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Telephone Module (Option P666) (GROUP 9, NO. 1/05)

WARNING: This page is about the Boxster Base, Automatic, which is a different variant/trim than selected.
Publication date: 2005-02-21
Reference number: GROUP 9, NO. 1/05

TELEPHONE MODULE (OPTION P666)

TELEPHONE MODULE (OPTION P666)

TECHNICAL SERVICE BULLETIN

Reference Number(s): GROUP 9, NO. 1/05, Date of Issue:  February 21, 2005
PORSCHE: Boxster (987)/Boxster S (987) As of 2005 (5)
GROUP: 9 - Electrical System
PART IDENTIFIER: 9155

CONCERN

Installation of telephone module (Option P666). Only for vehicles with PCM (Option P16) 

INFORMATION

The sound quality of the hands-free equipment has been improved on the new tri-band telephone module (900, 1,800, and 1,900 Mhz). The position of the hands-free microphone has been moved from the instrument cluster to the steering column, which orients the microphone's directional characteristics more toward the driver. If the telephone module is retrofitted, it can only be used with the ignition switched on.

Before ordering parts (telephone module and OpticalWave Guide - LWL), the existing vehicle equipment must be positively identified and taken into consideration to avoid compatibility issues! 

PARTS INFORMATION

PARTS INFORMATION

Part Number Description
997.044.900.71 Set, telephone module
997.622.702.00 Optical waveguide, only for vehicles with CD changer preparation
997.622.703.00 Optical waveguide, for vehicles with audio/navigation components
Fig 1: Telephone Module Components
G04581961
PARTS LIST

Part Number Qty. Description
997.642.216.00 1 x Holder for telephone module (Item A)
997.646.208.04 1 x Telephone module (Item B)
997.646.307.01 1 x Microphone (Item C)
900.378.035.09 4 x Hexagon-head bolt, M6 x 16 (Item D)
997.612.319.01 1 x Wire harness (Item E) consists of: antenna lead and microphone lead
999.073.236.0A 4 x M6 x 10 round head screw (Item G)
999.507.550.0A 4 x M6 speed nut (Item H)
999.073.210.00 2 x 4.8 x 13 tapping screw (Item K)
999.507.441.02 2 x Sheetmetal nut 4.8 (Item M)
999.650.356.12 1 x Socket contact (Item P)
999.650.529.00 1 x Cable ring eyelet (Item R)
997.647.127.00 1 x Holder for antenna, (Item S)
997.647.125.01 1 x Antenna (Item T)
N 103.358.01 1 x Socket contact (not shown)
999.650.535.00 1 x Cable ring eyelet (not shown)
999.650.512.40 1 x Plug socket (not shown)
997.610.122.00 1 x Connection point holder (not shown)
999.500.078.00 2 x M6 sheetmetal press nut (not shown)
999.507.697.40 1 x Adhesive clip (not shown)
WARNING: Risk of short circuit and fire - due to work on vehicle electrical system.
  • > When working on the electrical system, the battery must always be disconnected and covered.
  • > Always route the electric wires without tension and so that no chafing occurs and secure to existing harnesses/components with tie-wraps/insulating tape.
CAUTION: Damage to optical waveguide - due to incorrect installation or disregarding the requirements for handling the optical waveguide.
  • > Do not use tools to connect or disconnect plug connections!
  • > Maximum permissible tension load: do not exceed 60 N (44 ft-lb.)!
  • > Do not go below minimum bending radius of 25 mm after and during installation in the vehicle!
  • > Do not exceed maximum number of 10 twists per meter!
  • > Observe all requirements concerning working with an optical waveguide in accordance with POSES, 911 Carrera (996) Workshop Manual, Group 9: 9768 - Optical waveguide - MOST bus!

MATERIALS

MATERIALS

Part Number Qty. Description
000.043.204.82 1 x Adhesive compound
n/a   Electrical tape

TOOLS

TOOLS

Combination wrench, a/f 7/10 mm Plastic wedge
Ratchet 1/4", 3/8" with extension Shop light
Phillips screwdriver (medium) Crimping tool, stripping pliers
Flat screwdriver (medium) Torque wrench 25-130 Nm (19-96 ft-lb.)
Torx wrench T10/T20/T25/T27/E12 Torque wrench 2-10 Nm (1.5-7.5 ft-lb.)
Hexagon socket a/f 4/5 mm PIWIS Tester
Heat gun Battery charger
Needle nose pliers Press-out tools 90207, 90006, 93005 (Porsche set No. 155)

WORK PROCEDURE

  1. Preparatory work. 
    1. 1.1)  Remove battery (POSES, Workshop Manual, Group 2: 27 06 19).
    2. 1.2)  Remove right front seat (POSES, Workshop Manual, Group 7: 72 01 19).
    3. 1.3)  Remove right inner door sill trim (POSES, Workshop Manual, Group 6: 68 05 19).
    4. 1.4)  Remove right rear side trim panel (POSES, Workshop Manual, Group 7: 70 75 19).
    5. 1.5)  Carefully loosen carpeted floor (A) in the area of the A-pillar on the lower right.
    6. 1.6)  Unscrew fastening screws (C) and swivel floor support (B) to the side.
      Fig 2: Carpeted Floor And Floor Support
      G04581962
    7. 1.7)  Remove right wiring duct.
    8. 1.8)  Remove glove compartment (POSES, Workshop Manual, Group 6: 68 15 19).
    9. 1.9)  Remove air duct for right footwell.
    10. 1.10)  Remove display and PCM operator control unit (POSES, Workshop Manual, Group 9: 91 10 19).
    11. 1.11)  Remove center air nozzle (POSES, Workshop Manual, Group 8: 85 53 19).
    12. 1.12)  Unclip center air duct from the dashboard.
    13. 1.13)  Unclip cover for fuse carrier, unscrew fastening screws (A) and take off lower left A-pillar trim panel.
      Fig 3: Fuse Carrier And Fastening Screws
      G04581963
    14. 1.14)  Remove trim panel under dashboard (POSES, Workshop Manual, Group 7: 70 19 19).
    15. 1.15)  Remove luggage compartment cover (POSES, Workshop Manual, Group 7: 70 30 19).
    16. 1.16)  Remove covers on the right and left in the area of the cowl panel (POSES, Workshop Manual, Group 8: 85 22 19).
    17. 1.17)  Remove cover for cowl panel (POSES, Workshop Manual, Group 5: 50 87 19).
    18. 1.18)  Punch service grommet in the bulkhead.
  2. Install antenna, also see POSES, Workshop Manual, Group 9: 91 47 19. 
    1. 2.1)  Insert speed nuts (parts list, Item M) in cowl panel cover.
    2. 2.2)  Clip the antenna in cowl panel cover (arrows) and fasten with screws (parts list, Item K).
      3. Fig 4: Antenna Installation
      G04581964
    3. 2.3)  Install cover for cowl panel (POSES, Workshop Manual, Group 5: 50 87 19).
    4. 2.4)  Attach speed nut (parts list, Item H) for antenna holder on the bulkhead.
    5. 2.5)  Insert holder for antenna (parts list, Item S) and fasten with screws (parts list, Item G).
      Fig 5: Holder For Antenna Installation
      G04581965
    6. 2.6)  Route antenna lead as follows:

      Right seat base frame -> right wiring duct -> right A-pillar -> dashboard bracket (along original wire harness) -> through service grommet into the bulkhead -> antenna

    7. 2.7)  Connect antenna lead to antenna.
      Fig 6: Antenna Lead Routing
      G04581966
  3. Install optical waveguide. 
    1. 3.1)  Route optical waveguide:

      Right seat base frame -> right wiring duct -> right A-pillar -> dashboard bracket (along original wire harness) -> PCM installation slot -> through service grommet into the bulkhead -> plenum panel

      Fig 7: Optical Waveguide Routing
      G04581967
    2. 3.2)  Vehicles with optical waveguide components (navigation/audio) in luggage compartment only:

      Disconnect the optical waveguide connection point in the front luggage compartment.

    3. 3.3)  Remove connection point holder (A) from plenum panel using needle nose pliers and open clamp
      Fig 8: Optical Waveguide Connection Point In Front Luggage Compartment
      G04581968
    4. 3.4)  Cut open approximately 5 cm of the harness loom for the optical waveguide set in the plenum panel, in area (X).
    5. 3.5)  Cut through the original optical waveguide and pull forward out of the harness loom with plug socket and connection point holder (Fig 10, Item A).
      Fig 9: Cut In Harness Loom Of Optical Waveguide
      G04581969
    6. 3.6)  Route optical waveguide in the plenum panel.
    7. 3.7)  Guide optical waveguide (A) through harness loom.
      Fig 10: Optical Waveguide In Harness Loom
      G04581970
    8. 3.8)  Install optical contacts.
      1. 3.8.1)  Pull off protective caps (A).
      2. 3.8.2)  Insert optical contact input (B) and optical output (C) into the plug socket (D) until they are felt to engage.
        Fig 11: Inserting Optical Contacts Into Plug Socket
        G04581971
        NOTE: Arrows on plug socket and optical waveguide mark the optical input/output.
      3. 3.8.3)  Lock the secondary locking (E).
      4. 3.8.4)  Remove protective plastic cap (F).
      5. 3.8.5)  Clip plug socket into new connection point holder (997.610.122.00) if necessary. Fasten connection point holder on plenum panel and connect plug connection for optical waveguide connection point.
      6. 3.8.6)  Wrap harness loom in area X (Fig 9) with electrical tape.
  4. Route electric wire harness: 

    Right seat base frame -> wiring duct -> right A-pillar -> dashboard bracket (along original wire harness) -> PCM installation slot

    ELECTRIC WIRE HARNESS COMPONENTS

    Item Component
    A OG line
    B WH/RD wire, RD/GN wires
    C Telephone module connector
    D 3x BN wire
    Fig 12: Electric Wire Harness Routing
    G04581972
    NOTE: Secure wires, antenna lead, and optical waveguide with tie-wrap.
  5. Connect ground connection. 
    1. 5.1)  Crimp together three BN 2 x 0.752 /1 x 0.52 wires (terminal 31) of the wire harness for telephone module with cable ring eyelet (999.650.535.00).
    2. 5.2)  Fasten cable ring eyelet to "6" ground point (seat base frame).
  6. Install telephone module, to do this, also see POSES, Workshop Manual, Group 9: 91 90 19. 
    1. 6.1)  Slide in telephone module (parts list, Item B) in holder (parts list, Item A) and fasten with screws (parts list, Item D).
      Fig 13: Assembling Telephone Module And Holder
      G04581973
    2. 6.2)  Insert electric connector (A), antenna connector (B) and optical waveguide plug (C) into the telephone module.
      Fig 14: Connecting Telephone Module
      G04581974
    3. 6.3)  Press sheetmetal press nuts (999.500.078.00, Item E) into the holes of the floorpan assembly.
    4. 6.4)  Align holder with telephone module to the floorpan assembly, and tighten with screws (parts list, Item D).
      NOTE: Pay attention to wire routing.
  7. Mount adhesive clip (999.507.697.40, Item A) on bulkhead and clip in antenna lead. 
    Fig 15: Antenna Lead Clipped To Bulkhead
    G04581975
    1. 7.1)  Secure wire harness, antenna lead, and optical waveguide with tie-wrap.
  8. Connect the electrical wires. 
    1. 8.1)  Connect two RD/GN 0.752 wires (supply +) with RD/GN 2.52 wire (term. 30) from 8-pin connector A chamber 4 (PCM).
      1. 8.1.1)  Open secondary locking from 8-pin connector A (PCM).
      2. 8.1.2)  Press out socket contact of RD/GN 2.52 wire (term. 30) with press-out tool 90006 from 8-pin connector A chamber 4 (PCM).
      3. 8.1.3)  Crimp together RD/GN 2.52 wire (term. 30) and RD/GN 0.752 wires (supply +) as splice (A).
      4. 8.1.4)  Slide on heat-shrinking tube and shrink with a heat gun so that wires are watertight.
      5. 8.1.5)  Insert socket contact in the 8-pin connector A (PCM) chamber 4.
        Fig 16: Wire Splice
        G04581976
        NOTE: Ensure socket contact is seated securely.
      6. 8.1.6)  Lock secondary locking.
    2. 8.2)  Connect WH/RD 0.352 wire (Wake Up) to 20-pin connector C (PCM).
      1. 8.2.1)  Open secondary locking from 20-pin connector C (PCM).
      2. 8.2.2)  Press out socket contact of WH/RD 0.352 wire (Wake Up) with press-out tool 93005 from 20-pin connector C chamber 4 (PCM) and separate.
      3. 8.2.3)  Crimp together WH/RD 0.352 wires (Wake Up) with new socket contact (N 103.358.01).
      4. 8.2.4)  Insert socket contact into chamber 4 of 20-pin connector C (PCM).
        Fig 17: 20-Pin Connector C (PCM) Terminals
        G04581977
    3. 8.3)  Connect OR 0.52 wire (term. 86s) with BK/OR 0.352 wire (term. 15) from 10-pin connector X (air-conditioning control).
      1. 8.3.1)  Disconnect plug connection and expose wires.
      2. 8.3.2)  Open secondary locking from 10-pin connector X (air-conditioning control).
      3. 8.3.3)  Press out socket contact of BK/OR 0.352 wire (term. 15) with press-out tool 90006 from 10-pin connector X chamber 5 (air-conditioning control) and separate.
        Fig 18: 10-Pin Connector X (Air-Conditioning Control)
        G04581978
      4. 8.3.4)  Crimp together OR 0.52 wire (term. 86s) and BK/OR 0.352 wire (term. 15) with socket contact (999.650.356.12).
      5. 8.3.5)  Insert socket contact into chamber 5 of 10-pin connector X (air-conditioning control).
        NOTE: Ensure socket contact is seated securely.
      6. 8.3.6)  Lock secondary locking from 10-pin connector X (air-conditioning control).
      7. 8.3.7)  Wrap insulating tape around the wires and connect plug connection (see Fig 18).
  9. Install microphone, also see POSES, Workshop Manual, Group 9: 91 57 19. 
    1. 9.1)  Vehicles with BOSE Surround sound system (I No. 680) or Sound package plus (I No. 490) only: Replace the installed microphone with the microphone from the retrofit kit.
    2. 9.2)  Unscrew fastening screws for steering column trim panel and take off upper part of steering column trim panel.
    3. 9.3)  Insert microphone into the upper part of the steering column trim panel and fasten microphone and connector.
    4. 9.4)  Route the microphone wire harness:

      Steering column -> wiring duct -> PCM installation slot

      Fig 19: Microphone Wire Harness Routing
      G04581979
    5. 9.5)  Insert socket contacts of BU 0.352 wire and YE 0.352 wire from microphone wire harness (retrofit kit) into 20-pin connector C (PCM) (see Fig 17).
      20-PIN CONNECTOR C (PCM) TERMINALS

      Slot Color Diameter Designation
      C8 YE 0.352 Tel-
      CC9 BU 0.35 2 Tel +
      NOTE: Ensure socket contacts are seated securely.
    6. 9.6)  Lock secondary locking from 20-pin connector C (PCM).
    7. 9.7)  Insert socket contacts of BU 0.352 wires and YE 0.352 from microphone wire harness (retrofit kit) into plug socket (999.650.512.40).
      PLUG SOCKET (999.650.512.40) TERMINALS

      Slot Color Diameter Designation
      A1 BU 0.352 Tel +
      A2 YE 0.352 Tel -
      NOTE: Ensure socket contacts are seated securely.
    8. 9.8)  Crimp the cable ring eyelet (999.650.529.00) on the BN 0.52 shielding lead of the microphone wire harness.
    9. 9.9)  Attach cable ring eyelet to "5" ground point (A) of dashboard bracket.
      Fig 20: Fitting Cable Ring Eyelet To Ground Point
      G04581980
    10. 9.10)  Vehicles with BOSE Surround sound system (I No. 680) only.
      1. 9.10.1)  Press socket contacts of RD 0.352 and BN/RD 0.352 wires with press-out tool 90207 out of plug socket of microphone wire harness on vehicle side.
      2. 9.10.2)  Push in socket contacts of RD 0.352 and BN 0.352 wires into plug socket of microphone wire harness (retrofit kit) (see following table).
        MICROPHONE WIRE HARNESS TERMINALS

        Slot Color Diameter Designation
        A3 RD 0.352 VCN +
        A4 BN/RD 0.352 VCN -
        NOTE: Ensure correct seating of the socket contacts.
  10. Complete the vehicle. 
    1. 10.1)  Install the A-pillar trim panel on lower left, as well as the fuse carrier cover.
    2. 10.2)  Install trim panel under dashboard (POSES, Workshop Manual, Group 7: 70 19 19).
    3. 10.3)  Install air duct for right footwell, center air duct in dashboard and center air nozzles (POSES, Workshop Manual, Group 8: 85 53 19).
    4. 10.4)  Install display and PCM operator control unit (POSES, Workshop Manual, Group 9: 91 10 19)
    5. 10.5)  Fasten floor support and carpeted floor of A-pillar on lower right.
    6. 10.6)  Install glove compartment (POSES, Workshop Manual, Group 6: 68 15 19).
    7. 10.7)  Install right wiring duct.
    8. 10.8)  Install right inner door entry trim (POSES, Workshop Manual, Group 6: 68 05 19).
    9. 10.9)  Install right rear side trim panel (POSES, Workshop Manual, Group 7: 70 75 19).
    10. 10.10)  Install right front seat (POSES, Workshop Manual, Group 7: 72 02 19).

      Tightening torque: 50 Nm (37 ft-lb.)

    11. 10.11)  Seal the hole on the service grommet with adhesive compound.
    12. 10.12)  Install battery (POSES, Workshop Manual, Group 2: 27 06 19).
    13. 10.13)  Connect battery charger.
    14. 10.14)  Install cover on the right and left in the area of the cowl panel (POSES, Workshop Manual, Group 8: 85 22 19).
    15. 10.15)  Install luggage compartment cover (POSES, Workshop Manual, Group 7: 70 30 19).
  11. Code telephone module using PIWIS Tester. 
    1. 11.1)  Connect PIWIS Tester and switch on ignition.
    2. 11.2)  Select vehicle and control unit (CU) "Instrument cluster" and code.
    3. 11.3)  Select "Gateway" CU and code.
    4. 11.4)  Select "PCM2.1 MMI" CU and code.
    5. 11.5)  Select "Telephone" CU and code.
    6. 11.6)  Read out PCM2.1 fault memory and erase.
    7. 11.7)  After programming is complete, read out the fault memory of all systems, correct any existing faults, and erase the fault memory.
      NOTE: For further information and instructions on carrying out the individual menu items - see Workshop Manual.
  12. Carry out a function test. 
  13. Disconnect battery charger and close lid. 

WORKING TIMES

WORKING TIMES

Labor Operation Description Time Units
91 55 23 00 Telephone module installed
Includes: Installing antenna, microphone, telephone module, and corresponding wires, coding control units, reading out fault memory, and erasing if necessary. Performing a function test.		 460 TU

REFERENCES

POSES, Boxster (987), Groups 2/5/6/7/8/9

POSES, 911 Carrera (996), Group 9

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