Disclaimer2020 Porsche Boxster S (986) F6-3.2L Technical Service Bulletin # 61/04 Date: 040722
Restraints - Warning Light ON/DTCs 45, 46, 48 & 49
Boxster
1/04
Binder 6, Body Equipment
This bulletin replaces bulletin Group 6, # 6/99, dated 10-8-99.
Airbag Warning Light Comes On: Fault Codes 45, 46, 48 and 49
Vehicle Type:
Boxster/Boxster S
Model Year:
As of '97 (V)
Filing:
This bulletin replaces technical bulletin Group 6, # 6/99, dated 10-8-99. Please replace the filed bulletin in your Boxster Technical Manual with this
one.
Concerns:
Airbag warning light comes on. Fault codes 45, 46, 48 and 49.
Information:
If one or more of the above-mentioned fault codes are read out during diagnosis after the airbag warning light has come on, this means that -
depending on the model year - Measure A or B must be carried out on the driver's seat and/or the passenger's seat. Refer to the VIN numbers
shown.
Disclaimer
Measure - A
Work procedure for Measure A (both seats) with fault code 45, 46, 48 and/or 49
Changing the vehicle-side plug on the seat plug connection, installing new belt buckles and changing the ground wiring harnesses. In case of
repeated repair: If vehicle has airbag control module, part number, 996.618.219.00, replace with airbag control module, part number,
996.618.219.02.
2020 Porsche Boxster S (986) F6-3.2L Page 68
Applies for vehicles M.Y. 1997 (V) - 2000 (Y) with fault code 45, 46, 48 and/or 49 within the VIN ranges shown.
Parts Information
Tools
Work Procedure Measure A:
1. Disconnect battery.
Caution!
Danger of injury by airbag/side airbag when the power supply is interrupted. Assembly work can trigger the airbag unintentionally!
> Begin further work on the vehicle only after a waiting time of 1 minute.
2. Remove both seats; refer to the Boxster Technical Manual, Group 7, Repairs, 72 0119 - Removing and installing front seat.
3. Work on the "seat" plug connection (disconnection points X16 and X17 on the circuit diagram). The existing tin-plated contact springs must
be replaced by gold-plated and greased springs on the driver's side plug of the "seat" plug connection.
Connector X16 = driver's side,
Connector X17 = passenger's side.
3.1 Unwrap the banding of the driver's side wiring harness according to the new leads which are to be installed.
3.2 Open the vehicle-side plug. To do this, lever out the plug cap (Fig. 1, arrow A) at the pivot point using a small flat screwdriver. Then lift
the blue bar (arrow B) with the screwdriver and pull it out of the plug.
3.3 Carefully remove the movable side of the plug (arrow C), and pull the plug housing out (arrow D).
3.4 Work on the leads/contact springs in the plug (arrow D).
2020 Porsche Boxster S (986) F6-3.2L Page 69
Caution!
Possibility of mixing up the leads!
> Complete only one lead at a time.
> Work on the leads/contact springs in sockets B5, B6, B7 and B8 on the driver's side. On the passenger's side, work on only those
leads/contact springs that are in sockets B7 and B8.
> Trim the wires in such a way that the connection points are offset with respect to each other.
3.4.1 Unlock and push out a contact spring using pressout tool 89058 (Fig. 2).
3.4.2 Trim the lead in accordance with the new lead.
Note:
The new lead should be approx. 50 mm longer (allowance for wire-end ferrule and shrink tubing).
3.4.3 Strip approx. 10 mm of insulation from the ends of both leads, twist the ends together and insert them in a 2.5 x 7 wire-end ferrule
(Fig. 3).
3.4.4 Join the leads in the wire-end ferrule using a pair of wire-end ferrule pressing pliers (Fig. 4, Item A).
3.4.5 Solder the tips of the projecting ends of the leads (Item B).
3.4.6 Insulate the soldered joint with 4 x 35 shrink tubing.
Caution!
Damage to the interior and the leads from the heating effect of the heat gun!
> Observe the blower outlet direction of the heater gun during the shrinking procedure.
> Close the open end of the shrink-fit hose using a pair of flat-nosed pliers (Item C).
3.4.7 Snap the contact spring into the housing socket again.
3.4.8 Use adhesive tape to secure the lead to the wiring harness in the area of the shrink tubing.
3.5 Follow the same procedure for work on the other leads/contact springs. Trim the wires in such a way that the connection points are
offset with respect to each other.
3.6 Reassemble the plug in reverse order. When doing so, replace the previous plug cap (See Figure 1, Item A) with the plug cap contained
2020 Porsche Boxster S (986) F6-3.2L Page 70
in the service set.
Caution!
Airbag warning light lights up if tie-wrap is insufficiently fastened.
> Bundle all leads on the vehicle-side plug on the plug cap using a tie-wrap (Figure 5).
3.7 Band the seat ground lead again. Add more banding if necessary.
4. Replace belt buckle.
A new belt buckle with gold-plated contact pins must be installed. A strain relief element for the belt buckle wiring harness must be provided
on the seat-side plug.
4.1 Remove the previous belt buckle; see Boxster Technical Manual, Group 6, Repairs, 69 24 19 - Removing and installing the front belt
buckle.
4.2 Install the new belt buckle.
Distinguishing the belt buckles:
The belt buckles can be recognized by way of the stamped part number and by the plug color,
Driver's seat - 996.803.183.09, blue plug
Passengers seat - 996.803.183.10, green plug.
Caution!
Airbag warning light lights up if tie-wrap is insufficiently fastened.
> The tie-wraps for the strain-relief element of the belt buckle wiring harness for the seat-side plug must be installed according to the
following Steps 4.3 or 4.4. respectively.
4.3 Strain relief element for basic passenger's seat with option I No. 370 (elc. height adjustment):
Fasten the belt buckle wiring harness to the cushion carrier with a tie-wrap (Figure 6).
2020 Porsche Boxster S (986) F6-3.2L Page 71
4.4 Strain relief element for all other driver's and passenger's seats: Bundle the leads in the plug housing with a tie-wrap (Figures 7 and 8).
5. Modify the airbag ground wiring harness.
5.1 The airbag ground leads are branched out of the previous wiring harness and connected to the ground point as a separate lead. There is
a ground point under each seat (ground point 6 or 7 on the circuit diagram).
5.2 Unwrap banding of the ground lead over a length of approx. 20 cm in the area of the lead connection point. Unscrew the ground lead
from the ground point.
5.3 Work on the leads with 0.5 mm cross section (brown) coming out of the connection point.
Caution!
Risk of damage to the leads for child seat detection!
> If present, the wiring harness for the child-seat detection feature is located on the passenger's side.
> The plug housing for the two leads (brown or brown/orange, 0.5 mm) is then tied near the ground lead.
> Do not work on the leads for child seat detection!
5.3.1 Cut off the 0.5 mm cross section leads directly at the connector point (Figure 9). There can be up to four leads, depending on how the
vehicle is equipped.
5.3.2 Trim the service set lead (brown, 1.5 mm, 500 mm long) on the ground point.
Note:
The lead should be approx. 50 mm longer (allowance for wire-end ferrule and shrink tubing).
5.3.3 Strip approx. 12 mm of insulation from the ends of the cut-off leads and the service set lead, and then twist the ends together.
5.3.4 Insert all leads into the 4 x 9 wire-end ferrule (See Figure 3) from one side and join them with the crimping pliers.
5.3.5 Solder the leads and the wire-end ferrule together at the tip (See, Figure 4, Item B).
5.3.6 Insulate the soldered joint with 6 x 35 shrink tubing. Close the open end of the shrink tubing hose using a pair of flat-nosed pliers (See
Figure 4, Item C).
5.3.7 Place the new lead against the previous ground lead. Bundle the leads using electrical tape.
5.4 Clean the screw thread and the seat of the ground point using a narrow steel-wire brush. Remove all paint residue.
5.5 Install ground leads on the ground point.
Caution!
Airbag warning light lights up if ground lead tie-wrap is incorrectly fastened.
> The airbag must be fixed to the ground point right at the bottom.
2020 Porsche Boxster S (986) F6-3.2L Page 72
5.6 Bundle the ground leads again. Add more banding if necessary.
6. Repeat all the work listed in Steps 3 to 5.6 on the other seat or other side of the vehicle.
7. Only in case of repeated repair:
If vehicle has airbag control module 996.618.219.00, replace with airbag control module 996.618 .219.02, See Boxster Technical Manual;
Group 6, 69 63 29 - Removing and installing airbag triggering unit.
8. Reinstall both seats.
9. Connect the battery. Enter radio code, if necessary.
Working Time Measure A
Measure - B
Procedure for Measure B (one seat) with fault code 46 or 49:
Depending on the fault code, changing the driver's side seat plug connection plug and installing a new belt buckle on the driver's seat (fault code
46) or passenger's seat (fault code 49).
Applies for vehicles from M.Y. 2000 (Y) with fault code 46 and/or 49 with the VINs shown.
Parts Information
Tools
Work Procedure Measure B:
10. Disconnect battery.
Caution!
Danger of injury by airbag/side airbag when the power supply is interrupted. Assembly work can trigger the airbag unintentionally!
> Begin further work on the vehicle only after a waiting time of 1 minute.
2020 Porsche Boxster S (986) F6-3.2L Page 73
11. Remove seat; see Boxster Technical Manual, Group 7, Repairs, 72 01 19 - Removing and installing front seat.
12. Work on the "seat" plug connection (disconnection points X16 and X17 on the circuit diagram). The existing contact springs must be
replaced by gold-plated and greased springs on the vehicle-side plug of the "seat" plug connection.
Connector X16 = driver's side,
Connector X17 = passenger's side.
12.1 Unwrap the banding of the driver7s side wiring harness according to the new leads which are to be installed.
12.2 Open the vehicle-side plug. To do this, lever out the plug cap (Fig. 10, arrow A) at the pivot point using a small flat screwdriver. Then
lift the blue bar (arrow B) with the screwdriver and pull it out of the plug.
12.3 Carefully remove the movable side of the plug (arrow C), and pull the plug housing out (arrow D).
12.4 Work on the leads/contact springs in the plug (arrow 0).
Caution!
Possibility of mixing up the leads!
> Complete only one lead at a time.
> Work on the leads/contact springs in sockets B57, B67, B7 and B8 on the driver's side. On the passenger's side, work on only those
leads/contact springs that are in sockets B7 and B8.
> Trim the wires in such a way that the connection points are offset with respect to each other.
12.4.1Unlock and push out a contact spring using pressout tool 89058 (Fig. 11).
12.4.2Trim the lead in accordance with the new lead.
Note:
The new lead should be approx. 50 mm longer (allowance for wire-end ferrule and shrink tubing).
12.4.3Strip approx. 10 mm of insulation from the ends of both leads, twist the ends together and insert them in a 2.5 x 7 wire-end ferrule
(Fig. 12).
2020 Porsche Boxster S (986) F6-3.2L Page 74
12.4.4Join the leads in the wire-end ferrule using a pair of crimping pliers (Fig. 13, Item A).
12.4.5Solder the tips of the projecting ends of the leads (Item B).
12.4.6Insulate the soldered joint with 4 x 35 shrink tubing.
Caution!
Damage to the interior and the leads from the heating effect of the heat gun!
> Observe the blower outlet direction of the heat gun during the shrinking procedure.
> Close the open end of the shrink tubing using a pair of flat-nosed pliers (Item C).
12.4.7Snap the contact spring into the housing socket again.
12.4.8Use electrical tape to secure the lead to the wiring harness in the area of the shrink tubing.
12.5 Follow the same procedure for work on the other leads/contact springs. Trim the wires in such a way that the connection points are
offset with respect to each other.
12.6 Reassemble the plug in reverse order. When doing so, replace the previous plug cap (See Figure 10, Item A) with the plug cap
contained in the service set.
Caution!
Airbag warning light lights up if tie-wrap is insufficiently fastened.
> Bundle all leads on the vehicle-side plug on the plug cap using a tie-wrap (Figure 14).
12.7 Bundle the seat ground lead again. Add more banding if necessary.
13. Replace belt buckle.
A new belt buckle with gold-plated contact pins must be installed. A strain relief element for the belt buckle wiring harness is intended on the
seat-side plug.
13.1 Remove the previous belt buckle; see Boxster Technical Manual, Group 6, Repairs, 69 24 19 - Removing and installing the front belt
buckle.
13.2 Install the new belt buckle.
Distinguishing the belt buckles:
The belt buckles can be recognized by way of thee stamped number and by the plug color.
Driver's seat - 996.803.183.09, blue plug
Passenger's seat - 996.803.183.10, green plug.
Caution!
Airbag warning light lights up if tie-wrap is insufficiently fastened.
2020 Porsche Boxster S (986) F6-3.2L Page 75
> The tie-wraps for the strain-relief element of the belt buckle wiring harness for the seat-side plug must be installed according to the
following Steps 13.3 or 13.4 respectively.
13.3 Strain relief element for basic passenger's seat with option I No. 370 (elc. height adjustment):
Fasten the belt buckle wiring harness to the cushion carrier with a tie-wrap (Fig. 15).
13.4 Strain relief element for all other drivers and passenger's seats:
Bundle the leads in the plug housing with a tie-wrap (Figures 16 and 17).
14. Reinstall seat.
15. Connect the battery. Enter radio code, if necessary.
Working Time Measure 8
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