Recall - Defective Brake Pressure Reduction Valve
Group4
Number
9303
Model
911 T, 1991-1992
911 C2, America
Roadster, 1992-1993
Part Identifier
P03
December 21, 1993
Subject:
Replacement of the Hydraulic Brake Pressure Reduction Valve
ATTENTION: Service Manager / Service Technician
This is to notify you of a voluntary recall campaign which involves 911 Turbo vehicles of the model years 1991 to 1992 and 911 Carrera 2 America Roadster vehicles of the model years 1992 to 1993.
It has been determined that due to unfavorable tolerances in the hydraulic brake pressure reduction valve, an unacceptable hydraulic throttle effect may occur. Because of this, the rate of hydraulic pressure reduction from the rear wheels is slowed down. This could result in the rear wheels locking up and the potential for an accident, even with the ABS system in operation.
A total of 1,149 cars fail within the scope of this recall. All potentially have the defect and will be recalled to have a modified hydraulic brake pressure reduction valve installed.
The V!N ranges of the affected vehicles in the recall are: (see illustration)
Customer Notification
Porsche Cars North America, Inc. will notify all known owners of vehicles within the recall VIN ranges directly by first class mail during the week of January 3, 1994. See enclosed copy of the recall notification card to the consumers. A listing of all vehicles with owners' names and addresses in your area, within the recall VIN ranges, will be sent to you shortly. If a vehicle within the recall VIN range is in your dealership for service/repair or in dealer inventory, have the customer or receiving dealer contacted and the recall campaign performed.
Work Procedure
See attachments.
Parts Required
Quantity Part Number Description
1 965 355 305 01 Hydraulic brake pressure reduction valve
100 ml Brake fluid
Time Allowance
100 TU
Administrative Procedure
See attachments.
WORK PROCEDURE
Recall P03
Porsche 911 Turbo, Model Year 1991 to 1992 Porsche 911 America Roadster, Model Year 1992 to 1993
Replacement of the Hydraulic Brake Pressure Reduction Valve for the Rear Wheels.
First check the vehicle to determine if the recall has been previously performed.
Proceed as follows:
1. Open front hood and remove the luggage compartment carpet.
2. Inspect the hydraulic brake pressure reduction valve in the area "A" for a white paint marking.
- If yes, a new reduction valve is already installed; reinstall carpet and close front hood.
- If not, drive car onto a vehicle hoist and remove spare tire.
3. Remove brake pressure reduction valve.
CAUTION:
By the removal of the reduction valve, a small amount of brake fluid will escape; therefore, cover the area of the reduction valve with rags to avoid paint damage.
- Loosen the top brake line connection by using an 11 mm open-end wrench for the top connection and counterhold with a 19 mm open-end wrench.
ATTENTION:
Do not counterhold on the 22 mm hex part!
Loosen the bottom brake line connection on the angled connector using an 11 mm open-end wrench and a 13 mm open-end wrench to counterhold. Remove the clamp for the reduction valve and remove the valve.
- Remove the angled connector from the reduction valve using a 13 mm open-end wrench and counterhold with a 19 mm open-end wrench.
ATTENTION:
Do not counterhold on the 22 mm hex part!
4. Install angled connector into new reduction valve. Tightening torque: 14 N-m (10 ft.lb.).
5. Installation of new reduction valve.
- Connect the bottom brake line on the reduction valve, but do not tighten it. Reinstall the holding clamp for the reduction valve.
- Connect the top brake pipe.
- Torque top and bottom brake line connectors to 12-14 N-m (8.6 - 10.0 ft.lbs.)
ATTENTION:
Do not counterhold on the 22 mm hex part!
- Clean area of all brake fluid.
6. Bleed brake system on the right rear wheel. (Also see the Workshop Manual 911 Turbo, as of M.Y. 1991, Group 47.)
- Remove right rear wheel.
- Remove ignition key and pump the brake pedal approximately 25 times. The system is pressureless as soon as the brake pedal is hard when applied.
- Clamp the brake fluid reservoir vent hose shut with a small "C" clamp. With the pressure in the booster system released, fill the reservoir to the top with new brake fluid. Install a power bleeder. The bleeding pressure is approximately 1.5 bar.
- Connect a suitable bottle to collect the escaping brake fluid and to check for air bubbles. The bleeding has to be performed on both bleeder valves of the brake caliper.
- Put a bleeder hose on the bleeder valve of the brake caliper, open the valve until no bubbles appear, close valve and torque to 8-12 N-m (5.8 - 8.6 ft.lbs.).
- Repeat the same procedure on the other bleeder valve on the brake caliper.
- Remove bleeder hose, turn off the power bleeder and disconnect. Remove the "C" clamp from the vent hose.
- Turn on the ignition.
- As soon as the servo-hydraulic pump stops running, which can be heard, correct the brake fluid level in the reservoir.
CAUTION:
Do not fill above the "MAX" marking!
- Perform a visual inspection for leaks on the brake caliper bleed valves and on the connections of the pressure reduction valve.
- Reinstall wheel, torque wheel lugs to 130 N-m (93 ft.lbs.). (Also see Workshop Manual, page 44-1.)
7. Marking of the vehicle: Mark the hydraulic brake reduction valve with a white paint dot in the area "A".
NOTE:
Some new parts might already be marked with this white paint dot!
8. Reinstall spare tire and luggage compartment carpet.
9. Pump the brake pedal several times and verify correct operation.
10. Drive the car off the vehicle lift.
Required tools:
Open-end wrench - 11, 13, 15 and 19 mm
Box wrench -10 mm
Lug nut socket - P300 (19 mm)
Torque wrench - 5 to 20 N-m
Torque wrench - up to 200 N-m
Power brake bleeder
Required Parts:
Part Number Description
965 355 305 01 Hydraulic brake pressure reduction valve
000 043 202 04 (5 liter) Brake fluid, approximately 100 mi DOT3 or DOT4 (SAE J1703)
000 043 202 09 (1 liter) White touch-up paint
Time Allowance: 100 TU
ADMINISTRATIVE PROCEDURE
Recall P03
Installation of Brake Pressure Reduction Valve
Warranty claims should be submitted via IDCS. (Note: Always check the Voice Response System on the IDCS Recall Inquiry before performing the recall).
Affected VINS:
Warranty Code: R
Damage Code: AR03 99 P03 2*
Labor Operation: AR03 1900
Time Units: 100 TU
Part Number(s): 965 355 305 01 (Qty. 1) Brake valves, and
000 043 202 09, 100 ml brake fluid (Qty. 0.25)
Warranty Parts $: $26.36
* Dealers on IDCS should use claim template option from IDCS.
In cases where the Recall cannot be performed, submit the information on a claim via IDCS with the appropriate disposition code by inserting the code in the last digit of the damage code.
Owner Name and Address Change
If owner name and address are shown incorrectly, submit correction using name/address change postcard from the Warranty and Maintenance booklet or Recall mailing, or report to Porsche Cars North America via IDCS to the Warranty Department of change, including VIN.