees maximum leak-tightness and robustness The glass rear window made of heatable single-sheet safety glass is permanently molded into the convertible top fabric In contrast to the 987 model, the rear window is incorporated in the convertible top material without a visible external frame, thereby further enhancing the quality appearance of the convertible top Both the height and width of the rear window were increased in order to improve visibility Different lightweight construction materials are also used in order to reduce the weight of the convertible top frame The plastics used are glass-fiber-reinforced plastics The bows are made of aluminum extruded profiles The structural parts of the convertible top frame are made of diecast magnesium This contributes significantly to weight saving and stability It was possible to reduce the use of steel parts to a minimum In order to realize the required small stowage dimensions, the side sealing rails to the door side windows are now divided into three parts Convertible Top Drive Convertible Top Insulating Materials An insulating material was incorporated between the convertible top fabric and the roofliner This has an additional positive influence on the interior acoustics The insulating material also made it possible to reduce the outline marks of the convertible top bows, thereby further enhancing the quality appearance The insulating material and convertible top fabric are permanently joined to each other and can only be replaced together Convertible Top Roofliner The roofliner of the 981 Boxster convertible top is made of textile fabric as before When the convertible top is closed, the roofliner covers the whole visible area of the convertible top The roofliner is secured at the front at the roof bow and at the rear at the tensioning bar Attachment at the sides, which is also responsible for the visual design of the roofliner, is realized by way of tension bands and pull cords The convertible top drive for opening and closing the top is fully electrical and features two gear motor units monitored by a synchronization control unit Omission of the convertible top compartment lid means that no other drive units are required “Soft” Roof & Body Systems Page 1.3 Boxster (981) Convertible Top Sensors Position Switch #1 Switch #2 Micro Switch in Windshield Frame Reed Switch in Windshield Frame (Proximity Sensor) Hook Extended Microswitch in Latch Hook Retracted in Microswitch in Latch Page 1.4 Open Open Closed Closed Open Closed Open Midway Closed Closed (Opens at 2/3) Closed Open Open at 1/3 Open “Soft” Roof & Body Systems Closed Open Open Open Closed Closed Closes as Latching Boxster (981) Sealing in the area of the windshield frame (5) is realized on the body by way of a corresponding sealing profile The entire sealing concept features a second sealing contour, which provides additional protection against water ingress In order to minimize noise, all rubber seals are additionally coated with a special lifetime anti-friction coating Convertible Top Locking Mechanism The convertible top locking mechanism is identical to the part used in the 991 Carrera Cabriolet model line Driven by an electric motor, the locking hook travels into the convertible top lock in the windshield frame during the closing operation and tensions and locks the convertible top in position Exact positioning of the front roof frame with respect to the windshield frame is ensured by two additional guide pins at the side Convertible Top Sealing System The sealing system of the 981 Boxster convertible top consists of five individual components Due to the newly designed convertible top frame, three seals (1, 2, 3) are used in the area of the side windows These seals are fitted on the side seal retaining strips on the roof frame In order to simplify any adjustment work and to make sure that this is performed correctly, the seal retaining rails are provided with cross-hairs (arrow) in the area of the screw joints These guarantee fit accuracy and seal tightness of the fitted seals Side Convertible Top Covers The rear seal (4) is inserted in the aluminum profile of the tensioning bar and is responsible together with the seal fitted on the body for water management in the convertible top compartment/passenger compartment area The seal on the tensioning bar also features small water troughs that guarantee reliable draining of water if the convertible top is opened when wet, for example Two flaps (1) are fitted on the left and right in the area of the B-pillar to hide the convertible top mechanism from view when the convertible top is open These flaps are fitted in the area of the roll-over bar mounting They are connected to the convertible top mechanism by operating cables and are therefore positively controlled and not require a separate drive When the convertible top is closed, the flaps are in vertical position next to the rollover protection “Soft” Roof & Body Systems Page 1.5 Boxster (981) Convertible Top Emergency Operation In the event of failure of the convertible top drive system, the top can also be closed manually The following extract from the Owner’s Manual explains the procedure Take the open-ended wrench out of the tool kit Using the open-ended wrench (a/f 13), turn the emergency release screw A approx times by 360° in clockwise direction until the guide pin B is located in position C Repeat the procedure on the opposite side Closing the Convertible Top Move the driver’s and passenger’s seat forward and fold the backrests forward Reach with your hand between the carpeting gap (illustration), then carefully pull out the carpet lining from the bottom along the belt reel trim and fold over Unlocking the Convertible Top Drive Page 1.6 Get into the vehicle Lift with convertible top on the right or left side with one hand Grasp the convertible top in the middle with the other hand Pull up the convertible top out of its stowage position until the top is approximately half-closed “Soft” Roof & Body Systems 911 Cabriolet (991) Opening the Convertible Top Compartment Lid Re-connect plastic attachment B and metal insert Insert metal side of the emergency operation key between convertible top compartment lid and convertible top Ensure that the bend of plastic attachment B points towards the rear of the vehicle Guide the emergency operation key along the plastic trim until it slides into opening K up to marking of the plastic attachment B Turn the emergency operation key by approx 90° in the direction of travel so that plastic attachment B faces upwards Page 2.10 Insert the emergency operation key up to marking on the plastic attachment B and turn another 90° in the direction of travel until the resistance felt is overcome Remove the emergency operation key Repeat the procedure on the opposite side (steps to 6) Pull up the convertible top compartment lid firmly with both hands on the driver’s and passenger’s side Grasp the convertible top compartment lid in the middle from behind and lift it up “Soft” Roof & Body Systems 911 Cabriolet (991) Emergency Operation of the Flaps on the Rear Side Panel Press down both rear side flaps manually until the end position is reached Pull off green connector L Closing the Convertible Top Remove both screws M from the motor/gear unit Pull the motor/gear unit N forwards until the gears are no longer meshed Holding the convertible top in the middle with your hand, pull it out of its stowage position until the top is approximately half-closed “Soft” Roof & Body Systems Page 2.11 911 Cabriolet (991) Remove stopper O for convertible top latch emergency operation Pull the convertible top to the windshield frame manually Remove plastic attachment B from the emergency operation key Swivel the metal insert out of plastic attachment B approx 90° upwards and pull out towards the front Insert plastic attachment B into the convertible top latch Turn plastic attachment B in an counter-clockwise direction until the latching hook is fully extended (resistance can be clearly felt) In order to completely close the convertible top, keep turning plastic attachment B in a clockwise direction until the latching hook engages fully in the locking point (resistance can be clearly felt) Page 2.12 “Soft” Roof & Body Systems 911 Cabriolet (991) Closing the Convertible Top Compartment Lid Convertible Top Compartment Lid When closing the convertible top compartment lid, body parts can get caught between the convertible top compartment lid and fixed vehicle parts Place the hands on the convertible top compartment lid when pushing 911 (997) 911 (991) The convertible top compartment lid is significantly larger compared with the previous model as it includes the rear lid for service access to the engine compartment The kinematics meet strict requirements due to operation while driving at speeds up to approx 30 mph (50 km/h), the smaller lid joints and the longer travel distance General Information Stand behind the vehicle Grasp the convertible top compartment lid above the brake light and push forward against the perceptible resistance until it is completely closed Push the convertible top compartment lid into the closed end position manually The convertible top compartment lid is not locked Screw on emergency hand screw H hand-tight in a clockwise direction The new hinge with integrated lock is installed as a preassembled module “Soft” Roof & Body Systems Page 2.13 911 Cabriolet (991) The drive for the convertible top compartment lid is part of the hydraulics for the convertible top and requires only one cylinder for each side This is possible thanks to a countershaft (arrow) integrated in the hinge, which separates the lid movement and the locking Convertible top compartment lid hinge The entire inside surface of the convertible top compartment lid is covered with foam This foam pushes the convertible top downwards in the stored state and stabilizes the specified position Wind Deflector The wind deflector blends in perfectly with the contours of the rear trim panel in the stored end position, therefore ensuring that there is no negative impact on the overall look of the vehicle and that use of the rear seats is not restricted Concept Description In the 911 (991) Cabriolet, the wind deflector is permanently integrated in the rear area and can be raised or stowed in around two seconds Manual fitting and removal are therefore no longer necessary and storage in the luggage compartment is not required, thus saving valuable space Excellent draft proofing is also achieved Page 2.14 The wind deflector is mounted in the vehicle as a preassembled module It is installed in the rear area on the convertible top support and the roll-over protection system When the wind deflector is raised, open-meshed fabric is rolled out and stretched behind the front seats via two swivelling bars (tensioning and deflection bars) mounted on bearings in the side rear area When not in use, the bars fold towards the rear and the open-meshed fabric rolls up automatically “Soft” Roof & Body Systems 911 Cabriolet (991) However, the roll-over protection of the 911 (991) Cabriolet is now much more compact and lighter With the predecessor, individual modules were bolted to an aluminum subframe The new roll-over protection system is based on a compact, self-supporting portal made from welded, high-strength aluminum profiles Compared to the predecessor, the installation length of the module has been reduced from 122 mm (module with subframe) to 70 mm, which provides more leg room (+ 26 mm) for rear passengers The weight has been reduced by 25% from 49 lbs (22.3 kg) to 36.8 lbs (16.7 kg) Mechanical support Open-meshed fabric Tensioning bar Deflection bar Roll-up blind body Wind deflector drive with push/pull shafts The wind deflector is powered by a central electric drive, whose torque is transferred to the lateral mechanical components using flexible shafts in order to implement the kinematically linked movement of the tensioning and deflection bars The high level of functional integration, mounting and positioning of the rear side panel, mounting of the wind deflector wire harness and sensors require a lateral mechanical support made from glass-fiber reinforced plastic The tensioning bar is made from a 3D curved extruded aluminum profile encapsulated in polyurethane The roll-over protection system is designed as a freestanding supporting structure and is also used for the connection of seat belts, “Top Tether” fastening points, backrest locking mechanism, convertible top hydraulics and control unit as well as for the module mounting with the linkage flaps and the new wind deflector including their electric drives With the flat roof contour and the rear seat backrests moved back, the modules can only reach their maximum extension height through the rear window when the convertible top is closed A hard metal pin on each module breaks through the safety glass in this case Occupant Protection The airbag control unit is responsible for sensing, actuation and permanent monitoring There is a pyrotechnic trigger mechanism with low trigger current, whereby an airbag ignition pill is activated Additional coils as found on the predecessor are not required There have been no fundamental changes to the existing proven occupant protection system There are six airbags and extending roll-over protection on board as before The high component rigidity means that the retaining frame also contributes to the vehicle rigidity Diagonal struts to the B-pillar and to the convertible top compartment contribute to a noticeable increase in the dynamic intrinsic torsional frequency of the body “Soft” Roof & Body Systems Page 2.15 911 Cabriolet (991) Notes: Page 2.16 “Soft” Roof & Body Systems Reference Subject Page List of Materials Required to Eliminate Noises Conversion Charts “Soft” Roof & Body Systems Page 3.1 Reference Eliminating Noise Symptoms (List of Materials for Eliminating Noises) This list was compiled from PIWIS Workshop document WM 0X00IN “Eliminating Noise Symptoms” as of March 30, 2015 Always refer to PIWIS for the latest information Lubricants, Teflon Spray Part Number 000.043.204.40 000.043.206.65 000.043.207.56 000.043.204.21 999.917.557.00 000.043.207.16 Description/Use Silicone compound Used on door locks Krytox, grease Used on hardtop latches Polylub, grease Used on the guide mechanism for the panorama roof Lock cylinder grease Used on lock cylinders Special sliding compound, liquid Used on seals Teflon Spray, sliding compound Used on running rails/Targa roof air deflector Type/Qty/Size Spray can (200 ml container) Tube (50 ml container) Tube (50 ml container) Spray can (25 ml container) Krytox Bottle (30 ml container) Spray can (300 ml container) Acoustic Foam (2 components) Part Number 999.915.337.40 Description/Use Acoustic foam, components Used on the body front section > body cavities Type/Qty/Size Spraying (200 ml container) Description/Use Felt strips Used on rear-wall lining Felt strips Used on protective panel for A-pillar Felt strips Used on convertible top/roof frame Felt strips Used on middle part of seat backrest/roof lining Felt strips Used on convertible top/roof frame Felt strips Used on side trim panel Felt strips Used on side skirt Type/Qty/Size 15 mm wide, mm thick, 1,345 mm long pieces - 25 mm wide, mm thick, 25 mm long 26 mm wide, mm thick, 62 mm long 25 mm wide, mm thick, 730 mm long 30 mm wide, mm thick, 5,000 mm long 35 mm wide, mm thick, 22 mm long 35 mm wide, mm thick, 45 mm long Felt, Self-Adhesive Part Number 993.555.545.00 999.551.138.40 997.561.509.00 964.555.565.00 000.043.207.44 999.551.173.40/New 999.551.140.40 Page 3.2 “Soft” Roof & Body Systems Reference Textile Fabric, Self-adhesive Part Number 999.551.169.40 999.551.170.40 999.551.134.40 Description/Use Textile fabric, damping strips Used on the Carrera GT Textile fabric Used on carpet in footwell Textile fabric Used on metal clips for trim panels Type/Qty/Size mm wide, mm thick, 1,000 mm long 15 mm wide, mm thick, 1,000 mm long 20 mm wide, mm thick, 65 mm long Base Strap/Plastic Foam, Self-adhesive Part Number 999.911.227.40 999.911.201.40 999.911.695.40 997.555.895.00 999.911.664.40 993.556.245.00 Description/Use Base strap/plastic foam Used on the fuel tank cover Sealing strap Used on door panel Plastic foam strips, sealing strip Used on the front wheel housing liner Plastic foam strips Used for woofer in door panel area Plastic foam strips Used on the front wheel housing liner Plastic foam strips, sound absorber Used on sound absorber for bottom of rear window Type/Qty/Size 23 mm wide, mm thick, 10,000 mm long 10 mm wide, mm thick, 1,000 mm long 30 mm wide, 10 mm thick, 680 mm long 15 mm wide, 15 mm thick, 640 mm long 20 mm wide, 15 mm thick, 680 mm long 36 mm wide, 25 mm thick, 830 mm long Protective Film, Transparent Rubber, Self-adhesive Part Number 996.537.237.00 999.911.738.40 Description/Use Protective film, transparent Used on rear side section Adhesive film, black Used on spoiler drive, protects against soiling Type/Qty/Size mm wide, mm thick, 95 mm long pieces - 10 mm wide, mm thick, 30 mm long Description/Use Teflon tape, Used on Targa roof Teflon tape Used on front/rear trim panel Tricot Tape Type/Qty/Size strips on roll mm wide, 1,600 mm long 19 mm wide, 16,500 mm long Teflon Tape, Self-adhesive Part Number 000.043.207.27 000.043.204.83 999.551.127.40 “Soft” Roof & Body Systems Page 3.3 Reference Double-sided Adhesive Tape/Plastic Foam Part Number 000.043.206.04 000.043.207.26 000.043.207.63 000.043.113.00 Page 3.4 Description/Use Double-sided adhesive tape 1-mm thick plastic foam Used to secure molding Double-sided adhesive tape, 1-mm thick plastic foam Used on hood compartment lid Double-sided adhesive tape, Tesafix 4965, high temperature resistant Used on A-pillar trim Double-sided adhesive tape, 1-mm thick plastic foam Used on molding in sill cover area “Soft” Roof & Body Systems Type/Qty/Size mm wide, mm thick, 4,000 mm long mm wide, mm thick, 3,000 mm long 19 mm wide, 5,000 mm long 19 mm wide, 5,000 mm long Reference Conversion Charts Metric Conversion Formulas Temperature Conversion INCH X MM X MILE X KM (KILOMETER) X OUNCE X GRAM X POUND (lb) X kg (KILOGRAM) X CUBIC INCH X cc (CUBIC CENTIMETER) X LITERS X CUBIC FEET (cu.ft.) X CUBIC METERS X FOOTPOUND(ft lb) X Nm (NEWTON METER) X HORSEPOWER (SAE) X HORSEPOWER (DIN) X Kw (KILOWATT) X HORSEPOWER (SAE) X MPG (MILES PER GALLON) X BAR X PSI (POUND SQUARE INCH) X GALLON X LITER X FAHRENHEIT CELSIUS X 25.4 0394 1.609 621 28.35 0352 454 2.2046 16.387 061 0353 28.317 35.315 1.3558 7376 746 9861 1.34 1.014 4251 14.5 0689 3.7854 2642 32÷1.8 1.8+32 “Soft” Roof & Body Systems = = = = = = = = = = = = = = = = = = = = = = = = = = MM INCH KILOMETER (KM) MILE GRAM OUNCE KILOGRAM (kg) lb (POUND) CUBIC CENTIMETER (cc) CUBIC INCH CUBIC FEET (cu.ft.) LITERS CUBIC FEET (cu.ft.) NEWTON METER (Nm) ft lb (FOOT POUND) KILOWATT (Kw) HORSEPOWER (SAE) HORSEPOWER (SAE) HORSEPOWER (DIN) Km/l (KILOMETER PER LITER) POUND/SQ INCH (PSI) BAR LITER GALLON CELSIUS FAHRENHEIT Page 3.5 Reference Notes: Page 3.6 “Soft” Roof & Body Systems Part Number - PNA P60 005 Edition - 5/15 ... the dynamic intrinsic torsional frequency of the body Soft Roof & Body Systems Page 2.15 911 Cabriolet (991) Notes: Page 2.16 Soft Roof & Body Systems Reference Subject Page List of Materials... shell is optionally available in the exterior color Soft Roof & Body Systems Page 1.9 Boxster (981) Notes: Page 1.10 Soft Roof & Body Systems 911 Cabriolet (991) Subject Page Convertible... Reference Soft Roof & Body Systems Soft Roof & Body Systems Boxster (981) Subject Page Convertible Top