Ak01 Heat Shield Recall Porsche

Number

8901

Time Allowance a) 120 TU for vehicles with manual transmission and vehicles with automatic transmission up to VIN WPOJ B092_G S861000.

b) 190 TU for vehicles with automatic transmission from VIN WP0JB092_GS861001. Please see and refer to administrative procedure.

Administrative Procedure

See attachment.

Sincerely,

Farouk Tewfik Manager, Technical Service

Page 2 of 2 July 10, 1989

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SERVICE

(CUSTOMER NOTIFICATION)

Subject:

Recall Campaign 1985/86 Model Porsche 928S 1987 Model Porsche 928 S4

Replacement of Heat Shield for Catalytic Converter

Dear Porsche Owner:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

Porsche AG has determined that a defect exists with the heat shield above the catalytic converter on 1985-1987 928 models. The heat shield is inadequate under certain circumstances involving engine malfunction. The problem arises where, due to, among other reasons, improper maintenance or repair, such as improperly secured ignition wires, the engine misfires resulting in overheating of the catalytic converter. If this condition is not detected, materials in the vicinity of the catalytic converter including the lines for the automatic transmission fluid on vehicles so equipped could ignite and cause an underbody fire due to the insufficiency of the heat shield.

Therefore, you should arrange for an appointment with your Porsche dealer, as soon as possible, to have the original heat shield replaced with the larger improved heat shield. On vehicles equipped with automatic transmission, a mounting bracket will be replaced and heat resistant sleeves installed on the tranmission fluid lines in those models where the lines pass in the drive train tunnel. The ignition wiring will be checked to ensure that it was properly secured.

The necessary parts to perform this Recall should be available at your Porsche dealer. The estimated time to perform this repair is approximately one and one half (IV2) to two (2) hours depending on the vehicle model year and transmission version. However, your Porsche may have to be left longer at your Porsche dealership since the exhaust system has to cool down before work can commence. This repair will, of course, be free of charge to you.

If your Porsche dealer fails, or is unable to perform this repair within a reasonable period of time, you may call or write to:

Porsche Cars North America, Inc. Administrator

100 West Liberty Street National Highway Traffic Safety Administration

P.O. Box 30911 OR U.S. Department of Transportation

Reno, Nevada 89520-3911 Washington, D.C. 20590

Attn: Customer Assistance Telephone: (702) 348-3154

We regret any inconvenience this Recall may cause; nevertheless, we are confident you understand our interest in your safety. Therefore, we urge you to make prompt arrangements so that the necessary work may be performed without delay.

Sincerely,

Sincerely,

Farouk Tewfik Manager, Technical Service

JZ/tjs 931

Work Procedure for Vehicles with Manual Transmission

Model year 1985 all Model year 1986 all Model year 1987 all

And Vehicles with Automatic Transmission

Model year 1985 all

Model year 1986 through VIN 92_GS861000

1) Disconnect oxygen sensor wire plug located behind passenger side foot support on Central Electric Board. Push wire plug and grommet down through the floor board.

2) Lift car on hoist.

3) Remove rear part of engine cover plate; and remove the small right front heat shield.

4) Pull oxygen sensor wire through opening in catalytic converter heat shield.

5) Remove the exhaust hanger rear of catalytic converter.

6) Remove complete exhaust system rear of catalytic converter.

7) Remove heat shield above catalytic converter.

8) Install new heat shield.

9) Push oxygen sensor wire through opening in heat shield and floor board and install rubber grommet.

10) Reinstall exhaust system.

From Model year 1986 — VIN 92-GS861001 with manual transmission — do not reinstall exhaust hanger rear of catalytic converter.

The following parts are deleted:

a. 928 111 278 00, Top Bracket b. 928 111 287 00, Lower Bracket c. 928 111 288 00, Lower Bracket d. 999 512 325 02, Bracket e. 900155 036 02, Bolt f. 928 111 259 03, Rubber Hanger

11) Reinstall small right front heat shield.

12) Reinstall rear part of engine cover plate.

13) Connect oxygen sensor wire plug and close Central Electric Board cover.

14) The following ignition wiring connections must be checked for tightness and good contact. — CAUTION — turn off the ignition when working on the ignition system. (DANGEROUS HIGH VOLTAGE).

A) Ignition coil left and right:

- Terminal 1 and 15

- High tension ignition lead terminal number four (4). If high tension lead connection is not tight, pull lead from ignition coil and check for corrosion. If corrosion is visible replace ignition wire plug and/or ignition coil.

B) Ignition wire plugs on distributor caps left and right. If ignition wire plugs are not tight, pull plugs from distributor cap and check for corrosion. If corrosion is visible, replace high tension lead and/or distributor cap.

C) Spark plug connectors and high tension wires. If plug connectors are not tight, pull connections from spark plugs and check for corrosion. If corrosion is visible inside spark plug connector, replace spark plug connector.

D) Ignition final stages: Check plug connectors, ground connection and mounting bolts. See Figure 1.

Figure 1

Work Procedure for Vehicles with Automatic Transmission

Model year 1986 from VIN 92_GS861001 Model year 1987 all

1) Disconnect oxygen sensor wire plug located behind passenger side foot support on Central Electric Board. Push wire plug and grommet down through the floor board.

2) Lift car on hoist.

3) Remove rear part of engine cover plate; remove the small right front heat shield.

4) Pull oxygen sensor wire through opening in catalytic converter heat shield.

5) Remove and discard the exhaust hanger rear of catalytic converter.

The following parts are deleted:

a. 928 111 278 00, Top Bracket b. 928 111 287 00, Lower Bracket c. 928 111 288 00, Lower Bracket d. 999 512 325 02, Bracket e. 900 155 036 02, Bolt f. 928 111 259 03, Rubber Hanger

6) Remove complete exhaust system rear of catalytic converter.

7) Remove heat shield above catalytic converter.

8) Disconnect both ATF lines above the catalytic converter and plug the line openings — CAUTION — some ATF will drain from hose openings.

9) Loosen both ATF line mounting clamps on central tube and remove the front plastic bracket.

10) Push the protection sleeves over the ATF lines approx. 10cm (% inch) further than the end of the ATF lines. (Figure 1).

Figure 1

11) Reconnect ATF lines and tighten securely.

12) The ATF lines must be bent upward to gain clearance between the lines and the new heat shield. Support ATF lines with a wrench or similar tool (Approx. 20x6mm) close to ATF line bracket and bend ATF lines upward using a tire bar or similar tool. The tool contact area should be the threaded ATF line fittings as shown in Figure 2. At the same time, push ATF lines up by hand (counterhold) in the area of the longitudinal support.— CAUTION — Use only tools with rounded edges. Sharp edges could damage the ATF lines.

Figure 2

13) Pull back ATF line protection sleeves until ATF lines are fully covered (Figure 3).

Figure 3

14) Install new metal bracket on front ATF line clamp and reuse plastic bracket on rear ATF line clamp.

15) Install new heat shield and before tightening, make sure ATF line protection sleeves do not contact the heat shield. If necessary, remove the heat shield again and realign ATF lines. ATF lines must not contact heat shield.

16) Push oxygen sensor wire through opening in heat shield and floor board and install rubber grommet.

17) Reinstall exhaust system. Do not reinstall exhaust hanger rear of catalytic converter. Reinstall small right front heat shield.

18) Connect oxygen sensor wire plug and close Central Electric Board cover.

19) Start engine.

20) Check for ATF leaks in the area of the ATF lines. Check and correct ATF level.

21) Reinstall rear part of engine cover plate.

The following ignition wiring connections must be checked for tightness and good contact.

— CAUTION — turn off the ignition when working on the ignition system. (DANGEROUS

HIGH VOLTAGE).

A) Ignition coil left and right:

- Terminal 1 and 15

- High tension ignition lead terminal number four (4). If high tension lead connection is not tight, pull lead from ignition coil and check for corrosion. If corrosion is visible, replace high tension lead and/or ignition coil.

B) Ignition wire plugs on distributor caps left and right. If ignition wire plugs are not tight, pull plugs from distributor cap and check for corrosion. If corrosion is visible, replace high tension lead and/or distributor cap.

C) Spark plug connectors and high tension wires. If plug connectors are not tight, pull connections from spark plugs and check for corrosion. If corrosion is visible inside spark plug connector, replace spark plug connector.

D) Ignition final stages: Check plug connectors, ground connection and mounting bolts. See Figure 4.

D) Ignition final stages: Check plug connectors, ground connection and mounting bolts. See Figure 4.

Figure 4

Replacement of Heat Shield for Catalytic Converter

Warranty Claims should be submitted via DCS

Affected VINs:

for vehicles with manual transmission

Affected VINs:

for vehicles with auto transmission

WP0JB092-F S860061 WP0JB092-GS860061 WP0JB092-HS860061

WP0JB092-F S860061 WP0JB092-GS860061

WP0JB092_F S862279 WP0JB092-GS863010 WP0JB092_HS862481

WP0JB092-F S862279 WP0JB092-GS861000

Warranty Code:

Replacement of heat shield for 1985 through 1987 vehicles with manual transmission, and 1985 and shown, 1986 vehicles with automatic transmission; see work procedure for details.

Damage Code: AK01 99 K012

Labor Operation: 2601 19 01

Time Units: 120

Part Number: 928 504 991 00

Warranty Parts $: 83.39

In cases where the Recall cannot be performed, submit the information on a claim via DCS with the appropriate disposition code by inserting the code in at the last digit of the damage code.

Disposition Damage Code To Be Used Parts and Labor

3 - Total loss

AK01 99 K013

Not applicable

4 - Vehicle stolen

AK01 99 K014

rf

5-Vehicle left U.S.A.

AK01 99 K015

it

6 - Customer moved,

AK01 99 K016

"

new address unknown

7 - Vehicle sold, new

AK01 99 K017

II

owner unknown

9 - Customer refused to comply

AK01 99 K019

n

Owner Name and Address Change

If owner name and address is shown incorrectly, submit correction using name/address change postcard from the Warranty and Maintenance Booklet or Recall mailing, or report to PCNA via DCS to USPCWARRANTY including VIN.

Replacement of Heat Shield Kit for Catalytic Converter Warranty Claims should be submitted via DCS

Affected VINs: WP0JB092_GS861001 — WP0JB092_GS863010

for vehicles with WP0JB092_HS860061 — WP0JB092_HS862481 auto transmission

Warranty Code: R

Replacement of heat shield kit for shown 1986 and 1987 vehicles with automatic transmission; see work procedure for details.

Damage Code: AK01 99 K012

Labor Operation: 2601 19 02

Time Units: 190

Part Number: 000 043 125 00

Warranty Parts $: 96.47

In cases where the Recall cannot be performed, submit the information on a claim via DCS with the appropriate disposition code by inserting the code in at the last digit of the damage code.

Disposition Damage Code To Be Used Parts and Labor

3-Total loss AK0199K013 Not applicable

4 - Vehicle stolen AK01 99 K014

6 - Customer moved, AK01 99 K016

new address unknown 7-Vehicle sold, new AK0199K017

owner unknown 9 - Customer refused to comply AK01 99 K019

Owner Name and Address Change

If owner name and address is shown incorrectly, submit correction using name/address change postcard from the Warranty and Maintenance Booklet or Recall mailing, or report to PCNA via DCS to USPCWARRANTY including VIN.

Campaign Bulletin

Model

1990 928 S4/GT

Group 2

Subject: Inspection and/or Replacement of Fuel Level Sending Unit Mounting Nut

Campaign Code:

Number

9002

This is to notify you of a voluntary Recall Campaign which involves 19 Porsche 928 S4/GT vehicles, all of model year 1990 with the following VIN's:

WP0JB292XLS860351 WP0JB2921LS860352 WPOJ B2923LS860353 WPOJ B2927LS860355 WPOJ B2929LS860356 WP0JB2924LS860359 WPOJ B2920LS860360 WPOJ B2922LS860361 WPOJ B2926LS860363 WPOJ B2928LS860364 WP0JB292XLS86O365 WPOJ B2923LS860367 WPOJ B2927LS860369 WPOJ B2927LS860372 WPOJ B2924LS860376 WPOJ B2926LS860377 WPOJ B2928LS860378 WPOJ B2926LS860380 WPOJ B2923LS860384

It was determined that a potential defect exists on some of the above 19 vehicles.

The fuel level sending unit mounting nut, sourced from a secondary supplier and bearing no vendor identification, is made out of plastic and may contain a manufacturing defect. The defective mounting nut may crack and under certain fuel level and operating conditions result in fuel leaking from the fuel tank. If the leaking fuel were to come into contact with a hot exhaust system it could result in a fire.

Note: Fuel level sending unit mounting nut bearing the VW-, Audi trademark and part number 113 201 375 between the reinforcements on the nut, are in order and should not be replaced.

Customer Notification

Porsche Cars North America, Inc. will notify all known owners of vehicles within the Recall VIN ranges directly by first class mail during the week of June 18, 1990. See enclosed copy of letter to these consumers. A listing of all vehicles with owner's name and address in your area, within the Recall VIN ranges, will be sent to you shortly.

If a vehicle within the Recall VIN range is in your dealership for service/repair and/or in dealer inventory and/or demo use, the Recall Campaign should be performed without delay.

Page 1 of 2 June 15, 1990

Campaign Bulletin

Model

1990 928 S4/GT

Group 2

Subject: Inspection and/or Replacement of Fuel Level Sending Unit Mounting Nut

Campaign Code:

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