® AfterSales Training “Hard” Roof & Body Systems Cayenne (9PA), Cayman (987) & 911 (996/997) P65 Porsche AfterSales Training Student Name: Training Center Location: Instructor Name: Date: _ Important Notice:The contents of this AfterSales Training brochure was originally written by Porsche AG for its rest-of-world 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 © 2007 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®, CaymanTM, Tiptronic®, VarioCam®, PCM®, 911®, 4S®, and the model numbers and distinctive shapes of Porsche’s automobiles such as, the federally registered 911 automobile 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 However, specifications, standard equipment and options are subject to change without notice Part Number - PNA P65 001 Edition - 5/07 Table of Contents Description Section 911 (996) Body Equipment 911 (997) Body Equipment 911 Turbo (996) Body Equipment 911 Turbo (997) Body Equipment Cayman (987) Body Equipment Cayenne Body Equipment – 1st Generation Cayenne Body Equipment – 2nd Generation Conversion Charts “Hard” Roof & Body Systems “Hard” Roof & Body Systems 911 (996) Body Equipment P65 Subject Page Sunroof Operation Emergency Operation Adjustment General Information – 911 Targa (996) Body Shell Glass Sunroof Wind Deflector Front Lifting Unit 12 Sun Screen Motor 10 Lifting Rear Window 12 Sun Visor 12 Roof Channel 12 Seat Belt 13 Roof Module Construction 14 Body Equipment, Interior – 911 Targa (996) 20 Seats 21 Electrical System – 911 Targa (996) 22 Emergency Operation 24 Targa Roof Control Module Wiring Schematic 26 “Hard” Roof & Body Systems Page 1.1 911 (996) Body Equipment Notes: Page 1.2 “Hard” Roof & Body Systems 911 (996) Body Equipment The switch has three switch settings corresponding to the final positions: Sunroof Close - Open - Tilt The tilt-slide sunroof will operate: ● if the ignition is switched on (engine on or off) ● if the door is open ● if the door is closed and the ignition key is removed (but only until the door is opened for the first time) For the 911 Carrera (996) an electrically operated, infinitely adjustable tilt-slide sunroof is available as an optional equipment (RDW) and standard equipment for the North American market The tilt function integrated in the sunroof (opening height 28 mm) allows low-noise ventilation of the vehicle's passenger compartment, even at high speed Similar to the window lifters, there are two operating modes for the sunroof: One-touch function for open, close, and tilt Briefly pressing (approx < 300 ms) the appropriate button triggers automatic operation The sunroof can be stopped at any position by briefly pressing the button again In contrast to the previous model 911 Carrera (993), the roof opening is 18% larger (longitudinal direction) with virtually the same width The small installation height of the system increases head room by 36mm Direct coupling of the actuator transmission to the sunroof motor has resulted in a considerable reduction in operating noise Continuous operation for open, close, tilt, and lower The sunroof can be moved to the desired position by pressing the rocker switch The sunroof opens until it reaches a final low-noise position However, it can be opened completely by pressing the rocker switch again The sunroof is actuated via an illuminated rocker switch which is integrated in the cover of the drive unit at the front of the roof Further closing functions are possible with the vehicle key: ● Sunroof – 911 Carrera (997) (optional) ● The electric sliding/tilting roof is available as an option on the 911 Carrera/S (997) and is similar to the 911 Carrera (996) The roof can be moved to the desired position by pressing button in the remote control unit (at least seconds) The roof can be moved to the desired position by holding the vehicle key in the door lock at the locking position Anti-jam Device It is characterized by a low height and quiet running when operated The noise optimized end position to which the roof opens in response to "one-touch" opening has been modified slightly to reduce the noise level (approx -10 mm) It can be opened beyond this point to its full extent, if desired It is operated via the rear control unit An anti-jam device which, if necessary, stops the motion of the sunroof and causes it to open again is integrated in the closing cycle of the roof Note: If the vehicle is left unlocked for more than hours, the sunroof can no be actuated (this is to protect the vehicle's battery) “Hard” Roof & Body Systems Page 1.3 911 (996) Body Equipment Emergency Operation The fuse D should be checked before emergency operation is performed Using your fingernails or a screwdriver, carefully unclip both panels covering the infrared passenger compartment monitors The sunroof is opened, closed, tilted, and lowered by the electric drive (1) The system functions using a gearwheel and cables The cables are flocked The entire sunroof is a single assembly unit (2) and is attached to the appropriate mounting points of the vehicle's roof frame using the bolts (3) The mounting points (6) which are screwed to the side brackets (8) with the bolts (7) are attached to the sunroof cover (5) The sunroof panel liner (9) is attached and made of plastic Remove both screws Lower the rear end of the cover over the tilt/slide sunroof drive Remove the angled hexagon socket wrench from its holder Insert the hexagon socket wrench into the drive axle The side brackets form the connection between the cables and actuate the wind deflector (10) When the sunroof is opened, the spring-loaded wind deflector raises automatically When the roof is closed, the guide slide pushes the wind deflector down by means of a wire Water drainage nozzles to which drainage pipes are connected are attached to the front and rear of the assembly unit Sunroof Emergency Operation Push and hold down the hexagon socket wrench into the drive axle Then rotate the wrench clockwise until the tilt/slide sunroof is closed Remove the hexagon socket wrench Close the cover and screw in the screws Note: The tilt/slide sunroof must not be operated if emergency operation has been performed Page 1.4 Note: If the sunroof cover has been removed, the sunroof drive must not be operated electrically “Hard” Roof & Body Systems 911 (996) Body Equipment Adjustment Notes: The height and opening gap of sunroof cover can be adjusted at the labeled screws Initialization The position of the sunroof is detected using Hall-effect sensors The tilt position is used as the zero position and stored in the EEPROM The drive calculates the number of motor revolutions required for the “closed” and “open” positions to be reached from the zero position If the sunroof is being commissioned or the contents of the memory have been lost, the drive unit must be reinitialized Interruptions in the voltage supply, e.g if the vehicle's battery is changed, will not result in memory loss if the motor was not being operated at the same time However, if the voltage is interrupted while the motor is being actuated, reinitialization is required Reinitialization can be performed at any time This is done by holding down the rocker switch in the “close” position for 10 seconds with the sunroof already closed The roof then goes through the initialization procedure “Hard” Roof & Body Systems Page 1.5 911 (996) Body Equipment Body – 911 Targa (996) Body Shell General The body structure of the 911 Targa is basically the same as that of the Coupé The modifications and the changes made to the Coupé for the 2002 model year to improve rigidity were adopted The 911 Targa (996) is basically the same as the 911 Carrera below the window line To achieve this the side section, starting with the 911 Carrera Coupé, had to be shortened below the window line The roof module (glass sun roof, folding rear window, the roller blind for heat and cold protection, including attachments and fasteners) is attached to the basic bodyshell Both the windshield filler panel between the windshield and the glass sun roof and the side roof moldings are always finished in highly polished black, regardless of the exterior body color The side roof frames have been improved in strength and rigidity Along with the reinforcing tubes integrated into the roof rails this results in an extremely strong passenger compartment Front Water Drain Luggage Compartment With its vertically positioned high-pressure spare tire, the 911 Targa has the same luggage compartment as the 911 Carrera Coupé (996) with a capacity of 4.6 cu.ft (130 liters) As a result of accessibility through the folding rear window, the interior space is considerably more useable and can be made more versatile by folding down the rear seat backs In addition, the maximum storage capacity of 8.1 cu.ft (230 liters) resulting from the change in the roof line shape compared with the Coupé Page 1.6 Targa Body Shell The drain pipe is located to the side at the assembly frame for the roof module The hose for the water drain is pushed on and runs along the inner edge of the windshield frame to the discharge opening at the hinge pillar “Hard” Roof & Body Systems Cayenne Body Equipment - 1st Generation Notes: Page 6.16 “Hard” Roof & Body Systems Cayenne Body Equipment - 2nd Generation Subject Page General Information – Cayenne MY 2008 (2nd Generation) Body Shell Body – Front Body – Rear Automatic Rear Lid System Overview Checking Oil Hydraulic Schematics Advanced Airbags 10 “Hard” Roof & Body Systems Page 7.1 Cayenne Body Equipment - 2nd Generation Notes: Page 7.2 “Hard” Roof & Body Systems Cayenne Body Equipment - 2nd Generation Body-Equipment, Exterior General The second generation Cayenne models feature a new attractive dynamic design and include the following development goals: Additional features and options for the second generation Cayenne include: • Increased performance and less consumption • Improved active and passive safety • Improved everyday suitability and new attractive features • Hydrophopic side windows • Automatic tailgate (standard equipment) • New management system for the luggage compartment (optional) “Hard” Roof & Body Systems Page 7.3 Cayenne Body Equipment - 2nd Generation Body Shell The exterior body panelling received new design elements while the underling body shell structure components basically remained unchanged from the previous model The second generation Cayenne’s design criteria carried over from the previous models: • Excellent static and dynamic body stiffness • Excellent passive safety High-strength steel High-strength steel Sheet steel Aluminum Tailored Blanks Notes: Page 7.4 “Hard” Roof & Body Systems Cayenne Body Equipment - 2nd Generation Body – Front Body – Rear The front end changes included new front lights that have a flatter basic shape, which makes all new Cayenne models look wider The fact that the mid-point of the outer light unit for the headlights has been shifted further out also adds to this look See section for complete details on the new light systems and features The rear end changes included new tail lights that have also been redesigned with LED technology In addition to the white backup lights, the shape of the rear lights has also been adapted to suit the new rear end design See section for complete details on the new light systems and features Additional design changes include: Additional design changes include: • New designed front end and air inlets • Stronger contoured front fenders • • • • • Integrated tailpipes Lower rear diffusor panel Redesigned and enlarged roof spoiler Sharper contoured rear quarter panels New design of the rear cargo compartment Cayenne/S front view Cayenne/S rear view Cayenne Turbo front view Cayenne Turbo rear view “Hard” Roof & Body Systems Page 7.5 Cayenne Body Equipment - 2nd Generation Doors & Rear Lid Automatic Rear Lid The new automatic rear lid, which is much more convenient and highly practical for loading the vehicle, is available as an option for all Cayenne models The rear lid can be both opened and closed fully automatically at the touch of a button with this option Opening The Rear Lid Automatically When towing a trailer, the rear lid can only be opened using the release button on the rear lid The rear lid can be opened in three different ways: Option – With the ignition switched on, pull the switch in the driver’s door and hold it until the rear lid is fully open The process for opening the rear lid will be interrupted if you release the switch too soon Closing The Rear Lid Automatically Make sure that the load is not too close to the rear lid when closing it because otherwise the process for closing the rear lid will be aborted and the rear lid will stop and not fully close and lock Option – Press the release button on the rear lid The vehicle must be unlocked in this case The vehicle does not have to be unlocked if it has Porsche Entry & Drive You simply need to have the vehicle key with you, e.g in your pocket Option – Press the button on the key for approx second If the vehicle is locked, the doors will remain locked when you open the rear lid Page 7.6 Press the button in the rear lid trim Interrupting the opening/closing process in dangerous situations “Hard” Roof & Body Systems Cayenne Body Equipment - 2nd Generation The opening/closing process is interrupted immediately if one of the following buttons/switches is actuated: • Pressing the button on the key, or releasing the switch in the driver’s door, or pressing the button in the rear lid trim, or pressing the release button on the rear lid Malfunction Of The Rear Lid Drive The automatic function is not active if the battery voltage is too low Actuating a button releases the lock on the rear lid and a warning beep sounds for seconds The rear lid can now be opened manually Notes Automatic opening/closing can be resumed at any time To this, simply actuate the relevant button/switch Obstacle Detection While Opening The Rear Lid If the opening process is blocked by an obstacle, the rear lid will not open An alarm sounds Once the obstacle is removed, the rear lid can be opened by pressing the button on the key or pulling the switch in the driverís door or pressing the release button on the rear lid A warning beep sounds while the automatic rear lid is moving on vehicles designed specifically for the USA and Mexico Rear Lid Emergency Operation If the automatic opening/closing process is interrupted due to a fault, a warning beep sounds for approx seconds Open and close the rear lid manually Notes: Obstacle Detection When Closing The Rear Lid If the closing process is blocked by an obstacle, the closing process is aborted An alarm sounds and the rear lid remains partially open Once the obstacle is removed, the rear lid can be closed by actuating a button/switch Setting The Opening Height Of The Rear Lid The opening height of the rear lid can be set individually, for example, so that the rear lid will not hit the garage ceiling The vehicle height depends on the level settings for vehicles with level control Use these steps: Stand behind the vehicle and open the rear lid Use the button on the key to stop the automatic opening process at about 2/3 of the opening height Then move the rear lid up with your hand until it is at the required opening height When doing so, make sure the lid is far enough away from any obstacles Press the button in the rear lid trim and hold it for approx seconds An acknowledge tone sounds and the direction indicators flash once The opening height for the rear lid is now programmed The rear lid can now be closed by pressing the button This setting cannot be deleted If a different setting is required, repeat the procedure from Step to “Hard” Roof & Body Systems Page 7.7 Cayenne Body Equipment - 2nd Generation System Overview Checking Hydraulic Oil Level The automatic rear lid has an actuating unit with a hydraulic pump and a spring-supported hydraulic cylinder Before checking oil, open and close rear lid 2-3 times automatic to remove any air in the system • High oil level – Pressure in the tank could be too high during manual operation! • Low oil level – Pump noises due to air in system, incomplete opening and closing function! Hydraulic Pump A - Hydraulic cylinder with spring B - Hoses The hydraulic pump comprises an electric motor, the actual pump and an oil tank The pump is packed in a sound capsule to reduce noise and is secured in the rear left wheel housing by a support C - Hydraulic pump D - Support Component Overview A - Support A - Tank B - Pump C - Electric motor B - Quick-connectors C - Sound capsule D - Hydraulic cylinder E - Grommet F - Hoses Page 7.8 Notes Even when the cylinder is extended, the spring is still pretensioned by more than 1000 N “Hard” Roof & Body Systems Cayenne Body Equipment - 2nd Generation The spring-supported hydraulic cylinder is connected to the pump by quick connectors Pressure loading of the cylinder on the piston side drives the cylinder out Pressure is applied to the rod side by reversing the poles of the electric motor The control unit for rear lid hydraulics reverses the poles A maximum pressure of up to 2900 psi (200 bar) exists in the system The pressure in the system must not exceed 72 psi (5 bar) when removing/installing the quick connectors, otherwise the connectors can be damaged The automatic rear lid system also has diagnostic capabilities Removing the quick connectors Hydraulic Operating Schematics Rear lid opening Rear lid closing “Hard” Roof & Body Systems Page 7.9 Cayenne Body Equipment - 2nd Generation Airbags Notes: All second genertion Cayenne models are equipped with dual front Advanced Airbags that offer upper-body protection with an added degree of intelligence A weight sensor in the passenger seat automatically switches the passenger side bag off when unoccupied or fitted with a child seat These are augmented by a side-impact protection system featuring a thorax airbag in each front seat Curtain type airbags on each side of the roof provide optimal head protection for both rows of seats When these are deployed, they form a protective cushion along the side of the vehicle To provide better detection of a head-on collision, two additional impact sensors are located at the front of the new Cayenne As a result, the front airbags can be more accurately deployed in response to the specific characteristics of what can often be a complex impact scenario The driver and front passenger airbags use a gas generant based on an organic propellant The airbags are therefore lighter more compact and easier to recycle A rollover detection system provides additional protection in the event that the vehicle overturns Using sensor acquired data, the rollover detection system enables early deployment of the curtain airbags and triggers the seatbelt pretensioners Page 7.10 “Hard” Roof & Body Systems 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 “Hard” 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 8.1 Conversion Charts Notes: Page 8.2 “Hard” Roof & Body Systems Part Number - PNA P65 001 ... 2” Hard Roof & Body Systems Page 1.25 911 (996) Body Equipment Targa Roof Control Module (Wiring Diagram Schematic 1) Page 1.26 Hard Roof & Body Systems 911 (996) Body Equipment Targa Roof. .. Hard Roof & Body Systems Hard Roof & Body Systems 911 (996) Body Equipment P65 Subject Page Sunroof Operation ... the sunroof already closed The roof then goes through the initialization procedure Hard Roof & Body Systems Page 1.5 911 (996) Body Equipment Body – 911 Targa (996) Body Shell General The body