Reno Nevada Porsche Repair

Subject: Recall Campaign F03

1985 Porsche 928S Model Replacement of Engine Carrier

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 safety related defect may exist with the engine carriers installed on some 1985 Porsche 928S vehicles. Our records indicate that you are the owner of a vehicle which is equipped with one of these engine carriers. Due to a welding problem by the supplier of the engine carrier, the support bracket eyes could separate from the carrier. If this occurs, there would be no impairment of the steering mechanism or roadability of the car. However, this condition could weaken the engine carrier and, with higher mileage accumulation the engine carrier could break without warning resulting in a steering blockage.

Replacement parts will be available as of July 22nd. The estimated time to perform this repair is approximately six hours. The work will, of course, be free of charge to you.

You should arrange for an appointment with your Porsche dealer, as soon as possible, to have the engine carrier in your vehicle replaced.

If your dealer fails, or is unable to remedy the defect without charge within a reasonableamount of time, you may call or write to:

Porsche Cars North America 200 South Virginia Street Reno, Nevada 89501

Attn: Customer Assistance Telephone: (702) 348-3154 (702) 348-3157

Administrator National Highway Traffic Safety Administration OR U.S. Department of

Transportation Washington, D.C. 20590

We regret any inconvenience this action 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,

Farouk Tewfik

Manager, Technical Service

1. Disconnect battery.

2. Remove both front wheels.

3. Remove reinforcement plate under engine carrier.

4. Remove sway bar.

5. Remove lower universal joint from rack and pinion.

6. Remove wire harness clamp from carrier.

7. Remove hydraulic line connecting bolts from rack and pinion.

8. Lower rack and pinon (tie-rods remain connected).

9. Remove left and right engine carrier supports and discard.

10. Remove oil filter.

11. Remove rear bearing bracket (rubber bearing) from lower control arm.

12. Remove nuts for engine mounts on carrier.

13. Lift engine slightly off carrier, using jack and piece of wood under oil pan orusecranetolift engine slightly up.

14. Remove left and right bolts for engine carrier and remove same.

15. Remove heat shields from carrier and add to new one.

16. Install new engine carrier, torque bolts to specifications.

17. Install new left and right carrier supports, torque bolts to specifications.

18. Reinstall both lower control arm bearing brackets, torque bolts to specifications.

19. Lower engine to carrier and torque nuts.

20. Reinstall reinforcement plate under carrier.

21. Reinstall steering universal joint, using new nut and torque to specifications.

22. Reinstall clamp for wiring harness.

23. Reinstall hydraulic lines and torque bolts.

24. Install new oil filter.

25. Check engine oil level, replenish if necessary.

26. Reconnect battery.

27. Start engine, bleed power steering and check for leaks.

28. Check engine oil level, replenish if necessary.

29. Reinstall front wheels, torque lug nuts.

30. Check and adjust front wheel alignment, assure that steering wheel is centered.

31. Road test car.

Required Torque Specifications:

a. Upper control arm, to body (M14) 140 Nm (101 ft. lbs.)

b. Lower universal joint on rack and pinion (M8) 28 Nm (20 ft. lbs.)

c. Hydraulic line bolts on rack and pinon (M14) 30 Nm (21.5 ft. lbs.)

d. Reinforcement plate under engine carrier (M8) 23 Nm (16.5 ft. lbs.)

e. Reinforcement plate under engine carrier (M10) 46 Nm (33 ft. lbs.)

f. Engine mount to carrier (M12) 85 Nm (61 ft. lbs.)

g. Engine carrier to body (M10) 65 Nm (47 ft. lbs.)

h. Carrier support brackets (M12) 85 Nm (61 ft. lbs.)

i. Lower control arm, bearing caps (M12) 120 Nm (86.5 ft. lbs.) j. Sway bar to body (M10) 46 Nm (33 ft. lbs.) k. Wheel lug nuts (M14) 130 Nm (94 ft. lbs.)

Campaign Bulletin

Model

1987/928 S4

Group 2

Subject::

Replacement of Fuel Return Hose

Campaign Coda:

Number

8701

This is to notify you of a pre-delivery/recall campaign involving 1987 model 928 S4 Porsches. The affected vehicles may contain a defective fuel return hose provided by a new supplier for use beginning with the 1987 model year production. The return fuel line hose for the 1987 928 S4 received by Porsche AG was not ozone resistant. The lack of ozone resistance may cause cracking of the hose, resulting in a potential fuel leak and engine compartment fire.

The vehicles involved are within the following VIN ranges:

WP0JB092JHS860061 to WP0JB092_HS861049

Customer Notification

Porsche Cars North America will notify all known owners directly by first class mail during the week of March 23, 1987 as per the attached copy of notification.

For those vehicles which are in dealer's inventory or for which the sales information is not in our files, the notification will be addressed to the dealer. If the vehicle is in stock, the campaign should be performed without delay. If the vehicle has been retailed or dealer traded, the dealer is to make the necessary arrangements to have the customer or receiving dealer contacted and the campaign performed.

Work Procedure

See Attachment

Parts Requirements

The parts required to perform the pre-del¡very/recall campaign will be shipped to you in the amount required according to your affected vehicle allocation in the week of March 16, 1987. The parts required to perform this campaign are:

Quantity

Part Number

928.110.359.04 N 023.577.2

Description

Fuel Hose Clamps

Additional quantities, after the initial allocation is made, should be ordered, as needed, through normal parts channels using the above part numbers.

Time Allowance

100 time units w

Page 1 of 2 March 18, 1987

1987/928 S4

Replacement of Fuel Return Hose

Campaign Coda:

8701

Administrative Procedure See Attachment Sincerely,

Farouk Tewfik

Manager, Technical Service w

Page 2 of 2 March 18, 1987

Subject:

Pre-delivery/Recall Campaign 1987 Porsche 928 S4 Vehicles Replacements of Fuel Return Hose

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 may exist with the fuel return hose on some 1987 Porsche 928 S4 vehicles. Our records indicate that you are the owner of one of those vehicles which potentially contains this defect. This fuel hose which is located in the engine compartment is not ozone resistant. The lack of ozone resistance may cause cracking of the hose resulting in a potential fuel leak and engine compartment fire.

You, therefore, should arrange for an appointment with your Porsche dealer as soon as possible to have this fuel return hose replaced.

Replacement parts will be available at your Porsche dealer. The estimated time to perform this repair is approximately one hour. The work will, of course, be free of charge to you.

In the meantime, if you detect a fuel leak or have a fuel odor coming from the engine compartment, do not continue to drive your car. Have it towed to the nearest Authorized Porsche Dealer to inspect and perform the necessary repairs.

If your dealer fails, or is unable to remedy the defect without charge within a reasonable amount of time, you may call or write to:

We regret any inconvenience this action 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.

Porsche Cars North America, Inc. 200 South Virginia Street P.O. Box 30911 Reno, Nevada 89520-3911

Administrator National Highway Traffic Safety Administration U.S. Department of

Attn: Customer Assistance

OR Transportation

Washington, DC 20590

Telephone: (702) 348-3154

(702) 348-3157

Sincerely,

Sincerely,

Farouk Tewfik

Manager, Technical Service

JZ/nk

Important: Always follow the safety regulations for working on the fuel system.

1. Record customer's AM & FM preset radio stations. Raise rear lid and disconnect battery ground cable.

2. Raise front hood, use fender covers left and right side.

3. Remove air suction hoses from air filter.

4. Remove air filter cover with filter.

5. Remove air filter lower housing.

6. Remove injector rail cover right side (if necessary for clamp access). Loosen air mass sensor hose clamp using a long screwdriver.

7. Remove air mass sensor, and cover intake air duct with a rag.

8. Release fuel tank pressure by loosening gas cap.

9. Place rags under fuel return line to absorb possible fuel spillage.

10. Disconnect fuel line from pressure regulator using a 15mm and a 19mm wrench. Counterhold retaining nut to avoid damage. Loosen clamp for fuel return hose and mounting nut for pressure regulator (24mm wrench). Pull off vacuum hose and remove pressure regulator.

11. Disconnect fuel return hose from fuel line to fuel cooler.

12. Install new return hose with new hose clamp on fuel line to fuel cooler (do not tighten hose clamp at this time). Note: Do not use any lubricant on hose or fittings.

Install pressure regulator and connect new return hose, using new hose clamp. Insure that hose is not twisted or kinked. Position both hose clamps approximately 5mm from hose ends and tighten.

13. Reconnect fuel pressure lines. Counter hold retaining nut to avoid damage.

14. Reconnect vacuum hose to pressure regulator.

15. Reinstall air mass sensor. Reinstall right side injector rail cover (if removed).

16. Tighten gas cap.

17. Reconnect battery ground cable and start engine.

18. Check fuel system for leaks. Repair if necessary.

19. Reinstall air filter assembly.

20. Reset clock and customer's preset radio stations.

Warranty Claims should be submitted via DCS

Affected VINs: WP0JB092_HS860061 to WP0JB092JHS861049

Warranty Code: R

Damage Code: Labor Operation: Time Units: Part Number: Warranty Parts $:

249099H012 2458190A 100

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

3 - Total loss

4 - Vehicle stolen

6 - Customer moved, new address unknown

7 - Vehicle sold, new owner unknown

9 - Customer refused to comply

Damage Code To Be Used

249099H013

249099H014

249099H015

249099H016

249099H017

249099H019

Parts and Labor

Not applicable

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 on the warranty "Recall Owner Update" function.

PORSCHE CARS NORTH AMERICA, INC.

200 South Virginia Street

P.O. Box 300911

Reno, Nevada 89520-3911

WARRANTY CLAIM

DEALER NUMBER

SUBMISSION DATE

03 / 10 / 87

SERVICE OEi- 'I Ut^ER # 0060 RENO, NEVADA

STAMP OF AUTHORIZED PORSCHE DEALER

14587

SHADED AREAS FOR PCNA USE ONLY

REVIEW CODE FORCE CODE DATE RECEIVED

H

n

H

n

n

n

n

n

n

n

r-

COMMENTS

Iw

pj

Lo

Li

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M

M

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[0 0 6

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. REPAIR DATE

MILEAGE

DELIVERY DATE

87

(6) 1200

LABOR I WTY. PARTS PRICE | OTHER | CLAIM

35.00

6.23

41.23

DAMAGE CODE

LABOR OPERATION

2458190A

PART NUMBER

928 110 359 04

QUANTITY 1

SUBLET LABOR

N 023 5772

SUBLET PARTS

SUBLET TOWING

MISC OTHER

SERVICE AUTHORIZATION «

EXPLANATION

^"SAMPLE CLAIM - RECALL H01 TO BE SENT VIA DCS"

SIGNATURE.

DATE.

WHITE - PCNA. CANARY-DEALER ACCOUNTING, PINK-DEALER VEHICLE HISTORY. GOLDENROD - PCNA PARTS TESTING

Campaign Bulletin

1985/86 928S 1987 928 S4

Subject:

Porsche Classic Models

Porsche Classic Models

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