Technical Information · 2/00 W103 5

® 911 (996) Technical Information 2/00 W103 5 Scope 3: Replace the rear lid, seal the folded seam, and paint the surfaces. Parts Information: Part Number Description Dealer Cost Warranty Rate 996 512 011 01 GRV Rear lid (primed) $157.96 $221.15 999 591 974 07 Clamping washers (8 required) $0.14(ea.) $0.19(ea.) 000 043 204 38 Sealant (enough for approximately 4 lids) $16.71 $23.39 --- Adhesive tape --- Use cleaning and painting materials as per the Porsche Paint Manual, Group L 4. Note: Sealant reimbursed at 1/4th the Warranty rate. Tools: Ratchet with extension and 10mm socket Torque wrench Slotted and crosshead screwdrivers Cleaning cloth Repair Procedure: 3.0 Remove the rear lid. Unplug the electrical wiring harness and unclip it from the pneumatic spring. 3.1 Disassemble the old rear lid according to the 911 Carrera (996) Technical Manual, Group 5, Page 55 – 5ff. Refer to the Technical Bulletin, Group 6, 4/00 if the vehicle has a “Carrera” rear spoiler installed. 3.2 Prepare the new lid by sealing the folded seam. The sealer can be Figure 4 directly applied to the primer on the lid. Seal the rear edge and the left and right sides of the folded seam (figure 4) as follows: - Apply adhesive tape on the sides of the folded seam so that the folded seam is exposed 3 to 5 mm. - Apply sealant on the folded edge, spread smooth, and remove the tape. - Allow the sealant to dry for approximately 4 to 5 hours. Moistening the applied sealant with water can shorten the drying time. 3.3 Paint the rear lid following the instructions in the Porsche Paint Manual, Group L 5. 3.4 When the paint is dry, reinstall the removed components on the lid. Do not install the latch. 3.5 Reinstall the lid on the vehicle. Tighten the hinge bolts lightly. 3.6 Close the lid and check the gap around the lid. Correct if necessary. Tighten up the hinge bolts. 3.7 Reinstall the latch, and align it with the lower latching point. Torque the bolts to 7.5 nm. 3.8 Connect the electrical connection and attach the harness to the pneumatic spring on the right hinge. 3.9 Carry out a function test on the rear lid and on the 3rd brake light in the spoiler. On the cabriolet, check the functioning of the microswitch for the rear-lid/convertible-top interlock. With the rear lid open, it should not be possible to operate the convertible top. ©2001 Porsche Cars North America, Inc. Service Date:Page02-09-017 of 10