®

Technical Information
911 (996)
3/00 6315
Binder - Group 6 - Body
6
Installing Cup Aerokit This bulletin replaces bulletin ,
Group 6, #8/98, dated 11-6-98.

Vehicle Type: 911 Carrera Coupe (996)

Model Year: As of '99 (X)

Concern: Installation of the front spoiler, rear spoiler and side member panels (“Cup Aerokit”).

Information: The Cup Aerokit for the 911 Carrera (996) Coupe consists of a front spoiler with exchangeable spoiler
lip, two side member panels and a rear lid with spoiler. These components, when installed, reduce lift on
the front and rear axles, especially at higher speeds.

The front spoiler and rear lid/spoiler, must always be installed together; it is not permissible to install
one of these parts individually! Always set the adjustable spoiler to its lowest position (top side of
spoiler and side parts must be level and flush). Any other position of the adjustable spoiler will change
the driving characteristics of the vehicle, and are NOT approved for use on public roads!

New micro-encapsulated screws (see parts list) must be used if it should become necessary to remove
the spoiler. In exceptional cases, it is possible to clean the threads of the old screws and coat them with
Loctite Red (Type 262) screw locking agent.

The Cup Aerokit is also available on new 911 Carrera (996) Coupes with Exclusive option “XAA”.

On vehicles with Tiptronic transmission, the front spoiler must be trimmed before painting (below the
licence plate; refer to Step 1.2 on Page 5).

The rocker switch in the driver's footwell, which is used for manual control of the standard rear spoiler
(refer to the Owner’s Manual), will not function after the Aerokit is installed. However, the warning light of
the standard rear spoiler will still light up after the ignition is switched on. This warning light will go out
after the vehicle moves off.

All local laws and ordinances must be observed!

©2000 Porsche Cars North America, Inc. Date: 7-21-00

Service Page 1 of 9
 ®

6 911 (996)
6315 3/00
Technical Information

WARNING
There is a risk of damage to the spoiler or vehicle under certain driving conditions. Therefore, special
care must be used when:
> Driving on inclined surfaces. Due to the overhang of the Aerokit front spoiler, the bottom of the
spoiler can scrape the ground when the vehicle is driven in parking garages with very steep ramps.
Avoid steep access and exit ramps whenever possible. Adapt driving style to these conditions.
> Cleaning the vehicle in automatic car washes. Under certain conditions, accessories such as
spoilers might not be adequately recognized by car wash sensors, possibly resulting in damage. If
in doubt, consult the car wash operator before proceeding. Hand washing is always the preferred
method of washing.
> Pushing the vehicle by the spoiler.
> Opening the rear lid. Rapid opening of the rear lid can cause damage to the spoiler or the rear
wiper. Check and optimize the gap dimensions of the rear lid, and always open rear lid carefully.

Please advise your customer of these safeguards accordingly.

Parts Information: Part Number Description

000 044 801 02 Cup Aerokit, complete (see parts list)
000 044 000 37 Adhesive set BETALINK K2" incl. BETAPRIME" and BETACLEAN
996 559 237 00 70C* Carrera logo, color: Rally Black

* The logo must be ordered separately if this part is requested by the customer, as the bonding ability
of the adhesive cannot be ensured.

Parts List: Front Spoiler

Part Number Qty. Description
996 505 980 00 G2X 1 Front spoiler, primed finish
996 505 986 00 1 Spoiler lip
999 507 427 40 11 Expanding rivet; 16.0 mm, 8 mm long for spoiler lip
999 073 060 02 13 Sheetmetal screw, St 4.8 x 13
964 505 103 00 G2X 1 Cap for towing lug
999 651 225 40 1 Securing cord; 9 x 220
999 507 040 40 2 Expanding rivet; St 4.2 for licence plate holder
999 507 072 02 2 Sheetmetal nut; St 4.8
999 591 699 02 2 Sheetmetal nut; St 4.8
944 503 255 00 2 Spacer; 6.1 x 8.1 x 2.7
n/a 2 Retaining bracket

Rear Lid and Spoiler

Part Number Qty. Description
996 512 901 00 1 Rear lid with spoiler, not primed; material: fiberglass
996 512 988 00 1 Spoiler (Gurney flap), color: black
996 512 985 00 1 Strut, material: aluminium
n/a 1 Hexagon nut M4, self-locking
n/a 1 Washer, outer 16 mm, inner 4.1 mm, height 0.8 mm

Date: 7-21-00 ©2000 Porsche Cars North America, Inc.

Page 2 of 9 Service
 ®

Technical Information
911 (996)
3/00 6315 6
Parts List: (cont’d) Rear Lid and Spoiler
Part Number Qty. Description
996 512 997 00 1 Left-hand adjustment fitting
996 512 998 00 1 Right-hand adjustment fitting
999 704 185 40 6 Plastic washer
996 512 971 90 1 Left-hand guide fitting
996 512 972 90 1 Right-hand guide fitting
996 512 993 00 1 Left-hand support bracket
996 512 994 00 1 Right-hand support bracket
n/a 4 Hexagon-head bolt M6 x 20
900 249 064 07 4 Countersunk screw, M6 x 16; micro-encapsulated (MC)
900 249 066 07 12 Countersunk screw, M5 x 12; mc
996 512 973 90 2 Threaded plug with hexagon socket
900 249 066 07 2 Oval-head screw, M5 x 12; mc
n/a 2 Plug; hole 28.0 mm
996 512 987 00 2 Rubber pad with screw
996 612 070 51 1 Electrical wiring harness
n/a 2 Fastening clip for electrical wiring harness

Side Member Panel

Part Number Qty. Description
996 559 983 00 G2X 1 Left-hand side member panel, primed
996 559 984 00 G2X 1 Right-hand side member panel, primed
n/a 2 Retaining strip
n/a 6 Templates 1, 2 and 3; left and right (3 ea. per side)
n/a 22 Countersunk sheetmetal screw, 4.8 x 13
n/a 16 U-clip
n/a 1 Left-hand adhesive film
n/a 1 Right-hand adhesive film
n/a 2 Sheetmetal nut; St 4.8

Req.Materials: Part Number Description

999 915 400 40 Adhesive compound, color: black;
n/a Paint, corresponding to standard in accordance with paint code
n/a Loctite Red; Type 262
n/a Adhesive tape
n/a Acetone
n/a Cleaning cloth

Required Tools: Removal tool No. 21
Center bit up to 14.0 mm
Plastic spatula
Scriber
Steel drill bit 2.5 / 8.5 mm
Crosshead bit
Pointed-nose pliers
Allen key a/f 2.5 / 4 / 5
Torx T15 socket wrench
Plastic hammer
Special electrical cutter
Hand drill
Reciprocating saw
Open-end wrench, a/f 10 / 13
Crosshead screwdriver
M4/M5/M6 thread cutter/tap
Shop light
Torque wrench up to 10 Nm (7.5 ftlb.)
Lock file, flat
Hardwood wedge

©2000 Porsche Cars North America, Inc. Date: 7-21-00

Service Page 3 of 9
 ®

6 911 (996)
6315 3/00
Technical Information

Fitting: 1. Work before painting.

1.1 Disassemble rear lid and spoiler and remove all fittings.
Mask all threads on the rear lid and spoiler.

` 1.2 Mask outside of both grille frames (already fitted in the

front spoiler).

Only for vehicles with Tiptronic transmission:

Using the reciprocatingl saw, cut the air inlet out of the
front spoiler in accordance with the area marked in grey
in Figure 2. This cut is made along the first bead (Figure 2, Figure 2
dashed line), which is visible on the inside of the front spoiler.
The component is thinner in this area.

WARNING
Improper painting and drying procedures can result in the damage or warping of spoiler components
> Observe the specifications and instructions for the painting of plastics as contained in the Paint
Manual.
> To prevent warping or distortions, the components to be painted should be mounted on the special
fixtures provided in the parts kit.

1.3 Prime the rear lid and spoiler as described in the Paint Manual.

1.4 Paint the front spoiler, both side member panels and the rear lid with spoiler as described in the
Paint Manual.

2. Fit rear lid with spoiler.

2.1 Preparatory work.

2.1.1 Disconnect and cover the battery. Remove engine compartment fan with fan housing and interior
light, air guide, upper part part of trunk lock, rubber cover and hood strut from the standard rear
lid (See 911 Carrera (996) Technical Manual, Group 5, Section 5590).

2.1.2 Remove rear lid.

2.1.3 Carefully re-cut all threads on the new rear lid and spoiler with the M4, M5 or M6 tap; as well as
the stud bolt in the hollow of the rear lid.

2.2 Fit spoiler on the new rear lid.

2.2.1 Insert strut through the opening (bottom of the rear lid) into the hollow and position it over the
stud bolt. Place strut on the stud bolt and check whether the ends of the strut are properly seated
in the guides inside the rear lid. If this is not the case, the strut must be removed and re-bent.

Date: 7-21-00 ©2000 Porsche Cars North America, Inc.

Page 4 of 9 Service
 ®

Technical Information
911 (996)
3/00 6315 6
Fitting: (cont’d) 2.2.2 Clean guides with BETACLEAN and prime with
BETAPRIME. Apply BETALINK adhesive in the
guides, insert strut into the rear lid and fasten on
the stud bolt with a washer and self-locking M4
hexagon nut.

2.2.3 Fasten both guide fittings (Figure 3, Item 1) on

the appropriate sides of the spoiler with two coun-
tersunk screws M5 x 12 mc each.

2.2.4 Place two plastic washers (Item 2) between the

support bracket (Item 3) and the associated
adjustment fitting (Item 4). As shown in Figure 3,
Figure 3
fit the adjustment fitting on the support bracket with
the oval-head screw M5 x 12 (Item 5) and the threaded
plug with hexagon socket (Item 6).

2.2.5 Fit the adjustment fitting (Item 4) on the appropriate side of the spoiler on the rear lid using four
M5 x 12 micro-encapsulated countersunk screws.
Tightening torques: 2.8 Nm (2.0 ftlb.) for thread size M4
5.5 Nm (4.0 ftlb.) for thread size M5
9.7 Nm (7.0 ftlb.) for thread size M6.

2.2.6 Push a plastic washer on the guide pin (Item 7).

2.2.7 Guide spoiler onto the screw heads of the adjustment fittings from front to rear without tilting.
Slide the spoiler forward as far as it will go (arrow A) and then use the ball of your thumb to move
it downward (arrow B) until the top side of the spoiler is level with the spoiler side parts.

2.2.8 Lower the spoiler (arrow C), guiding both openings on to the support brackets. Fasten the spoiler
on the support bracket with two M6 x 16 countersunk screws on each side.

WARNING
Rattling noise or spoiler detachment due to frequent spoiler adjustment (e.g. during sport events).
> Always use new micro-encapsulated fastening screws (see parts list) when installing the spoiler.
> In exceptional cases, clean the threads of the old screws with a wire brush and coat them with Loctite
Red (Type 262) screw locking agent before installation.

2.3 Fit rear lid on the vehicle and fit all remaining parts at the rear of the vehicle.

2.3.1 Place rear lid with spoiler onto the hinges and put in the new M6 x 20 hexagon-head bolts (4 ea.).
Align the rear lid so that the screw heads at the bottom of the hinges assume their original
positions (non-painted contact surface of the screw head). Tighten screws slightly.

2.3.2 Fit the pneumatic spring, fan with fan housing, upper lock part and rubber cover.

©2000 Porsche Cars North America, Inc. Date: 7-21-00

Service Page 5 of 9
 ®

6 6315
911 (996)
3/00
Technical Information

Fitting: (cont’d) 2.3.3 Observe the identification (letters) on the outside when fitting the air guide.

2.3.4 Check whether there is a jumper connecting pin 2 (which is already jumped from pin 1) to pin 5 on
plug X23 of the new wiring harness (connection to the vehicle). If this is the case, the spoiler
extended signal will be constantly present at the control module and the warning light of the
retractable rear spoiler will not light. (at speeds above 74mph or 120 km/h.

2.3.5 Connect the plug connection of the new wiring harness to the vehicle. Route the wiring harness
along the hood shock to the fan housing and attach it on the rear lid with two (2) fastening clips.
Connect the fan and interior lamp plugs.

2.3.6 Screw new rubber pads (2) into the bottom side of the new rear lid.

2.3.7 Close the right and left bores on the bottom side of the rear lid using the dummy plugs.

2.3.8 Test close the rear lid and check the gap dimensions to adjacent parts, including the gap dimen-
sion between the spoiler and the wiper arm of the rear wiper when the lid is open. Damage to the
spoiler when the rear lid is opened rapidly must possible. If necessary, re-align the rear lid and re-
adjust the upper and lower lock parts. Carefully tighten all screws on the rear lid.
Tightening torques: 9.7 Nm (7.0 ftlb.) for thread size M6;
5.5 Nm (4.0 ftlb.) for thread size M5.

2.4 Stick on the gurney flap (Figure 3, Item 8) and logo.

2.4.1 Measure the gurney flap and transfer the width dimensions to the lower plane of the spoiler.

2.4.2 Apply adhesive, part number 999 915 400 00 on the bottom of the gurney flap in the center and
along its entire length. Diameter of the bead approx. 3 mm.Stick on the gurney flap flush with the
radius transition of the edge at the lower plane of the spoiler. Make sure that the gurney flap is
parallel with the edge. Immediately remove any emerging adhesive. Use adhesive tape to hold the
gurney flap in place during the adhesive hardening process (approx. 12 hours).

2.4.3 Measure the logo and transfer the width dimensions to the rear lid. The bonding height is 50 mm
from the lower edge. Remove film from the logo and stick the logo symmetrically onto rear lid.

3. Fit both side member panels.

3.1 Raise vehicle to working height.

3.2 Detach the wheel housing liners at the rear wheel housings (911 Carrera (996) Technical Manual,
Group 5, Section 5190).

3.3 Use removal tool No. 21 to remove the plastic expanding rivet on the wheel housing liner behind
the front axle. Clip in a sheetmetal nut at this position behind the wheel housing liner.

3.4 Clean side member up the level of the stone shield and inside of the retaining strip with
BETACLEAN and prime with BETAPRIME.

Date: 7-21-00 ©2000 Porsche Cars North America, Inc.

Page 6 of 9 Service
 ®

Technical Information
911 (996)
3/00 6315 6
Fitting: 3.5 Open vehicle doors and remove film from the
adhesive points of a template set (3 ea.).
Position the left and right-hand retaining strips
with the respective template set on the vehicle
side member in accordance with Figure 4 and
the markings on each template (Hi for rear, Mi
for middle and Vo for front).
Dimensions: A = 50 mm; B = 268 mm;
C = 570 mm; D = 440 mm.

Note: The position (heights) of the templates

is determined by the body contour and the
shape of the respective template. Do not drill
holes in the vehicle side panels, as this would
Figure 4
introduce the risk of corrosion.

3.6 Generously mask the body above the retaining strips. When fitting, additionally secure the
retaining strips with adhesive tape or have a assistant hold them. Using a hand drill and a phillips
head bit, screw in the 3.5 x 16 countersunk sheetmetal screws for the retaining strips.

Note: Sheetmetal screws are self-tapping, and will pull themselves into position. After fitting the
retaining strip, check and correct the gap dimension with respect to the vehicle side member
along the entire length.

3.7 Insert rear end of the side member panel into the rear wheel housing and temporarily engage the
side member panel in the retaining strip.

Note: The stone shield applied as standard (side panel) must no longer be visible, and the side
member panel must be located approx. 5 mm below the vehicle side member. Carefully drive the
side member panel into the retaining strip, carefully striking it using a plastic hammer and
hardwood wedge if necessary.

3.8 Clip in the U-clips at the bottom of the vehicle as described below:
- at the height of the individual slots of the side member panel
- with the tab pointed toward the side member (outside of the vehicle).

3.9 Transfer fastening points of the side member panel on the front and rear wheel housings to the
ends of the side member panel of the respective wheel housing. Disengage the side member
panel and drill a hole ( approx. 6 mm) at the markings with the center bit. At the outside of the
side member panel, stick on the adhesive film for the front wheel housing and cut out or punch
out the hole.

3.10 Apply adhesive in the groove of the retaining strip along its entire length.
Important: Observe notes regarding the work or processing times in the bonding instructions for
K2 adhesive.

3.11 Engage side member panel in the retaining strip and position it according to the instructions in
Step 3.7.

©2000 Porsche Cars North America, Inc. Date: 7-21-00

Service Page 7 of 9
 ®

6 911 (996)
6315 3/00
Technical Information

Fitting: 3.12 Fasten side member panel to the wheel housings using the original screw at the rear end and the
countersunk screw with conical washer at the front end. At the vehicle floor, fasten the side
member panel to the U-clips with the 4.8 x 13 sheetmetal screws. When the side member panel is
screwed on, it must be pressed outwards to reduce the gap dimension with respect to the vehicle
side member.

Note: The hardening time of the adhesive is around one hour. During this time, the side member
panels should be additionally fixed on the vehicle with wedges and adhesive tape so that the gap
dimension between the side member panel and vehicle side member is as small as possible.

4. Fit front spoiler.

4.1 Remove both main headlights (911 Carrera (996) Technical Manual, Group 9, Section 9415).
Remove direction indicators, and only detach the front spoiler (Group 6, Section 6315).

4.2 Insert plastic spatula between the wheel housing liner and front spoiler and lever the wheel
housing liner out and over the front spoiler. Remove remaining screws of the front spoiler. Remove
lower trunk lock cover and remove front spoiler from the vehicle.

4.3 Fit retaining bracket on the existing sheetmetal nuts

on the radiator bracket with a phillips head screw
(Figure 5). Clip in the sheetmetal nut on the forward
end.

4.4 Clip in sheetmetal nuts in the area of the direction

indicators. Engage the front spoiler upper side first
into the front end of the vehicle. Ensure that the
upper side is correctly seated in the guides in the
area of the main headlights and direction
indicators.

4.5 When securing it on the retaining strip, press the Figure 5

upper side of the front spoiler towards the front of
the vehicle. Then fasten the front spoiler in the area of the direction indicators.

4.6 Tighten the horizontal screws first, followed by the vertical screws.

4.7 Observe gap dimensions. At the gap between the front spoiler and front lid, the front spoiler
should be around 3 mm higher than the front lid.

4.8 Using the plastic spatula, guide the wheel housing liners behind the sides of the front spoiler and
then completely fasten the front spoiler on the vehicle. Affix wheel housing liners on the front
spoiler with the plastic expanding rivets. Bond in temperature sensors in the grille frames with K2
adhesive.

4.9 Fit cover of the lower trunk lock part. Fasten cap for the towing lug on the bumper using the
securing cord. To do this, drill two 2.5 mm holes at the markings of the front spoiler. Guide the
securing cord through the bores and close. Insert cap into the front spoiler.

Date: 7-21-00 ©2000 Porsche Cars North America, Inc.

Page 8 of 9 Service
 ®

Technical Information
911 (996)
3/00 6315 6
Fitting: 4.10 Align rubber seals of the two radiators with respect to the front spoiler so that they pass by on the
outside of the ventilation grilles.

4.11 Clip both expanding nuts for the licence plate bracket into the front spoiler. Rework holders with a
lock file if necessary.

4.12 Use expanding rivets (11 ea.) to fit the spoiler lip on the bottom of the front spoiler.

4.13 Install both main headlights (Technical Manual, Group 9, Serv. No. 9415).

5. Complete the vehicle and reset the time on the clock. Input the radio code; if necessary, read the
code from the DME control module in menu item Vehicle data using the PST 2. (This also applies
to Porsche Communication Management - PCM.)

Working Time: Labor Operation Time Units Description

55 90 61 40 700 Rear lid, including spoiler, primed and painted
63 15 61 40 360 Front spoiler painted
66 31 62 40 230 Side member panels painted
–––––––
1290 Total of all paint work

63 15 19 40 220 Front spoiler removed and installed

94 15 20 00 40 Main headlights removed and installed
55 90 19 40 250 Rear lid removed and installed
66 50 55 00 20 Rear logo replaced
66 31 24 00 300 Side member panels installed
–––––––
830 Total for fitting, including function test and customer instruction
(safety notes).

Literature: 911 Carrera Technical Manual, Groups 5/6/9, Sections:

51 90 19 - Removing and installing underbody cover
53 69 19 - Removing and installing wheel housing liners and wheel housing covers
55 90 37 - Disassembling and assembling rear lid
63 15 19 - Removing and installing front spoiler
94 15 19 - Removing and installing main headlights
Paint Manual, 4/6/8 cylinder plastic painting

Important Notice: Porsche Cars N.A Technical Bulletins are intended for use by professional technicians, not a “Do-it-yourselfer.” They are written to inform these technicians of conditions that may occur
on some vehicles, or to provide information that could assist in the proper service of a vehicle. Special tools may be required to perform certain operations identified in these bulletins. Use of tools and proce-
dures other than those recommended in these bulletins may be detrimental to the safe operation of your vehicle. Properly trained technicians have the equipment, tools, safety instructions and know-how to do
a job properly and safely. If a condition is described, do not assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See your Porsche Dealer for information on whether your
vehicle may benefit from the information. Part numbers listed in these bulletins are for reference only. Always check with your authorized Porsche dealer to verify correct part numbers.
©2000 Porsche Cars North America, Inc.

Dealership
Distribution Service Manager Shop Foreman Service Technician
Routing Asst. Manager Warranty Admin. Service Technician
Porsche, the Porsche marque, Carrera, Boxster, Tiptronic, VarioCam, VarioRam, Tequipment and PCM are registered trademarks. The 911 and the distinctive shapes of the Porsche automobiles are trademarks
of Dr. Ing. h.c.F. Porsche AG.

©2000 Porsche Cars North America, Inc. Date: 7-21-00

Service Page 9 of 9