Technical Information 911 (996) Turbo Service - Bethnrayndogs.com

®
Technical Information
Aerokit “Turbo”
911 (996) Turbo
6
6/01 6658
Binder - Group 6 - Body Equipment,
Exterior
Vehicle Type: 911 Turbo (996)
Model Year: MY 2001 (1)
Concerns:
Information:
Retrofitting
The Aerokit "Turbo" consists of a new spoiler lip for the front spoiler and a new rear lid (hereafter
referred to as trunk lid) with a solid spoiler. A brake light in the spoiler will replace the standard
additional brake light fitted in the standard spoiler.
The new spoiler lip and the new trunk lid with spoiler must always be mounted on the vehicle simultaneously.
The installation of one of these parts is not permitted and not approved!
After removing the spoiler from the trunk lid (e.g. when repairing), new microencapsulated screws must
be used. These can be ordered separately (see parts list). The Aerokit "Turbo" is also available ex-works
for new vehicles under Exclusive option No. "XAF". In addition, the standard side member panels are
painted the same colour as the vehicle.
Figure 1
Information: The Porsche logo and the Part numbers are visible on the inner side of the spoiler lip. On the new
trunk lid, the Porsche logo
and the Part numbers can be found on the under side of the trunk lid.
Important:
Observe the respectively valid legal regulations in the various countries!
©2001 Porsche Cars North America, Inc.
Service
Date: 9-28-01
Page 1 of 8

®
6 6658 ©2001 Porsche Cars North America, Inc.
911(996) Turbo
6/01
Technical Information
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CAUTION!
Damage to the rear spoiler when cleaning car in automatic car washes – in some cases the rear spoiler
is not adequately detected by the light barriers.
> If inf doubt, seek the advice of the operator of the automatic car wash.
> Only wash the vehicle manually.
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CAUTION!
Damage to the rear spoiler due to incorrect and improper use – by pushing the vehicle or by
opening/closing the rear lid too violently.
> Never use the rear spoiler to push the vehicle.
> Carefully, i.e. gently, open the trunk lid.
> Check the gap dimensions of the trunk lid relative to the body from time to time and, if necessary, get
the Porsche Center to re-adjust.
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CAUTION!
Damage (risk of destruction or damage) to the accessories or to the vehicle itself when ascending or
descending steep ramps (loading the vehicle, lifting platforms, multi-storey parking lot ramps etc.) - due
to the smaller overhang angle of the front spoiler in relation to the standard part.
> Avoid steep access and exit ramps wherever possible.
> Adopt your driving style to the local situation.
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Please inform your sales department of this information. Give your customer a copy of the
first two pages of this Technical Information bulletin.
Part Numbers: 000.044.801.99 Description: 1 x Aerokit
Date: 9-28-01
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Service

®
Technical Information
911(996) Turbo
6
6/01 6658
Part Numbers.: 000 044 801 99 1 x Aerokit "Turbo"
996 559 237 03 4PU* 1 x "Turbo" logo, colour: silver
* May be ordered separately if desired by the customer. Installation procedure is described in the Technical Manual.
Parts List: 996.505.986.01.G2X 1 x Spoiler lip; primered; material: PUR- R RIM
996.512.992.01.G2X 1 x Spoiler; primered; material: EP-GM 30
900.119.126.02 4 x Cheese head screw M6 x 18, –DIN6912–, microencapsulated
996.612.070.30 1 x Electric wiring harness
996.512.543.00 1 x Cover trim for underside of lid
900.378.214.07 10 x Hexagon-head bolts M6 x 18, –DIN1665–
996.631.165.00 1 x Cap for 3rd brake light
996.631.050.01 1 x Complete brake light (incl. bulbs)
996.512.987.00 2 x Adjusting element (rubber buffer) incl. collar (2 x)
996.512.991.01.G2X 1 x Trunk lid; primered; material: GP/UP-GM 25 incl.supporting plate (2
x) and bracket for 3rd brake light (1 x)
Tools: Socket wrench for hexagon sockets a/f 4 / 5
Porsche System Tester 2 – PST2
Triangular scraper
Pointed-nose pliers
Handlamp
Various slotted and crosshead screwdrivers
Hexagon socket wrench a/f 10
Pocket knife
Sheeted paper
Lifting platform
Installation: 1.0 Work before painting:
1.1 Set the new trunk lid carefully on the spoiler, remove the hexagon-head bolts M6 x 18 (10 x) from
the cover trim (underside of the trunk lid) and remove the cover trim.
1.2 Remove the 4 cheese-head screws which fasten the spoiler to the trunk lid and carefully lift the
trunk lid away from the spoiler.
1.3 Mask all threads (if necessary also on the spoiler supporting plates) on the trunk lid and the
spoiler.
Information:
The supporting plates for the spoiler may not be removed from the new trunk lid, as the fastening
screws are securely attached.
Furthermore, the supporting plates are positioned on the trunk lid to provide optimum gap dimensions.
The bracket for the 3rd brake light can also remain attached to the trunk lid.
©2001 Porsche Cars North America, Inc.
Service
Date: 9-28-01
Page 3 of 8

®
6 6658 ©2001 Porsche Cars North America, Inc.
911(996) Turbo
6/01
Technical Information
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CAUTION!
Damage or warping can occur to the trunk lid and the spoiler – in the event of improper painting and
drying processes.
> Observe the specifications and instructions for the painting of plastics as contained in the Paint Manual.
> During the painting and drying process, place the parts without tension on the painting fixtures
provided for this purpose (included in the packages).
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Installation: 1.4 Paint the spoiler lip and trunk lid with spoiler in compliance with material specifications according
to the Paint Manual.
2.0 Fit the new spoiler lip (Figure 2, shaded grey) to the
front spoiler.
2.1 Remove the crosshead screws from the wheel arch
area of the standard spoiler lip.
2.2 Beginning at the middle, and working from the inner
to the outer side of the spoiler lip, unclip the locking
lugs using a slotted screwdriver.
2.3 Beginning with the middle locking lug, carefully clip
the new spoiler lip to the front spoiler.
Figure 2
2.4 Fasten the spoiler lip to the front spoiler using the two crosshead screws at the sides.
3.0 Fit the spoiler to the trunk lid.
3.1 Check the threads of the painted parts for paint impurities and, if necessary, re-cut using an M6 tap.
3.2 Remove right taillight (Technical Manual, Group 9, Serv. No. 9433).
3.3 Using a pointed-nose pliers, unclip the cable clip, situated at the right in the engine compartment,
for the wiring harness of the luggage compartment lid (hereafter referred to as trunk lid) and dis
connect the electric plug connection X23.
3.4 Remove the trunk lid without the hinge with the help of a second person (Technical Manual, Group
5, Serv. No. 5590).
3.5 Fit right tail light (Technical Manual, Group 9, Serv. No. 9433).
Date: 9-28-01
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®
Technical Information
911(996) Turbo
6
6/01 6658
Installation: 3.6 Lay the new trunk lid (Item A) carefully on the
underside of the spoiler (Item B), position
and securely fasten to the spoiler using the
microencapsulated cheese head screws
M6 x 18 (Item C, see also parts scope).
Tightening torque: 10 Nm (7.4 ftlb.).
4.0 Complete the rear lid and mount it on
the vehicle.
4.1 Fit the 3rd brake light.
4.1.1 Feed the 2-pole connector for the 3rd brake
light in through the mounting point towards
the innerside of the trunk lid and connect to
the 2-pole connector of the new
wiring harness.
Figure 3
4.1.2 Carefully fit the 3rd brake light on the trunk
lid. Ensure that the 3rd brake light is
positioned evenly on the gap and that the
seal is correctly positioned on the trunk lid.
If necessary loosen the bracket for the 3rd
brake light and position the 3rd brake
light together with the bracket into the
slot in the trunk lid.
4.1.3 Fasten the hexagon-head bolts M6 x 18 to
the bracket of the 3rd brake light.
Tightening torque: 10 Nm (7.4 ftlbs.).
4.1.4 Position the remaining connectors in the
wiring harness at the other connection points
on the underside of the trunk lid (see
Figure 5).
Figure 4
4.2 Complete the trunk lid.
4.2.1 Fit the new cover trim (Figure 5) to the
underside of the trunk lid using the
hexagon-head bolts M6 x 18 (10 x)
(Technical Manual, Group 5, Serv. No. 5590).
Tightening torque: 10 Nm (7.4 ftlb.).
Figure 5
©2001 Porsche Cars North America, Inc.
Service
Date: 9-28-01
Page 5 of 8

®
6 6658 ©2001 Porsche Cars North America, Inc.
911(996) Turbo
6/01
Technical Information
Installation: 4.2.2 Remove fan and fan housing (Figure 6,
Item A) and the engine compartment light
from the old trunk lid and fit in the new
trunk lid (Technical Manual, Group 5, Serv.
No. 5590).
4.2.3 Remove the air duct (Item B) for the air
cleaner from the old trunk lid and fit in
the new trunk lid (Technical Manual, Group
5, Serv. No. 5590).
4.2.4 Attach both collars (Item C) for the rubber
buffer (Item D) to the bores in the trunk lid.
Note:
Figure 6
While doing so, be careful not to damage
the wedge incorporated into the bores, as this serves as a locking device for the collar! Remove
paint runs, if any, from the bores using a pocket knife or a triangular scraper. De-burr the bores if
necessary.
4.2.5 After positioning the collar, carefully drive it into the bore using a plastic hammer.
4.2.6 Carefully remove the rubber seal from the old trunk lid and fit in the new trunk lid.
4.3 Mount the new trunk lid on the vehicle.
4.3.1 With the help of a second person, place the trunk lid on the lid hinges and loosely position
the old hexagon-head bolts (4 x).
4.3.2 Clip the electric wiring assembly into the cable guide at the right shock absorber and feed
in to the engine-compartment, to the connector on the right-hand side.
4.3.3 Create a 12-pole electric plug connection.
4.3.4 Position the trunk lid on the trunk lid hinges corresponding to the areas stripped of paint by the
screw heads and check the joint dimensions according to the Technical Manual, Group 5.
4.3.5 Fasten the hexagon-head bolts to the trunk lid hinges.
Tightening torque: 10 Nm (7.4 ftlb.).
4.3.6 Remove the upper part of the lock from the old trunk lid and loosely pre-fit in the new trunk lid.
4.3.7 Adjust the upper part of the lock and fasten securely.
Tightening torque: 10 Nm (7.4 ftlb.).
Date: 9-28-01
Page 6 of 8
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®
Technical Information
911(996) Turbo
6
6/01 6658
Installation: 5.0 Function tests.
5.1 Perform a closing test on the new trunk lid
and, if necessary, re-adjust the upper part of
the lock.
5.2 Test that the 3rd brake light is functioning.
Ensure that all bulbs in the brake light light
up.
If it is functioning correctly, clip in the side
cap of the 3rd brake light (Technical Manual,
Group 5, Serv. No. 5590).
Figure 7
5.3 Switch on the car ignition, connect and
switch on the PST2.
5.4 Select vehicle type "911 (996)", read out the error log and, if necessary, delete.
5.5 Function test "Engine-compartment purge fan".
5.5.1 Select the menu item "DME control module" and confirm with the >> key.
5.5.2 After reading out the DME control module, select the menu item "Engine compartment
purge fan" and start with the F8 key.
5.5.3 Hold a sheet of paper between the spoiler and the engine compartment lid in the area of
the ventilation slots.
5.5.4 If the fan is functioning correctly, the sheet should be sucked on to the trunk lid.
5.5.5 Return to the main menu of the PST2, switch off the PST2 and disconnect it from the diagnostic
socket.
Working Time: 55 90 61 60 –Aerokit "Turbo" trunk lid (1 x) painted– 190 TU
Trunk lid removed –new part painted–
Without: Paint preparation (separate LO No.)!
Materials:
11 MU
66 58 61 60 –Aerokit "Turbo" spoiler (1 x) painted– 190 TU
Spoiler removed –new part painted–
Without: Paint preparation (separate LO No.)!
Materials:
10 MU
©2001 Porsche Cars North America, Inc.
Service
Date: 9-28-01
Page 7 of 8

®
6 6658 ©2001 Porsche Cars North America, Inc.
911(996) Turbo
6/01
Technical Information
Working Time 66 58 31 03 –Rear spoiler (1 x) converted– 170 TU
(cont’d.): Includes: Standard spoiler lip and standard trunk lid
removed, standard trunk lid disassembled.
Aerokit "Turbo" trunk lid completed, fitted and
gap dimensions adjusted.
Aerokit "Turbo" spoiler lip fitted.
Functioning of brake light in new rear spoiler
and engine-compartment purge fan in new
trunk lid checked.
66 58 55 09 –Rear spoiler (1 x) replaced– 150 TU
Includes: Trunk lid removed, disassembled and new
Aerokit "Turbo" trunk lid completed, fitted and
gap dimensions adjusted. Functioning of brake
light in new rear spoiler and engine-compartment
purge fan in new trunk lid checked.
66 03 61 60 –Aerokit "Turbo" spoiler lip (1 x) painted– 110 TU
Aerokit "Turbo" spoiler lip removed –new part
painted –
Without: Paint preparation (separate LO No.)!
Materials:
4 MU
66 03 55 09 –Spoiler lip (1 x) replaced– 50 TU
Spoiler lip removed and new Aerokit "Turbo"
spoiler lip fitted.
References: 911 Turbo Technical Manual, Groups 5/6/9:
> Repair: 5 - Rear body joint dimensions
55 90 19 - Removing and installing rear lid
55 90 37 - Disassembling and assembling rear lid
63 15 37 - Disassembling and assembling front spoiler
94 33 19 - Removing and fitting bulb for taillight
Important Notice: Porsche Cars N.A Technical Bulletins are intended for use by professional technicians, not a “Do-it-yourselfer.” They are written to inform these technicians of conditions that may occur
on some vehicles, or to provide information that could assist in the proper service of a vehicle. Special tools may be required to perform certain operations identified in these bulletins. Use of tools and procedures
other than those recommended in these bulletins may be detrimental to the safe operation of your vehicle. Properly trained technicians have the equipment, tools, safety instructions and know-how to do
a job properly and safely. If a condition is described, do not assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See your Porsche Dealer for information on whether your
vehicle may benefit from the information. Part numbers listed in these bulletins are for reference only. Always check with your authorized Porsche dealer to verify correct part numbers.
©2001 Porsche Cars North America, Inc.
Dealership
Distribution
Routing
Service Manager Shop Foreman Service Technician
Asst. Manager Warranty Admin. Service Technician
Porsche, the Porsche marque, Carrera, Boxster, Tiptronic, VarioCam, VarioRam, Tequipment and PCM are registered trademarks. The 911 and the distinctive shapes of the Porsche automobiles are trademarks
of Dr. Ing. h.c.F. Porsche AG.
Date: 9-28-01
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