- power windows - alarm system - electric door mirror control - door warning light - central locking - seat memory

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1 Door Wiring Harness Plug Connections Binder -, Electrics Vehicle Type: (86) Model Year: 7 (V) Concern: Door wiring harness plug connections X11 / X12. Information: The rubber boot for the door connector is now equipped with a vent hose. Moisture seepage into the plug connection of the door wiring harness can cause failures or malfunctions of the following components: - power windows - alarm system - electric door mirror control - door warning light - central locking - seat memory The following modifications were made in production: As of May 7, 17 from Vehicle Identification Number 8 VS Installation of a frame reinforcement for the rubber boot. As of August 26, 17 from Vehicle Identification Numbers 8 XWS WU Installation of a rubber boot with vent hose. Note: The wire assignment in the connector has been changed in production coinciding with the installation of the rubber boot with vent hose. Repair section 1 details the procedure for installing the new rubber boot for the door wiring harness plug connections at the left and right door hinge pillars if moisture seepage into the connector is determined on vehicles prior to the August 26, 17 production date (refer to VIN range). The updated rubber boots must be installed for both passenger and driver door wiring harness plug connections. Installation of one side only is not permissible. Repair section 2 details the procedure for replacement of the male contact pins and female receptacles if inspection reveals corrosion. Repair section 2 also details the procedures for replacement of the door wiring harness and installation of the plug connection repair kit if the 10-pole plug connector is corroded and requires replacement. Important Vehicles with airbag/side airbag: The capacitor in the airbag control module still carries a charge after disconnection of the battery. Wait a minimum of 1 minute after disconnecting the battery before beginning further work on the vehicle. During repair work a charged capacitor can result in unintentional triggering of the airbag! Page 1 of

2 732 3a/7 Repair Information: Section 1 Replacement of the passenger s side rubber boot. 1.1 Disconnect the battery and cover both battery terminals. 1.2 Move both seats to full rear position. 1.3 Remove the passenger s door. Refer to Technical Manual, Group 5, Repair , Removing and Installing Door. Figure Remove the sill cover (Figure 1, arrow A). 1.5 Detach and fold over the carpet in the area of the hinge pillar and sill cover. 1.6 Remove holder in area of the hinge pillar (Figure 2, arrow E) 1.7 Remove the 45 mm dia. plug (Figure 3, arrow) located below the hinge pillar in the inner lower side member. Note: The plug might be covered by body sealant and paint. 1.8 If it is present, remove the frame reinforcement (Figure 4) in the rubber boot. To remove the reinforcement open the locking lever (Figure 4, arrow J). Figure 2 1. Engage the securing latch of the plug again. Pull plug through the rubber sleeve into the passenger compartment Remove all traces of moisture from the connector with a blow dryer. Inspect the contact pins and receptacles for corrosion. Repair corroded connectors as instructed in Repair Section 2 before continuing with this section Pull the originally installed rubber boot (boot without vent hose) towards the outside of the vehicle. Figure 3 Figure 4 Page 2 of

3 Repair Information: Section 1 Passenger s Side (cont d) 1.12 Use a 7 mm drill bit to carefully drill open the rivet nut fastening the previously installed rubber boot. If necessary, hold the rivet nut with a pair of pliers. Protect the painted body surface and if necessary, rework with primer and touch up paint. Remove drilling chips with compressed air (use safety glasses for eye protection) From the outside of the vehicle, guide a wire or flexible cable through the plug cut-out of the hinge pillar to the bore in the lower side member (Figure 3, arrow). Note: Route the wire behind the door hinge holder to the bore (Figure 5, arrow G) Make an open eyelet at the upper part of the wire. Engage pull strap of the vent hose into this wire eyelet Thread the vent hose into the hinge pillar and pull through the bore in the lower side member Fit the vent hose in the bore. Then disengage the wire. Note: The vent hose must not be installed twisted Grease the contact pins of the plug connection with Optimol MPO. Bring the plug through the rubber sleeve to the outside of the vehicle Fit the rubber boot in the hinge pillar. 1.1 Install and lock the frame reinforcement (Figure 4, arrow J) Press the plastic expanding rivet through the rubber boot and into the fastening bore (Figure 5, arrow H) Reinstall the holder (Figure 2, arrow E). Take care not to trap the wiring harness Lay the carpet and install the sill cover Grease the round receptacles of the door-side plug connection with Optimol MPO. Install the passenger s door. Refer to Figure 5 Technical Manual, Group 5, Repair , Removing and installing door. Fasten the plug connection with the new screw, part number, Tightening torque: 2.5 Nm (2.0 ft/lb.). Page 3 of

4 732 3a/7 Repair Information: Section 1 (cont d) Replacement of the driver s side rubber boot. Ensure that steps 1.1 and 1.2 have been performed Remove the driver s door. Refer to Technical Manual, Group 5, Repair Removing and installing door Remove the sill cover (Figure 1, arrow B). Refer to Technical Manual, Group 5, Repair , Disassembling and assembling release for front lid. Note: It is not necessary to detach the Bowden cables Remove the fuse box lid and trim (Figure 6, arrow F) Remove fastening screw of the fuse carrier and set fuse carrier aside Detach and fold the carpet over. 1.2 Remove fastening screws of the support (Figure 1, arrow C) Remove the 45 mm dia. plug (Figure 3, arrow) located below the hinge pillar in the inner lower side member. Note: The plug might be covered by body sealant and paint. Figure If it is present, remove the frame reinforcement (Figure 4) in the rubber boot. To remove the reinforcement open the locking lever (Figure 4, arrow J) Engage the securing latch of the plug again. Pull plug through the rubber sleeve into the passenger compartment Remove all traces of moisture from the connector with a blow dryer. Inspect the contact pins and receptacles for corrosion. Repair corroded connectors as instructed in Repair Section 2 before continuing with this section Pull the originally installed rubber boot (boot without vent hose) towards the outside of the vehicle Use a 7 mm drill bit to carefully drill open the rivet nut fastening the previously installed rubber boot. If necessary, hold the rivet nut with a pair of pliers. Protect the painted body surface and if necessary, rework with primer and touch up paint. Remove drilling chips with compressed air (use safety glasses for eye protection) From the outside of the vehicle, guide a wire or flexible cable through the plug cut-out of the hinge pillar to the bore in the lower side member (Figure 3, arrow). Note: Route the wire behind the door hinge holder to the bore (Figure 5, arrow G). Page 4 of

5 Repair Information: Section 1 Driver s side (cont d) 1.37 Make an open eyelet at the upper part of the wire. Engage pull strap of the vent hose into this wire eyelet Thread the vent hose into the hinge pillar and pull through the bore in the lower side member. 1.3 Fit the vent hose in the bore. Then disengage the wire. Note: The vent hose must not be installed twisted Grease the contact pins of the plug connection with Optimol MPO. Bring the plug through the rubber sleeve to the outside of the vehicle Fit the rubber boot in the hinge pillar Install and lock the frame reinforcement (Figure 4, arrow J) Press the plastic expanding rivet through the rubber boot and into the fastening bore (Figure 5, arrow H) Reinstall the support (Figure 1, arrow C). Note: Check the rubber covered nut (Figure 1, arrow D) before securing the support Install the sill cover. Refer to Technical Manual, Group 5, Repair Disassembling and Assembling Release for Front Lid Install the fuse carrier. Take care not to trap the wiring harness Install the fuse box trim and fit the fuse box lid Grease the round receptacles of the door-side plug connection with Optimol MPO. Install the passenger s door. Refer to Technical Manual, Group 5, Repair , Removing and Installing Door. Fasten the plug connection with the new screw, part number, Tightening torque: 2.5 Nm (2.0 ft/lb.). Page 5 of

6 732 3a/7 Repair Information: Section 2 Repairing corroded contact pins and round receptacles. Inspect the 10-pole plug (Figure 7, arrow 3). If the 10 pole plug is corroded follow the procedures from step 2.10 through 2.1. If there is no corrosion in the 10-pole plug, follow the procedures in step 2.1 through 2.. Passenger compartment side plug connection. 2.1 Disassemble the plug. Begin by removing the blue locking bar (Figure 7, arrow 1). Press the tab (arrow 2) and pull out the 10-pole plug (arrow 3). Press the tabs (arrow 4) and lever the holding frame out of the plug housing. Pull the holding frame out by around 20 mm (arrows 5). 2.2 Press a corroded contact pin out of the housing with tool and cut off with side cutters. 2.3 Crimp on a new contact pin and grease with Optimol MPO. Engage contact pin in the original housing position. 2.4 Repair all corroded contact pins in the same way. 2.5 Reassemble the plug in reverse order. Door side plug connection. Figure Disengage the 10-pole plug. 2.7 Detach the holding frame out of the housing and push back as far as possible. 2.8 Change the corroded round receptacles one by one and grease with Optimol MPO. 2. Reassemble the plug in reverse order. Page 6 of

7 Repair Information: Section 2 (cont d) Repairing corroded 10-pole plug (Figure 7, arrow 3). Door side plug connection 2.10 Replace the entire door wiring harness. Part numbers are listed in the Parts section of this bulletin. After replacement of the door wiring harness, grease the round receptacles of the door side plug connection with Optimol MPO. Passenger-compartment side plug connection. The 10-pole plugs are available as a repair set. Part numbers are listed in the Parts section of this bulletin. Only the plug found to be corroded should be replaced Detach the 10-pole plug by removing the blue locking bar (Figure 7, arrow 1), then pressing the tab (arrow 2) and pulling out the 10-pole plug (arrow 3) Select the required plug from the repair set. Ensure that the plug lead colors agree Use the length of the wire lead in the repair set as a guide in cutting the first lead from the corroded plug. Allow an additional 10 mm for the solder joint Strip approximately 10 mm of insulation from the repair set lead and passenger compartment lead. Insert the stripped ends of the leads together into one wire-end ferrule (Figure 8) and crimp using a pair of crimping pliers (Figure, item A) Solder the ends of the leads (Figure, item B). Install heat shrink tubing and apply heat with a hot-air gun (item C). Figure Repair the remaining leads, one lead at a time. Offset each solder joint to avoid an excessively thick wiring harness. There might be extra leads in the repair kit, either cut off and insulate the extra leads or tie the leads back Grease the contact pins in the repair plug with Optimol MPO Replace the corroded contact pins in the 26-pole plug (refer to this bulletin, Repair Section 2, steps 2.1 through 2.). 2.1 Reassemble the plug in reverse order. Figure Page 7 of

8 732 3a/7 Parts Information: Part Number Quantity Description Rubber boot with vent hose Frame reinforcement for rubber boot Plastic expanding rivet Screw as required Round receptacle connector as required Round receptacle connector as required Contact pin Optimol MPO grease (80 gr. tube, quantity sufficient for several vehicles set 10-pole plug repair set Mod. 7 (V) set 10-pole plug repair set Mod. 8 (W) Note: Plug repair sets consist of: 2 each black, 10-pole plug housings with contact pins and leads with the required colors. 2 each white, 10-pole plug housings with contact pins and leads with the required colors. 15 or 30 wire-end ferrules 15 or 30 shrink caps Door wire harnesses by Vehicle Identification Number as of VINs 8 XWS WU Part Number Description Option Driver s/passenger s door Driver s/passenger s door M Driver s door M Passenger s door M Driver s door M273 + M Passenger s door M273 + M Driver s/passenger s door M Driver s/passenger s door M563 + M Driver s door M563 + M Passenger s door M563 + M Driver s door M563 + M273 + M Passenger s door M563 + M273 + M40 from VIN 8 2VS to VIN 8 8WS Part Number Description Option Driver s/passenger s door Driver s/passenger s door M Driver s door M Passenger s door M Driver s door M273 + M Passenger s door M273 + M40 Page 8 of

9 Parts Info: (cont d) up to VIN 8 0VS Part Number Description Option Driver s/passenger s door Driver s/passenger s door M Driver s door M Passenger s door M Driver s door M273 + M Passenger s door M273 + M40 M273 = Electrically heated and adjustable mirrors M40 = Sound system M563 = Side impact airbag Warranty Info: Labor Operation Time Units Description T.U. Remove and install both doors Install new rubber boots Change round receptacles and contact pins T.U. Replace one door wiring harness includes: Remove and install one door trim panel and film T.U. Replace one door wiring harness includes: Remove and install one door trim panel, one film and one loudspeaker T.U. Replace two door wiring harnesses includes: Remove and install two door trim panels and two films T.U. Replace two door wiring harnesses includes: Remove and install two door trim panels, two films and two loudspeakers Damage Code X3L 1 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. Dealership Distribution Routing Manager Shop Foreman Technician Asst. Manager Warranty Admin. Technician The trademarks Porsche, Targa, Carrera,,Tiptronic, Varioram and the Porsche Crest are registered trademarks of Dr. Ing. h.c.f. Porsche AG and its affiliate, Porsche Cars North America, Inc. Date: Page of

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