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AH01

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AH01 - Replacing Fastening Screws For Fuel Collection Pipes (Stop-Sale Campaign)

Revision:

February 23, 2017
This revision amends AH01 as follows:
1 — The work procedure was amended to include removing the rear-axle cross member completely to
gain additional space when lowering the engine.
2 — Scope 12 was added for cars where a replacement engine was installed but not documented. With
this scope, the engine number must be checked according to a list published via PPN to determine if the
newly installed engine is affected or not.

Model Year:

2017

Vehicle Type:

718 Boxster (982)/718 Boxster S (982)

Subject:

Fastening screws for fuel collection pipes

Concern:

There is a possibility that the fastening screws for the fuel collection pipes on the affected
vehicles can shear off due to stress corrosion cracking.
If this happens, the high fuel pressure that builds up in the fuel injection system when the engine is running
can press the relevant fuel collection pipe off the fuel injectors. This can cause a fuel leak in the engine
compartment.

Remedial
Action:

Replace fastening screws for both fuel collection pipes.
Information
Vehicles with replacement engine installed
On vehicles in which a replacement engine was installed and the relevant engine number was not
documented, we cannot be sure that the correct fastening screws were used. These vehicles are also
assigned to Scope 12.
The engine number on the vehicles must first be checked. The fastening screws may or may not have to
be replaced, depending on the result of the check.
For instructions and further information, see  Technical Information 'AH0100 Scope 12 - Checking
engine number'.
To find out which campaign scope is assigned to the respective vehicle for this campaign, see PIWIS
Vehicle Information.

Parts Info:

NOTE: NECESSARY PARTS FOR THIS CAMPAIGN ARE STILL BEING MANUFACTURED AND ARE
EXPECTED TO ARRIVE CW07. ONCE THE REQUIRED PARTS FOR THIS CAMPAIGN HAVE ARRIVED, PCNA

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WILL BEGIN THE AUTOMATIC ALLOCATION PROCESS FOR UP TO 50% OF THE VEHICLES THAT ARE
SERVICED AT YOUR DEALERSHIP. APPROXIMATELY 45 DAYS AFTER YOUR FIRST ALLOCATION, YOUR
DEALER WILL AUTOMATICALLY BE ALLOCATED AN ADDITIONAL 30% OF THE REQUIRED PARTS FOR THE
VEHICLES THAT ARE STILL IN NEED OF REPAIR.
Installation
position:

1
2

Overview of installation position (shown on 718 Boxster as an example)
– Fuel collection pipe
– Fastening screws (replace)

Affected
Vehicles:

Only the vehicles assigned to the campaign (see also PIWIS Vehicle information). This campaign affects
4,518 vehicles in North America.

Parts required
Part No.:

Feb 7, 2017
Page 2 of 12

Part No.

Designation
– Use

Qty.

000 043 306 00

 Torx screw, BM 6 x 85
– Fuel collection pipe

4 ea.

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999 076 053 01

 Hexagon nut, M10
– Rear diagonal brace

12 ea.

999 072 840 01

 Hexagon-head bolt, M10 x 35
– Diagonal brace to body

2 ea.

N 908 484 05

 Hexagon nut, M12 x 1.5
– Engine carrier to engine mount

2 ea.

AH01

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Required tools
Tools:

•
•
•
•
•
•
•
•
•
•

Torque screwdriver, 1.5 - 3 Nm (1 - 2 ftlb.), e.g. VAS 6494 - Torque screwdriver
Torque wrench, 6 - 50 Nm (4.5 - 37 ftlb.), e.g. V.A.G 1331 - Torque wrench, 6-50 Nm (4.5-37
ftlb.)
Torque wrench, 40 - 200 Nm (30 - 148 ftlb.), e.g. V.A.G 1332 - Torque wrench, 40-200 Nm
(30-148 ftlb.)
Torque/torque angle screw tool, 20 - 400 Nm (15 - 296 ftlb.), e.g. VAS 6942 - Torque/torque
angle screw tool
Hydraulic transmission jack, e.g. VAS 6931 - Engine and gearbox jack
VAS 6918 - Quick-Clamping Unit
9229/1 - Puller hook
Battery Charger/Power Supply - Suitable for AGM Type batteries, recommended current rating of
70A fixed voltage 13.5V to 14.5V.
9900 - PIWIS Tester 3
Plastic assembly wedge (commercially available)

If the wheel alignment values must be corrected during suspension alignment, the following tools will
also be required:
•
•
•
•
•
•

9626 - Insert for torque wrench
9730 - Socket-wrench insert
9847 - Socket-wrench insert
VAS 6430/1A - Setting Device with Reflector
VAS 6430/3 - ACC reflector mirror
VAS 6190/2 - T-bar Setting Tool for ACC Sensor

Preparatory work
Work Procedure: 1

Raise the vehicle on a lifting platform  Workshop Manual '4X00IN Lifting the vehicle'.

2

Move convertible top to service position  Workshop Manual '6101IN Convertible-top service
position'.

3

Relieve fuel pressure in the system.
3.1

Remove cover on the fuse carrier in the passenger compartment at the front left.

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3.2

Pull out fuse for fuel pump.
The fuse (20 A) is in row B  Fuse carrier
in passenger compartment at the front left
-1-, slot FB5  Fuse carrier in passenger
compartment at the front left -2-.

Fuse carrier in passenger
compartment at the front left
WARNING
Exhaust gases
•

Risk of Carbon Monoxide (CO) Poisoning



Before starting the engine, position an exhaust extraction system behind the vehicle’s exhaust
pipes and switch it on.

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3.3

Start the engine and leave it running at idle speed until it cuts out.
This can take up to 5 minutes.

3.4

Switch off ignition and remove ignition key.

3.5

Re-insert fuse for fuel pump.

4

Disconnect ground line at the battery  Workshop Manual '2X00IN Work instructions after disconnecting the battery'.

5

Remove trim panel for convertible top compartment  Workshop Manual '700819 Removing and
installing trim panel for convertible top compartment/engine compartment lid'.

6

Remove engine compartment lid  Workshop Manual '557819 Removing and installing engine
compartment lid'.

7

Remove air cleaner housing  Workshop Manual '242519 Removing and installing air cleaner
housing'.

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8

Remove rear wheels  Workshop Manual '440519 Removing and reinstalling wheel'.

9

Remove cover for rear underbody  Workshop Manual '519419 Removing and installing cover for
rear underbody'.

10 Remove diagonal braces on the rear axle  Workshop Manual '421320 Removing and installing
struts'.
11 Remove support plate on the rear axle  Workshop Manual '421419 Removing and installing
support plate'.
12 Remove rear-axle cross member  Workshop Manual '420619 Removing and installing rear-axle
cross member'.

Replacing fastening screws for fuel collection pipes
Work Procedure: 1

Lowering the engine to complete other work.
1.1

Loosen fastening nuts  Turning tailpipe
cover -2- on both clamps  Turning tailpipe
cover -1- for the tailpipe cover and turn the
tailpipe cover as far as required until the
tailpipes are pointing downwards.
Information

1.2

•

The weight must be distributed uniformly
on the oil pan.

•

Never apply localised pressure to the oil
pan.

Support the engine at the oil pan using a
suitable transmission jack.

Turning tailpipe cover

Information

1.3

•

When lowering the engine, it must not rest on the rear-axle cross member.

•

The exhaust system must not touch against the body or rear apron when lowering it.

•

Always be careful of hoses, lines and cables when lowering the system!

•

Always avoid collisions!

Lower the engine as far as required until the fastening screws for the fuel collection pipes are
accessible.
For instructions, see  Workshop Manual '1001IN Lowering the engine to complete other
work'.

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Replace fastening screws for fuel collection pipes.
2.1

Loosen and unscrew front fastening screw

 Replacing fastening screws -2- (viewed in
direction of travel) for fuel collection pipe on
cylinder 1–3  Replacing fastening screws
-1-.

2.2

Screw in and tighten new fastening screw,
Part No. 000 043 306 00.
Tightening torque 13 Nm (9.5 ftlb.)

2.3

Loosen and unscrew rear fastening screw
 Replacing fastening screws -3- for fuel
collection pipe on cylinder 1–3  Replacing
fastening screws -1-.

2.4

Screw in and tighten new fastening screw,
Part No. 000 043 306 00.
Tightening torque 13 Nm (9.5 ftlb.)

2.5

Replacing fastening screws
Repeat steps 3.1 to 3.4 on the fuel collection
pipe on cylinder 4–6  Replacing fastening screws -4- in order to replace the fastening
screws  Replacing fastening screws -5 and 6-.

3

Raise the engine to installation position and secure it.
For instructions, see  Workshop Manual '1001IN Lowering the engine to complete other work'.

4

Turn tailpipe cover into installation position and align it with respect to the rear apron. Then secure
the tailpipe cover.
For instructions, see  Workshop Manual '263519 Removing and installing tailpipe cover'.

Concluding work
Wok Procedure: 1

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Install rear-axle cross member  Workshop Manual '420619 Removing and installing rear-axle
cross member'.

2

Install support plate on the rear axle  Workshop Manual '421419 Removing and installing support
plate'.

3

Install diagonal braces on the rear axle  Workshop Manual '421320 Removing and installing
struts'.

4

Install cover for rear underbody  Workshop Manual '519419 Removing and installing cover for
rear underbody'.

5

Install rear wheels  Workshop Manual '440519 Removing and reinstalling wheel'.

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AH01