High Performance Audio System Installation (GROUP 9, NO. 9/99)

Publication date: 2000-12-25
Reference number: GROUP 9, NO. 9/99

HIGH PERFORMANCE AUDIO SYSTEM INSTALLATION

TECHNICAL SERVICE BULLETIN

Reference Number(s): GROUP 9, NO. 9/99, Date of Issue: February 25, 2000

HIGH PERFORMANCE AUDIO SYSTEM

Model(s): 1997-on Porsche Boxster, Boxster S

Group: 9 - A/C & Electrics

Bulletin No.: 9/99

Part Identifier: 9144

Date: February 25, 2000

CONCERNS

Installation instructions

EQUIPMENT

Approved only for vehicles with option:

M490 - Sound package

The system can also be installed on vehicles with M680 - Digital Sound Processing (DSP). However, the extended sound adjustments with DSP can no longer be made (The high performance amplifier does not have DSP inputs).

INFORMATION

The High Performance Audio System is an exclusive, high-quality system calibrated to the vehicle, and offers increased performance (2 x 200 Watt at 2 ohm), as compared to standard systems. The additional tuning allows for a rich and powerful bass in the lower ranges.

The HPAS is a 2-channel system with two mid-range loudspeakers in the dash and double bass loudspeakers in each door.

It is recommended to use at least an 80 Ah battery with the High Performance Audio System.

NOTE: In order to ensure optimum sound, all radio settings (bass, pitch, loudness, etc.) should be set to zero, or neutral.

DIAGNOSIS

Four light-emitting diodes are located on the amplifier which can be used for diagnosis. The following table specifies the position of the diodes from top to bottom, colors, designations, functions and possible fault sources.

LED DIAGNOSTIC INFORMATION

Item	Color	Designation	Status; Note
1	Green	Remote on	on = O.K.; switch on, power from radio is on. off = fault; switch on, power from radio is not on.
2	Green	Power on	on = O.K.; permanent positive is on. off = fault; permanent positive is not on or other faults are present.
3	Yellow	Speaker Protect.	on = fault; fault in loudspeakers. off = O.K.
4	Red	Temp. Protect.	on = fault; amplifier overheated (after cooling, the amplifier should automatically switch on, and the light-emitting diode will go off). off = O.K.

PARTS INFORMATION

Part Number	Qty.	Description
000 044 900 42	1	High Performance Audio System, complete

KIT CONTENTS

Part Number	Qty.	Description
000 044 900 45	1	left front midrange loudspeaker with crossover network
000 044 900 46	1	right front midrange loudspeaker with crossover network
000 044 900 49	1	left door bass speaker housing
000 044 900 48	1	right door bass speaker housing
000 044 900 51	4	bass loudspeaker; 160 mm (fitted)
000 044 900 58	1	right crossover network and wiring harness (fitted)
000 044 900 61	1	left crossover network and wiring harness (fitted)
000 044 900 53	1	left loudspeaker grille (fitted)
000 044 900 52	1	right loudspeaker grille (fitted)
000 044 900 50	1	amplifier
000 044 900 59	1	fuse holder including fuse
000 044 900 60	2	insulating material for back of door trim panels, including 2 x templates (left/right)
000 044 900 57	1	parts kit, including PORSCHE logo (2 x)

All separate parts listed above can also be ordered through normal parts ordering channels.

MATERIAL INFORMATION

Part Number	Qty.	Description
999 915 400 40	1	adhesive compound
--------------	1	adhesive tape
--------------	5	commercially available tie-wrap
--------------	0.5l	acetone

REQUIRED TOOLS

Clips (radio disassembly tool)
Torx socket wrench T27
10 mm open end wrench
Allen key, 3/5 mm
Slotted and Phillips screwdrivers
Sharp knife
Side cutters
Steel drill bit 4.5/4.0 mm
Socket wrench 10 mm
Electric drill
Jig saw with saw blade for plastics
Porsche System Tester 2 (PST 2)
File
Shop light

WORK PROCEDURE

Preparation
1. 1.1)
  Remove spare tire.
2. 1.2)
  Remove battery cover. Disconnect and cover the battery.
3. 1.3)
  Remove standard amplifier and disconnect both plug connections. Fit the new amplifier onto the holding bracket of the original amplifier.
4. 1.4)
  Remove CD changer (if so equipped).
5. 1.5)
  Remove both door panels and loudspeakers (Fig. Fig 1 ) (Technical Manual, Group 5, Repair Group 5751).
6. 1.6)
  Remove original bass loudspeakers from both door trim panels.
7. 1.7)
  Unclip loudspeaker covers from both door trim panels (Technical Manual, Group 7, Repair Group 7059).
8. 1.8)
  Replace the clips (color: white) in both door panels (9 ea. per door) with the new clips.
9. 1.9)
  Remove both loudspeakers from the dash panel (Fig. Fig 2 ) and disconnect plug connection (Technical Manual, Group 7, Repair Group 7018).
Install amplifier and connect power supply. Install amplifier back into its original position in the luggage compartment.
1. 2.1)
  Connect both plug connections to the new amplifier.
  NOTE: The large 20-pin plug may have to be inserted at a l80° angle in certain circumstances.
  
  NOTE: Ensure adequate cooling by allowing at least 5 mm distance between the amplifier and the carpet lining.
2. 2.2)
  Wrap adhesive tape around the power supply wires, RE; 6.0² and BK; 6.0² up as far as the grommet (Fig. Fig 3 , Item B) on the firewall plus 5 cm beyond it.
3. 2.3)
  Connect power supply.
  1. 2.3.1)
    Make a hole in the carpet lining next to the amplifier just large enough to accommodate the wires (Fig. Fig 3 , Item A).
  2. 2.3.2)
    Remove grommet from the firewall, (Fig. Fig 3 , Item B) and cut on the lower side.
  3. 2.3.3)
    Route the wire through the hole in the carpet and the grommet in the firewall. Install the grommet with the wires into the firewall. Fix wires to the firewall using a tie-wrap or adhesive tape. Seal the wire passage (Fig. Fig 3 , Item B) with adhesive sealer, part number, 999 915 400 40 on the battery side.
  4. 2.3.4)
    Wrap support bar with 50 mm of adhesive tape as shown (Fig. Fig 4 ).
  5. 2.3.5)
    Partially assemble fuse holder and connect the side with the red positive lead 6.0² , to the positive terminal of the battery.
  6. 2.3.6)
    Trim the positive lead 6.0² ; color: red, of the wiring harness to the fuse holder and secure in the gold-plated bushing (second half of the fuse holder) with the hexagon socket head bolt.
  7. 2.3.7)
    Screw the fuse holder together and use a tie-wrap to fit it onto the support bar that was wrapped with adhesive tape in step 2.3.4 (Fig. Fig 4 ).
  8. 2.3.8)
    Crimp the cable lug A6 to the ground lead 6.0² , color: black, and secure the ground lead to the firewall at the ground point beside the battery.
Rework the door panels and prepare for installation.
1. 3.1)
  Align and attach the supplied templates on the inner side of the door panels (Fig. Fig 5 ).
  NOTE: Observe the inscriptions on the templates.
2. 3.2)
  Transfer the templates cut lines onto the door panels.
3. 3.3)
  Trim the door panel along the mark with jig saw. Then deburr the cut edge with a file.
4. 3.4)
  Put door trim panel (without loudspeaker) onto the inside of the door and check trim. There must be sufficient space for both bass loudspeakers, 160 mm.
5. 3.5)
  Make a hole for the fastening clip in the small insulating mat, as shown in Fig. Fig 6 , Item A.
  WARNING: Danger (death/serious injury to driver or passenger) in the case of incorrect deployment of the side airbag.
  
  For vehicles with side airbags, the cut-out for the side airbag (Fig. Fig 6 , Item B) must be removed before sticking on the large insulation mat.
6. 3.6)
  Only vehicles with side airbag: Stick supplied insulation mats onto the inner side of each door panel (Fig. Fig 6 ). They are marked left and right.
7. 3.7)
  Check correct seating of both sheetmetal nuts on door (Fig. Fig 7 , Item A) for fastening of the door trim panel. Clip a sheetmetal nut into the slot available in the door (Item B).
Install door panels.
1. 4.1)
  Position the door trim panel on the door, aligning the lower edges.
2. 4.2)
  Bolt the front of the door trim panels (Fig. Fig 8 , Item A) using 2 sheetmetal screws 4.2 x 60.
3. 4.3)
  Insert the sheetmetal screw 4.2 x 70 on the bottom of the rear loudspeaker cut-out (Fig. Fig 8 , Item B) and tighten hand tight only.
  WARNING: Potential for damage to components in the door and the door trim panel from the drill chuck or drill bit while drilling.
  
  Mask drilling area and use a power drill with bit stop.
  
  Carefully carry out drilling and avoid too much pressure.
4. 4.4)
  Carefully drill a 4.5 mm hole above the rear loudspeaker (Item C); using the door trim panel bore as a guide.
5. 4.5)
  Fasten speaker housing to door trim panel at Item C with an M4 x 40 screw and sheetmetal nut. Tighten the screw beneath the loudspeaker cut-out (Item B).
  NOTE: If the cut-out in the inside of the door and the positions of the fastening points in the door trim panel overlap in an unfavorable manner, the door trim panel can alternatively be fastened at Fig. Fig 8 , Item D with screws and nuts.
6. 4.6)
  Check the gap dimensions of the door trim panels against the inside of the doors and retighten all screws.
Complete door trim panels.
1. 5.1)
  Affix electric wires to the bass loudspeakers with adhesive tape or tie wraps.
2. 5.2)
  Connect wires to the bass loudspeakers and fit into the door trim panel (Fig. Fig 9 ), with the connections towards the front (in the direction of travel).
3. 5.3)
  Gently bend the lower tabs (Fig. Fig 10 , Items A and B) on the loudspeaker grille outwards. Gently bend the side tabs (Items C and D) inwards. The grille should gently bulge outwards overall in order to increase the contact pressure when screwing it on.
4. 5.4)
  Affix plastic spacer (Item E) on the back of the loudspeaker grille or on the door trim panel using adhesive.
5. 5.5)
  First clip the loudspeaker grille into the door trim panels with the lower tabs. Center loudspeaker grille and tilt towards door trim panel. While tilting, insert the side tabs into the door trim panel.
6. 5.6)
  Bolt the loudspeaker grille on the top side with the door trim panel (Fig. Fig 11 ).
  NOTE: The entire surface of the loudspeaker grille should not rock when fitted.
7. 5.7)
  Clean bonding surface (Fig. Fig 11 , inset). Let dry, then stick on the PORSCHE logo (Do this at room temperature).
Install midrange loudspeakers into the dash panel.
1. 6.1)
  Connect wires to the new midrange loudspeakers.
2. 6.2)
  Insert midrange loudrange speakers into the dash panel, tilting back as they are inserted.
3. 6.3)
  Secure the midrange loudspeakers with screws, observing gap D dimensions.
Complete vehicle and carry out function test.
1. 7.1)
  Install CD changer (if so equipped).
2. 7.2)
  Connect battery and set clock.
3. 7.3)
  Input radio or PCM code, if necessary.
4. 7.4)
  Check the function of all the individual loudspeakers, using the balance (left/right) and fader (front/rear) controls on the radio.
5. 7.5)
  Ensure the LED on the amplifier is lit during the function test (see DIAGNOSIS ).
6. 7.6)
  Reinstall trim panels in the luggage compartment.

WORKING TIME

LABOR OPERATION: 91 44 31 00

TIME UNITS: 350

DESCRIPTION: High Performance Audio System (1 ea.) installed

Includes: Converting loudspeaker amplifier, routing and connecting electrical wiring harness. Reworking door panels, door trim panels incl. fitting low-pitch system and installing front middle/high-pitch system.