Disclaimer2020 Porsche Boxster S (986) F6-3.2L Technical Service Bulletin # 3/00 Date: 000630
Interior - Noises in the Door/Door Trim Panel Area
Boxster
3/00
7059
Binder - 7, Body Interior Equipment
Noises In The Door/Door Trim Panel Area
Vehicle Type:
Boxster/Boxster S
Model Year:
As of 1997 (V)/2000 (Y)
Concern:
Noises in the door/door trim panel area
Information:
The following information contains the most up to date specifications for repairing complaints of noises in the door/door panel area. Most of the
following procedures were implemented during production (see notes). Before beginning the work, please road test the vehicle to isolate the area
where the noise is coming from. Then refer to the technical bulletin for assistance. After completing the work, road test the vehicle again to confirm
the noise was eliminated. Apart from the complaints listed and the relevant remedy, other causes of noise may occur in the door trim panels. It will
be necessary to seek out these causes and systematically eliminate them on your own.
Parts Information:
Work Procedure:
2020 Porsche Boxster S (986) F6-3.2L Page 93
Refer to figure 1 for the parts overview. In order to remedy noises in the door/door panel, the following items must first be removed only if
necessary.
Part to be removed. Notes for disassembly:
Door panel (left or right). 1. Disconnect and cover battery terminal first. See warning.
2. Caution! The bowden cable can be damaged if bent in the area of the hook. On vehicles with the new style bowden cable, push the hook into
the end piece of the cover after disassembly.
3. Always replace the fastening clips before reinstalling the panels. See figures 2 and 3 for the proper use of the clips.
Figure 2 - Large ribbed area. For non-leather door panels, use gray clips (999 507 505 40). For leather door panels, use white clips (999 507
582 40)
Figure 3 - Small ribbed area. Use white clips for both leather and nonleather door panels. This type of door panel was introduced into
production as of 11/99.
2020 Porsche Boxster S (986) F6-3.2L Page 94
Power window (left or right)
Only if necessary! Remove according to directions in the workshop manual.
! CAUTION
There is a danger of injury caused by airbag or side, even after the power supply is interrupted. The airbag can be unintentionally triggered if
sufficient time not allowed after disconnection the battery.
> Wait at least one minute after disconnecting the battery proceeding with work.
Complaint 1:
Rattling and knocking noises from the entire door area (left or right side).
Cause:
The door film is striking the door trim panel from the inside.
Repair:
Construct 2 sets of tape strips. Cut 6 strips of sponge rubber tape 70 mm long. Stick together 3 strips so that a total thickness of approximately 10
mm is achieved. Stick both sponge rubber sets on to the door film. See arrows in figure 4.
Notes:
Before re-installation of the door panel, all eight plastic clips (K in figure 1) and the plastic expanding nut must be replaced. See door panel
notes for disassembly for plastic clip application.
Make sure the allen head bolt under the plastic airbag cover (E in figure 1) is tightened to 5.9 nm (4.5 ft lb.).
Complaint 2:
Creaking noises from the front or rear of the door area (left or right side).
Cause:
The told of the artificial leather or of the leather on the door panel is rubbing on the inner door panel.
2020 Porsche Boxster S (986) F6-3.2L Page 95
Repair:
Cut a 20 mm wide piece of Teflon tape to a length of 300 mm. Then cut it in half to have two 10 x 300 mm strips. Apply these strips to the door at
the front and rear area where the leather/artificial leather on the door panel contacts the door. Make sure the tape is in far enough so not to be
visible with the door panel installed. See arrows in figure 5.
Notes:
Before re-installation of the door panel, all eight plastic clips (K in figure 1) and the plastic expanding nut must be replaced. See door panel
notes for disassembly for plastic clip application.
Make sure the allen head bolt under the plastic airbag cover (E in figure 1) is tightened to 5.9 nm (4.5 ft lb.).
Complaint 3:
Clicking/crackling from the area of the side airbag.
Cause:
In some cases, the barcode sticker is applied to the interior of the airbag cover on the door panel. During driving, it is possible that this sticker may
detach itself from the cover and cause clicking or crackling noises.
Repair:
Remove the sticker and place it on another part of the door panel. See figure 6.
Notes:
Before re-installation of the door panel, all eight plastic clips (K in figure 1) and the plastic expanding nut must be replaced. See door panel
notes for disassembly for plastic clip application.
Make sure the allen head bolt under the plastic airbag cover (E in figure 1) is tightened to 5.9 nm (4.5 ft lb.).
Complaint 4:
Grating from the door lock F
Cause:
The catch bar is rubbing in the door lock.
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Repair:
Spray the door lock with silicone lubricant spray. Spray in the inner area of the lock, in which the catch bar engages. See arrow in figure 7.
Notes:
Do not use greases or other lubricants on the door lock. They attract dirt and will cause mechanical problems.
Complaint 5:
Clicking from the power window mechanism.
Cause:
Movement of parts against each other in the power window assembly. Up to model year 99, the parts were manufactured with a silver metallic
finish.
Repair:
Model year 99 and up, the power window components were powder coated (black) to reduce noise. If your car is manufactured before model year
99, replacement of the entire power window assembly is necessary.
Notes:
Make sure that the vehicle was manufactured before the above mentioned year and the parts have a silver metallic finish.
Concluding Work:
After repairing the presumed noise sources, install the door panel with new clips. Connect the battery and enter the radio code if necessary. Road
test the vehicle to confirm the noise was eliminated.
Working Time:
Literature:
Boxster Technical Manual, Groups 5, 6, and 7:
57 51 37 Disassembling and assembling door
69 .. .. Safety regulations for airbag vehicles
69 63 19 Removing and installing the side airbag unit
70 59 37 Disassembling door trim panel