Technical Information

Transcription

1 Dook Lock System Diagnosis and Repair Binder -, Body Vehicle Type: / S/ Turbo Model Year: As of 03 (3) Concern: Information: Complaints and malfunctions on door lock/door locking system. This Technical Information provides an overview of possible complaints in the door lock and door locking system and the required remedial measures. Component Complaint Remedy/measure Outer door handle Outer door handle gets stuck in actuated position See Page 2 or does not fully return to its original position. Lock cylinder On the driver's door, the vehicle can neither be See Page 4 locked nor unlocked with the vehicle key. Lock cylinder On the driver's door, the key bit of the vehicle key See Page cannot be inserted into the lock cylinder. Door lock On the driver's door, the vehicle can either be only See Page locked or only unlocked with the vehicle key. Outer door handle Function of outer door handle affected. See Page 6 Inner door release Function of inner door release affected See Page 7 Outer door handle/ Function of outer door handle and the inner door See Page 9 inner door release release affected. Page 1 of 13

2 717 1/04 Technical Information Outer door handle gets stuck in actuated position or does not fully return to its original position. With too little clearance between the bearing pins on the door handle and the respective mounting in the supporting bow of the door handle in the vehicle door, as well as in the area of the sliding surface between the grip hook on the door handle and the lock cylinder (driver's door) or the lock cylinder housing (remaining doors), the door handle can get stuck in the actuated position or not fully return to its original position. In the case of a complaint, the bearing surfaces on outer door handle, as well as the sliding surfaces of the guide for the lock actuation on the door handle, and on the lock cylinder (driver's door) or on the lock cylinder housings (of the remaining doors) need to be lubricated. Parts Information: Part Number Description Grease for door lock - Grease sliding surfaces on the lock cylinder or on the lock cylinder housings and on outer door handle, - Grease bearing surfaces of outer door handle. 1. Remove outer door handle, see Workshop Manual, Group, Removing and reinstalling front door handle and 8 11 IN - Removing and reinstalling rear door handle. Do not completely remove the door handle on vehicles with Porsche Entry & Drive, instead only disengage door handle on the side of the guide for lock actuation and swivel out 90. Grease door handle in this position. 2. Grease sliding surfaces and bearing surfaces. 2.1 Completely and lightly grease sliding surface on lock cylinder (driver's door) or on the lock cylinder housings (remaining doors) over the entire length with a brush using door lock grease, part number, (Figure 1). Figure 1 Page 2 of 13

3 (cont d) 2.2 Using a brush, lightly grease the bearing hooks on the door handle (in front in direction of travel) on the upper and lower sides (Figure 2, arrows A) and in the area of the holding slot (Figure 2, arrow B). For vehicles with Porsche Entry & Drive, lightly grease the bearing hook in swiveled-out position to the extent possible Figure Using a brush, lightly grease grip hook on door handle (Figure 3) on the three sliding surfaces (arrows A) and on the bearing pins (arrows B). 3. Install outer door handle. Observe additional assembly instructions and check function of outer door handle as described in the Workshop manual, see Workshop Manual, Group, Removing and reinstalling front door handle and 8 11 IN - Removing and reinstalling rear door handle see Function test after assembly work. Figure 3 Page 3 of 13

4 717 1/04 Technical Information On the driver's door, the vehicle can neither be locked nor unlocked with the vehicle key. Cause of fault a): - The lock cylinder is located in the free wheel lock function. Identifying feature - The slot in the cover of the lock cylinder where the key bit of the vehicle key is inserted (Figure 4, arrow) is not vertical. Remedying the fault a): 1. Swivel out the key bit of the vehicle key and insert completely into the lock cylinder. Figure 4 2. Turn the vehicle key in one direction until the free wheel lock engages audibly and is felt to engage on the key. The function of the lock cylinder has been reestablished. Cause of fault b): - The control shaft of the lock cylinder does not engage into the corresponding mounting on the door lock. Remedying the fault b): 1. Remove the lock cylinder from the driver's door, see Workshop Manual, Group, Removing and installing lock cylinder. Do not unclip the cover of the lock cylinder. 2. Install lock cylinder. When doing so, insert the lock cylinder horizontally into the mounting in the driver's door. When installing, the lock cylinder must be able to be inserted into the mounting in the driver's door without tilting. If the lock cylinder is tilted when installing, the movable control shaft of the lock cylinder will be pointing slightly upward or downward, and it will not engage in the mounting of the door lock. In this case, take out the lock cylinder from the mounting in the driver's door again, and insert it again as described into the mounting on the driver's door. If the vehicle is still not able to be unlocked or locked with the vehicle key after the lock cylinder has been properly installed, the door lock is defective and the door lock must be replaced. Page 4 of 13

5 The key bit of the vehicle key cannot be inserted into the lock cylinder on the driver's door or the vehicle key can be inserted into the lock cylinder, but it cannot be turned. Fault cause: - The mechanism in the lock cylinder has been deformed or damaged by possible manipulation. - There is a foreign object in the lock cylinder. - Incorrect vehicle key. Remedying the fault: 1. Remove the lock cylinder on the driver's door, see Workshop Manual, Group, Removing and installing lock cylinder. 2. Replace the lock cylinder. 3. Use the vehicle key intended for the vehicle. On the driver's door, the vehicle can either only be unlocked or only be locked with the vehicle key. Fault cause: - Mechanical fault in door lock. Remedying the fault: 1. Replace door lock, see Workshop Manual, Group, Removing and installing the door lock. Page of 13

6 717 1/04 Technical Information The door cannot be opened by actuating the outer door handle. Ensure that the function "individual door opening, driver's door" is not activated. If "individual door opening, driver's door" has been activated, only the driver's door is unlocked when unlocking the vehicle. The remaining doors can be opened from the inside by pulling twice on the inner door release. In the main menu of the multi-function display, check the settings for unlocking the doors under "Settings > Comfort > Door opening > Doors" and change them if necessary. See the Owner's Manual, Chapter "Controls, Safety, Instruments" "Multi-function display". Fault type: - The doors are unlocked, the door cannot be opened from the outside by actuating the outer door handle. - The affected door can only be opened by pulling on the inner door release. Fault cause: - The lock actuation (Figure, Item A) is not clipped in or is too loosely clipped into the guide on the grip hook of the door handle (Figure, Item B). Remedying the fault: 1. On the affected door, remove the lock cylinder (driver's door) or the lock cylinder housing (remaining doors). Removing the lock cylinder: See Workshop Manual, Group, Removing and installing the lock cylinder. Figure Removing the lock cylinder housing: See Workshop Manual, Group, 8 11 IN --- Removing and installing rear door handle, work steps Unclip the lock actuation (Figure 6, Item A) from the guide on the grip hooks of the door handle using a small screw driver. 3. Latch the actuating lever of the lock actuation using the T10118 assembly tool, See Workshop Manual, Group, Removing and installing front door handle or Removing and installing rear door handle Latching the lock actuation. Figure 6 Page 6 of 13

7 (cont d) Caution! Malfunction of the door control if the lock actuation is installed incorrectly! > If the lock actuation is clipped into the guide on the outer door handle under traction, the door lock is prematurely triggered and the affected door cannot be opened on the outer door handle after initial locking and unlocking. In addition, the function of the inner door release can be affected. 4. Clip the lock actuation into the guide on the outer door handle firmly, but not under traction using the tip of your pointing finger.. Install the lock cylinder or lock cylinder housing, but do not close the door afterwards. 6. Check the function of the outer door handle with the door open, see Workshop Manual, Group, Removing and installing front door handle or 8 11 IN Removing and installing rear door handle, Function test after assembly work. During the initial actuation of the outer door handle, the latch on the lock actuation clearly disengages audibly. Function of inner door release affected. If the affected door is a rear door, first check if the child lock function is activated on the rear doors. In this case, the door cannot be opened from the inside. Deactivate the child lock function on the rear doors as necessary, see Owner's Manual, Chapter "Controls, Safety, Instruments". Fault type: - Vehicle doors are unlocked. - The doors can be opened by actuating the outer door handle. - Function of inner door release is affected when actuating once or twice. Cause(s) of fault: a) The actuating cable is not properly engaged on the inner door release and/or on the door lock. b) The installed actuating cable is too long, and the actuating lift of the inner door release is not sufficient. Remedying the fault - applicable for Fault cause a) and Fault cause b): 1. Pull on the outer door handle and open the vehicle door. 2. Check the actuating cables of the inner door release. 2.1 Remove door trim panel and check if the actuating cable for the door lock is engaged on the inner door release, see Workshop Manual, Group 7, Removing and installing front door trim or Removing and installing rear door trim. Page 7 of 13

8 717 1/04 Technical Information (cont d) 2.2 Engage the actuating cable for the door lock if necessary, and check the function of the inner door release Engage the rotary latch in the door lock of the opened door (Figure 7, arrow) completely to the second catch using a screw driver Pull on the inner door release and check if the rotary latch releases, - if yes Install the door trim panel done. - if no Continue with Step Remove door sub-frame and check if the actuating cable of the inner door release is engaged on the door lock, see Workshop Manual, Group, Removing and installing front door subframe or Removing and installing rear door sub-frame. Figure If necessary, engage the actuating cable of the inner door release on the inner door release, see Workshop Manual, Group, Removing and installing inner door release for door lock (front door) or Removing and installing inner door release for door lock (rear door). 2. Check the function of the inner door release, see Steps and Rotary latch released Install door sub-frame and door trim panel, done. - Rotary latch does not release Replace actuating cable of inner door release, see Workshop Manual, Group, Removing and installing inner door release for door lock (front door) or Removing and installing inner door release for door lock (rear door). 2.6 Install door sub-frame and inner door trim panel, done. Page 8 of 13

9 - The door cannot be opened from the outside by actuating the outer door handle. - Function of inner door release affected. Ensure that the function "individual door opening, driver's door" is not activated. This function unlocks only the driver's door when the vehicle is unlocked. In the main menu of the multi-function display, check the settings for unlocking the doors under "Settings > Comfort > Door opening > Doors" and change them if necessary. See the Owner's Manual, Chapter "Controls, Safety, Instruments" "Multifunction display". Fault type: - Vehicle is unlocked. - The door cannot be opened from the outside by actuating the outer door handle. - Function of inner door release affected. - Door lock is prematurely triggered. Cause(s) of fault: a) The lock actuation (Figure 8, Item A) is clipped in the guide on the grip hooks of the door handle under traction (Figure 8, Item B). Figure 8 b) The actuating lever of the lock actuation (Figure 9, Item A) gets stuck on the cover of the door lock (Figure 9, Item B). c) The actuating lever of the lock actuation (Figure 9, Item A) jams or is bent and no longer reaches its original position. Item C shows the clip of the lock actuation which is clipped in the guide on the grip hook of the door handle. d) The actuating cable of the inner door release is too short or installed under excessive stress. Figure 9 Page 9 of 13

10 717 1/04 Technical Information (cont d) Remedying the fault - applicable to fault cause a) to d): 1. Press outer door handle of the affected door inward to the door with the ball of your thumb (Figure 10, arrow). 2. Pull outer door handle and check if the door can be opened. This measure only functions if the door lock is slightly prematurely triggered. - The door can be opened, Continue with Step 2.1. Figure 10 - The door cannot be opened, press the outer door handle inwards again toward the door and attempt to open the door. If the door cannot be opened then, Continue with Step 3 (front door) or with Step 4 (rear door). 2.1 Remove lock cylinder or lock cylinder housing out of the opened door. Removing the lock cylinder: See Workshop Manual, Group, Removing and installing the lock cylinder. Removing the lock cylinder housing: See Workshop Manual, Group, 8 11 IN --- Removing and installing rear door handle, work steps Unclip the lock actuation (Figure 11, Item A) from the guide on the grip hooks of the door handle using a small screw driver. 2.3 Latch the actuating lever of the lock actuation using the T10118 assembly tool, see Workshop Manual, Group, Removing and installing front door handle or 8 11 IN Removing and installing rear door handle Latching the lock actuation. Figure 11 Page 10 of 13

11 (cont d) Caution! Malfunction of the door control if the lock actuation is installed incorrectly! > If the lock actuation is clipped into the guide on the outer door handle under traction, the door lock is prematurely triggered and the affected door cannot be opened on the outer door handle after initial locking and unlocking. In addition, the function of the inner door release can be affected. 2.4 Clip the lock actuation into the guide on the outer door handle firmly, but not under traction using the tip of your pointing finger. 2. Install the lock cylinder or lock cylinder housing, but do not close the door afterwards. 2.6 Check the function of the outer door handle, see Workshop Manual, Group, Removing and installing front door handle or 8 11 IN Removing and installing rear door handle, Function test after assembly work. During the initial actuation of the outer door handle, the latch on the lock actuation clearly disengages audibly done. 3. Front door cannot be opened. 3.1 Remove rear door to get access to the lock cylinder (driver's door) or lock cylinder housing (passenger's door), see Workshop Manual, Group, Removing and installing rear door. 3.2 Remove lock cylinder or lock cylinder housing of the affected front door, see Workshop Manual, Group, Removing and installing the lock cylinder. 3.3 Unclip lock actuation out of the guide on the outer door handle using a small screw driver (see Figure 11, page 10). 3.4 Pull inner door release and open door. 3. Light up the opening on the lock cylinder or lock cylinder housing with a flashlight and check if the actuating lever of the lock actuation gets stuck or is visibly bent on the door lock cover at the top (Figure 12, Item A) and/or laterally (Figure 12, Item B). Figure 12 Page 11 of 13

12 717 1/04 Technical Information (cont d) Case 1: Actuating lever does not get stuck on the lock cover and is not bent. Proceed with Step 2.3 to 2.6 described on page 9 and 10 then check the function of the inner door release with the door open, see Step and Step on page 8. If the function of the inner door release is affected, replace the actuating cable of the inner door release, see Workshop Manual, Group, Removing and installing inner door release for the door lock. If necessary, repeat the function test on the inner door release. Install rear door done. Case 2: Actuating lever gets stuck on the lock cover and is visibly bent. Continue with Step. 4. The rear door cannot be opened from the outside when the vehicle is unlocked. 4.1 Remove window shaft seal in order to be able to open the door afterwards Remove window shaft seal of the rear door, see Workshop Manual, Group 6, Removing and installing the rear window shaft seal Insert long wire hook in the window shaft and hook in the wire hook on the lock actuation. Use a flashlight for better orientation Pull wire hook carefully in the direction of travel. This measure only functions when the actuating lever of the lock actuation gets stuck on the covering for lock. Pulling returns the actuating lever again to its original position Pull outer door handle and open door. 4.2 Remove outer door handle of the rear door, see Workshop Manual, Group, 8 11 IN Removing and installing door handle, then Continue with Step.. Remove door lock and check the function of the actuating lever..1 Remove door sub-frame, see Workshop Manual, Group, Removing and installing front door sub-frame or Removing and installing rear door sub-frame..2 Remove door lock, see Workshop Manual, Group, Removing and installing door lock (front) or Removing and installing door lock (rear)..3 Check if the actuating lever of lock actuation gets stuck on the covering for lock, or if it is bent. - Actuating lever gets stuck on the covering for lock Replace covering for lock. - Actuating lever is bent Replace door lock and covering for lock. 6. Install door lock. 7. Install door unit carrier. Page 12 of 13

13 8. Install outer door handle, see Workshop Manual, Group, Removing and reinstalling front door handle and 8 11 IN - Removing and reinstalling rear door handle. After installing the door handle, do not close the door. 9. Check the function of the outer door handle, see Step 2.6 on page Check function of inner door release with the door open, see Step and on page 8. - Rotary latch releases when pulling on the inner door release done. - Rotary latch does not release, Replace the actuating cable for the inner door release, see Workshop Manual, Group, Removing and installing inner door release for door lock. 11. Repeat test if necessary. 12. Install rear door if necessary done. References: POSES, Workshop Manual: > Group : Removing and installing lock cylinder Removing and installing front door handle Removing and installing door lock Removing and installing front door sub-frame Removing and installing inner door release for door lock (front door) 8 11 IN Removing and installing rear door handle Removing and installing rear door sub-frame Removing and installing inner door release for door lock (rear door) > Group 6: Removing and installing rear window shaft seal > Group 7: Removing and installing front door trim Removing and installing rear door trim Owner's Manual for the, S and Onwer's Manual for the Turbo: > Chapter Controls, Safety, Instruments "Multi-function display" 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 Service Manager Shop Foreman Service Technician Asst. Manager Warranty Admin. Service Technician Dr. Ing. h.c. F. Porsche AG is the owner of numerous trademarks, both registered and unregistered, including without limitation the Porsche Crest, Porsche, Boxster, Carrera,, Tiptronic, VarioCam, PCM, 911, 4S, and the model numbers and distinctive shapes of Porsche s automobiles such as, the federally registered 911 automobile. The third party trademarks contained herein are the properties of their respective owners. Porsche Cars North America, Inc., believes the specifications to be correct at the time of printing. However, specifications, standard equipment and options are subject to change without notice. Printed in the USA Page 13 of 13