2020 Porsche Boxster S (986) F6-3.2L Technical Service Bulletin # 1/02 Date: 020722
Interior - R/H Side Instrument Panel Clicking Noises
Boxster
1/02 7018
7/22/02
Binder - Group 7, Body Equipment Interior
Clicking Noises from the Instrument Panel/Passenger's Side
Vehicle Type:
Boxster / Boxster S
Model Year:
MY 1997 (V) to MY 2002 (2)
Concerns:
Clicking noises from the instrument panel on the passengers side
Information/Cause:
2020 Porsche Boxster S (986) F6-3.2L Page 137
Relative motion at the pickup point of instrument panel support frame and cowl panel on the passenger's side (Figure 1, arrow)
Remedy:
As of the introduction date stated below, Teflon film (999 911 697 40) is stuck between the instrument panel support frame holder and the cowl
panel holder on the passenger's side of new vehicles. If complaints indicating "clicking noises from the instrument panel on the passenger's side"
are received on vehicles which built before the above date, they should be retrofitted with an intermediate layer of Teflon film.
Introduction:
New vehicles with Teflon film between the support frame holder and the cowl panel holder: January 23, 2002 or February 11, 2002 (Finland), as
from Vehicle Ident. Nos. shown.
Material Required
Work Procedure:
Refer to Boxster Technical Manual, Groups 6 and 7:
1. Remove the side nozzle on the passenger's side (Figure 2, Item 1); to do so, pull the covers down and off. On the left in the recess and on the
outer side, undo the two T20 Torx screws, respectively.
2. Pull out the side nozzle.
3. Remove the A-pillar trim on the front passenger's side.
2020 Porsche Boxster S (986) F6-3.2L Page 138
4. Lift the cover of the alarm readiness display (Figure 2, Item 2) and unclip it at the rear.
5. Lift and unclip the defroster cover on the passenger's side (Figure 2, Item 3).
6. To remove the loudspeaker on the passenger's side (Figure 2, Item 4), undo the two T20 Torx screws, raise the outer side of the loudspeaker,
and pull out the loudspeaker. Press the locking lug at the plug and unplug connector.
7. Remove passenger footwell bulkhead (position: Figure 2, Item 5) by undoing two plastic slotted screws and taking off bulkhead.
8. Pull off air guide in footwell on passenger's side (position: Figure 2, Item 6)
9.0 Remove airbag on passenger's side (position: Figure 2, Item 7) as follows:
9.1 Remove ignition key.
9.2 Disconnect battery and cover battery terminals.
WARNING!
Danger of injury caused by airbag: the capacitor in the airbag control module still carries a charge after disconnection of the battery. With a
charged capacitor, assembly work can result in unintentional triggering of the airbag!
> Begin further work on the vehicle only after a waiting time of 1 minute (= capacitor discharging time).
> Observe safety regulations for handling vehicles with airbags - Technical Manual, Group 6, Page 69-1.
9.3 Unscrew the airbag unit from below (2 hexagon-head bolts - a/f 15 mm).
9.4 Pull out unit.
9.5 Pull off electrical lead.
10.0 Decouple contact surfaces of both the support frame holder (Figure 3, Item A) and the cowl panel (Figure 3, Item A) on the passenger's side
by applying a Teflon film (Figure 3, Item F).
10.1 Refer to Figure 3 for item designations.
Item B: Unscrew the fastening screw (M6, a/f 10 mm - Figure 3, arrow B) on the passenger's side through the opening in front of the
2020 Porsche Boxster S (986) F6-3.2L Page 139
loudspeaker (Figure 4).
Lefthand drive vehicle = right screw (BR)
Righthand drive vehicle = left screw (BL).
Item C: Unscrew the fastening screw (M8, a/f 13 mm) for the center strut on support frame (Figure 5, arrow) through the opening of the
passenger's airbag that has been removed.
Item D: In the passenger door brake area, laterally loosen 2 fastening screws of the support frame (M8, a/f 13 mm; Figure 6, arrow) - do not
completely unscrew.
Notes:
By completing Items C and D, the instrument panel support frame is detached (see Item E).
Two people are required for the work procedure described in Items E and E
Item E: To create a gap (space) for the Teflon film between the support frame holder and the cowl panel holder, pull the instrument panel
laterally upwards on the passenger's side and hold this position.
Item F: Insert the Teflon film (Figure 7, Item F) between the two holders (Figure 7, arrows) through the loudspeaker opening from the
front. If required, correctly position the Teflon film with a small screwdriver, scriber or similar tool. Space is limited!
Installation:
11. Refer to Figure 3, for item designations:
Item B: Screw in hexagon-head bolt (M6 x 18/a/f 10) to secure instrument panel support frame and cowl panel (Figure 4, arrow B).
Position the screw but do not tighten it!
Item C: Screw in hexagon-head bolt (M8 x 18/a/f 13) on the center strut of the support frame through the airbag opening (Figure 5, arrow).
Only position screw, do not tighten it!
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Item D: Tighten 2 hexagon-head bolts (a/f 13) in the passenger door brake area (Figure 6, arrows). Tighten all fastening screws (Items B, C,
D) with the specified tightening torque shown.
12.0 To insert passenger airbag, proceed as follows:
WARNING!
Danger of injury caused by airbag: the capacitor in the airbag control module still carries a charge after disconnection of the battery. With a
charged capacitor, assembly work can result in unintentional triggering of the airbag!
> Begin further work on the vehicle only after a waiting time of 1 minute (= capacitor discharging time).
> Observe safety regulations for handling vehicles with airbags - Technical Manual, Group 6, Page 69-1.
12.1 Insert the passenger airbag into the instrument panel and secure it from below with two hexagon-head bolts (M8 x 95, a/f 15). While
the fastening screws are being tightened for the airbag unit, the airbag cover must be evenly pushed forward by a second person so that
it is under slight tension after tight ening and a uniform gap width to the instrument panel section is achieved.
Tightening torque: 20 N.m (15 ft.lb.).
12.2 Insert the air guide in the passenger footwell.
12.3 Install and secure the passenger footwell bulkhead.
12.4 Install loudspeaker, connect plug connection. Insert the loudspeaker in the instrument panel and secure with two T20 Torx screws.
12.5 Install the A-pillar trim, defroster cover and alarm readiness display cover.
12.6 Fit side nozzle by inserting and screwing it tight in the instrument panel. Press in cover cap.
12.5 Reconnect battery and perform all subsequent work necessary after the battery has been disconnected in accordance with the
instructions in the "Entire Vehicle - General" chapter of the Technical Manual, Group 0, Page 0-49.