Porsche training p60 soft roof and body systems

Convertible TopGeneral Information The following development goals were realized in development of the 981 Boxster convertible top: • Roofline with significantly reduced sag points for

AfterSales Training

“Soft” Roof & Body Systems

Sports Cars (9x1)

P60

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Description Section

Boxster (981) Convertible Top 1

911 Carrera (991) Convertible Top 2

Reference 3

Subject Page

Convertible Top 2

Convertible Top Operating Concept 2

Convertible Top Fabric 3

Convertible Top Insulating Materials 3

Convertible Top Roofliner 3

Convertible Top Frame 3

Convertible Top Drive 3

Convertible Top Sensors 4

Convertible Top Locking Mechanism 5

Convertible Top Sealing System 5

Convertible Top Covers 5

Convertible Top Emergency Operation 6

Convertible Top Service Position 8

Wind Deflector 9

Roll-over Protection 9

Convertible Top

General Information

The following development goals were realized in

development of the 981 Boxster convertible top:

• Roofline with significantly reduced sag points for a

high-quality appearance

• Small stowage package above the engine compartment

without convertible top compartment lid

• Opening and closing while driving up to 31 mph (50

km/h)

• Reduction in interior noise from 74 dB to 71 dB at 62

mph (100 km/h)

Due to omission of the convertible top compartment lid

(weight savings of 26.5 lbs/12 kg), it was necessary to

stabilize the convertible top in the stowage position A

passive stowage lock was developed for this purpose in

the 981 Boxster

When in stowed position, the convertible top is pressed

onto the support surfaces of the centering pins with an

increased counter-force of approx 140 N per side by way

of subsequent tensioning of the kinematic system

Operating Concept

"Open convertible top" switch

"Close convertible top" switch

The 981 Boxster convertible top is fully-automatic In otherwords, manual unlocking and locking of the front lockinghook on the window frame when opening and closing theconvertible top is no longer necessary The top isoperated by way of two one-way switches in the area ofthe center console, one each for opening and closing, oroptionally by way of the vehicle key A correspondingdisplay with information text is shown on the multi-functiondisplay on the instrument cluster The entire opening orclosing operation is completed in only approx 9 seconds,which represents an absolute top value

Convertible Top Fabric

In order to enhance driving comfort, the convertible top is

designed using an improved “soundproofing fabric” The

material thickness was increased by 0.5 mm for this

purpose The convertible top fabric features a “lap seam”

that is additionally welded on the rear This guarantees

maximum leak-tightness and robustness

The glass rear window made of heatable single-sheet

safety glass is permanently molded into the convertible

top fabric In contrast to the 987 model, the rear window

is incorporated in the convertible top material without a

visible external frame, thereby further enhancing the

quality appearance of the convertible top Both the height

and width of the rear window were increased in order to

improve visibility

Convertible Top Insulating Materials

An insulating material was incorporated between the

con-vertible top fabric and the roofliner This has an additional

positive influence on the interior acoustics The insulating

material also made it possible to reduce the outline marks

of the convertible top bows, thereby further enhancing the

quality appearance The insulating material and convertible

top fabric are permanently joined to each other and can

only be replaced together

Convertible Top Roofliner

The roofliner of the 981 Boxster convertible top is made

of textile fabric as before When the convertible top is

closed, the roofliner covers the whole visible area of the

convertible top The roofliner is secured at the front at the

roof bow and at the rear at the tensioning bar Attachment

at the sides, which is also responsible for the visual design

of the roofliner, is realized by way of tension bands and

pull cords

Convertible Top Frame

Different lightweight construction materials are also used

in order to reduce the weight of the convertible top frame.The plastics used are glass-fiber-reinforced plastics Thebows are made of aluminum extruded profiles The struc-tural parts of the convertible top frame are made of die-cast magnesium This contributes significantly to weightsaving and stability It was possible to reduce the use ofsteel parts to a minimum In order to realize the requiredsmall stowage dimensions, the side sealing rails to thedoor side windows are now divided into three parts

Convertible Top Drive

The convertible top drive for opening and closing the top

is fully electrical and features two gear motor unitsmonitored by a synchronization control unit Omission ofthe convertible top compartment lid means that no otherdrive units are required

Page 1.4 “Soft” Roof & Body Systems

Switch #2 Closed Closed (Opens at 2/3) Open

Micro Switch in Windshield Frame Closed Closed Open

Reed Switch in Windshield Frame (Proximity Sensor) Open Open Closed

Hook Extended Microswitch in Latch Closed Open at 1/3 Closed

Hook Retracted in Microswitch in Latch Open Open Closes as Latching

Convertible Top Sensors

Convertible Top Locking Mechanism

The convertible top locking mechanism is identical to the

part used in the 991 Carrera Cabriolet model line Driven

by an electric motor, the locking hook travels into the

convertible top lock in the windshield frame during the

closing operation and tensions and locks the convertible

top in position Exact positioning of the front roof frame

with respect to the windshield frame is ensured by two

additional guide pins at the side

Convertible Top Sealing System

The sealing system of the 981 Boxster convertible top

consists of five individual components Due to the newly

designed convertible top frame, three seals (1, 2, 3) are

used in the area of the side windows These seals are

fitted on the side seal retaining strips on the roof frame

The rear seal (4) is inserted in the aluminum profile of the

tensioning bar and is responsible together with the seal

fitted on the body for water management in the

convert-ible top compartment/passenger compartment area The

seal on the tensioning bar also features small water

troughs that guarantee reliable draining of water if the

convertible top is opened when wet, for example

Sealing in the area of the windshield frame (5) is realized

on the body by way of a corresponding sealing profile Theentire sealing concept features a second sealing contour,which provides additional protection against water ingress

In order to minimize noise, all rubber seals are additionallycoated with a special lifetime anti-friction coating

In order to simplify any adjustment work and to make surethat this is performed correctly, the seal retaining rails areprovided with cross-hairs (arrow) in the area of the screwjoints These guarantee fit accuracy and seal tightness ofthe fitted seals

Side Convertible Top Covers

Two flaps (1) are fitted on the left and right in the area ofthe B-pillar to hide the convertible top mechanism fromview when the convertible top is open These flaps arefitted in the area of the roll-over bar mounting They areconnected to the convertible top mechanism by operatingcables and are therefore positively controlled and do notrequire a separate drive When the convertible top isclosed, the flaps are in vertical position next to the roll-over protection

Page 1.6 “Soft” Roof & Body Systems

Convertible Top Emergency Operation

In the event of failure of the convertible top drive system,

the top can also be closed manually The following extract

from the Owner’s Manual explains the procedure

1 Move the driver’s and passenger’s seat forward and fold

the backrests forward

2 Reach with your hand between the carpeting gap

(illus-tration), then carefully pull out the carpet lining from the

bottom along the belt reel trim and fold over

Unlocking the Convertible Top Drive

1 Take the open-ended wrench out of the tool kit

2 Using the open-ended wrench (a/f 13), turn theemergency release screw A approx 3 times by 360° inclockwise direction until the guide pin B is located inposition C

3 Repeat the procedure on the opposite side

Closing the Convertible Top

Get into the vehicle

1 Lift with convertible top on the right or left side with onehand

2 Grasp the convertible top in the middle with the otherhand

3 Pull up the convertible top out of its stowage positionuntil the top is approximately half-closed

4 Using the open-end wrench, carefully lever the plastic

cover of the convertible top latch out of the clip-in

points (illustration) and remove

5 Take key F for convertible top emergency operation out

of the tool box

6 Insert key F into convertible top latch and turn in

clockwise direction until the locking hook is completely

extended (resistance can be clearly felt when turning)

7 Carefully grasp the convertible top by hand at the

convertible top latch motor (illustration) and pull to the

windshield frame If parts of the body are located in the

movement area of the convertible top or in the area of

the convertible top latch during the closing operation,these may become pinched or crushed

Make sure that:

• no persons are in the movement range of the ible top during the closing operation

convert-• hands cannot be pinched or crushed by parts of theconvertible top latch

8 In order to completely close the convertible top, keepturning key F in clockwise direction until the lockinghook completely engages in the locking point and the convertible top is completely closed (resistance can beclearly felt when turning)

9 Drive slowly to a qualified workshop We recommendthat you ask a Porsche partner to perform this workbecause they employ trained workshop personnel andhave access to all the necessary parts and tools

Page 1.8 “Soft” Roof & Body Systems

Convertible Top Service Position

In order to obtain access to the engine compartment for

service work, the rear convertible top tensioning bar must

be moved to the service position

The following work steps must be performed to do

this:

• Remove the wind deflector inserts from the roll-over

bars on the left and right

• Open the convertible top until the dimension A (approx

100 mm) is reached between the windshield frame and

front convertible top bow

• Reach through the opening of the roll-over bar anddetach the tension cords (arrow) from the guides on thetensioning bar (2)

• Open the convertible top until the dimension A (approx

470 mm) is reached between the windshield frame andfront roof frame (1)

• With the rear lid open, grasp the rear tensioning bar (2)from outside and pull up

Caution: Danger of crushing

• Undo the retaining strap (3) from the attachment point

on the rear tensioning bar (2)

• Pull the retaining strap (3) over the convertible topfabric to the left tip of the convertible top

Wind Deflector

The wind deflector on the 981 Boxster is inserted in the

roll-over bar and covered with a net All wind deflector

parts can be easily installed and removed thanks to a

plug-in system The wplug-ind deflector can be stored plug-in a separate

bag in the front luggage compartment

Roll-over Protection

The roll-over protection has been redesigned comparedwith the previous model The new roll-over protectionoffers the same functionality, but is now much morecompact and lighter The roll-over protection system isdesigned in five parts in the 981 Boxster

A Roll-over bar, left and right

B Cross member

C Mountings, left and right

The trim panelling of the roll-over protection consists oftwo parts The rear shell is optionally available in theexterior color

Page 1.10 “Soft” Roof & Body Systems

Notes:

Subject Page

Convertible Top 2

Convertible Top Operating Concept 2

Convertible Top Fabric 3

Convertible Top Insulating Materials 3

Convertible Top Roofliner 3

Convertible Top Frame 4

Convertible Top Storage Package 4

Convertible Top Mechanism 5

Convertible Top Sensors 6

Convertible Top Locking Mechanism 7

Convertible Top Side Covers 7

Convertible Top Emergency Operation 8

Convertible Top Compartment Lid 13

Wind Deflector 14

Occupant Protection 15

Convertible Top

General Information

The 911 Carrera Cabriolet features a unique and

com-pletely redesigned fabric convertible top This new

convertible top is a logical enhancement of the previous

Porsche convertible top systems in terms of both looks

and quality

Although it may look like a conventional fabric convertible

top from the outside, the current Cabriolet actually

fea-tures a “soft top with top bows” This convertible top

design combines the advantages of a fabric convertible

top with respect to opening and storage with the noise

and heat insulation benefits of a hard top

The use of a 0.5 mm thicker acoustic covering with fleece

and insulation material combined with the fixed top bows

on the inside provide coupé-like comfort in the passenger

compartment when the convertible top is closed For this

reason, the hard top that is normally optionally available is

not offered for the Carrera/S Cabriolet

Another important new feature is the convertible topmechanism Both the convertible top and the convertibletop compartment lid are now powered via a centralhydraulic unit

Increased use of magnesium instead of steel has made itpossible to reduce the overall weight by around twopounds despite the enhanced comfort features

The sequence when opening and closing the convertibletop has been changed The convertible top and convert-ible top compartment lid now move consecutively ratherthan simultaneously Despite this, the time it takes tocomplete the entire opening and closing process has beenreduced from 20 seconds (2nd generation 997) to 13seconds As before, the convertible top operates atspeeds of up to approx 30 mph (50 km/h)

Operating Concept

The new Carrera Cabriolet convertible top is fully matic The top is operated by means of two one-wayswitches in the area of the center console, one each foropening and closing, or optionally by way of the vehiclekey A corresponding display with information text isshown on the multi-function display on the instrumentcluster during operation

auto-“Open convertible top” “Close convertible top”

Convertible Top Fabric

The appearance of the new convertible top is significantly

enhanced by the increased material thickness and the

insulating layer attached to the fabric This combination

prevents the convertible top bows from showing When the

convertible top is opened, the convertible top fabric folds

into the familiar “Z-fold”

Another new feature of the convertible top is the glazing

concept for the rear window in the convertible top fabric

This involves the foaming in of the rear window directly

with the fabric using polyurethane foam material

There is only a barely visible plastic edge between the

fabric and the rear window, therefore creating a flush

tran-sition that allows the rear window to blend in seamlessly

with the styling of the outer skin

Convertible Top Insulating Materials

The acoustic properties of the convertible top systemhave been significantly enhanced by the insulating mat,which covers the entire area under the outer material

Convertible Top Roofliner

A Sturdy roofliners

B Roofliner made from fabric

The central sturdy roofliners, which are combined with aconventional roofliner in the side area, create a new, high-quality feeling inside the vehicle that has never beforebeen seen in this form in the fabric convertible topsegment

Convertible Top Frame

To meet the requirements for extremely lightweight

convertible top frame construction, the 991 convertible

top makes greater use of magnesium in addition to

aluminum Both the flat support elements (roof frame, top

bows and rear window frame) and most of the frame rods

are therefore made from this material

Two different production methods are used here The

larger parts are still produced by casting, while the rods

and rear window frame are produced using the semi-solid

metal casting method With this method, more complex

component geometries with greater variations in wall

thickness and significantly more homogeneous structures

can be achieved This allows components to be designed

according to specific requirements and helps to ensure

that weight targets are reached A key innovation is the

bearing concept, whereby the bolts are molded directly

onto the rods Given the fact that demoulding bevels are

not always required with the selected production method

(special magnesium injection molding process), no further

Conven-on each side

Storage Package

With the Z-fold of the convertible top already being used

by Porsche, the upper side of the front roof frame is at thetop even when the convertible top is open The convertibletop compartment lid covers only the rear part of the openconvertible top The front part remains visible This designallows very low pack dimensions when the convertible top

is open, thus contributing to a flat and harmonious look forthe rear section of the vehicle

The rear engine design of the Carrera model line means

that there is very limited storage space available for the

convertible top above the engine in the cabriolet version

For this reason, the flat center roof elements, including the

rear window, are nested in four levels aligned one above

the other Extremely compact storage is thus achieved in

combination with the package-optimized material folding

Convertible top closed

Convertible top 25% open

Convertible top 50% open

Convertible top 75% open

Convertible top open

Convertible Top Mechanism

The convertible top system is powered by a centralhydraulic unit behind the rear seat system This unit hasthe two drive cylinders of the convertible top as well

as another two smaller cylinders, which are used to powerthe convertible top compartment lid

A Hydraulic unit

B Convertible top drive cylinder

C Convertible top compartment lid drive cylinder

Installed Position of Convertible Top Mechanism