No. 62-23

Symptom-based workshop manual
Service
62/23
ENU
2440
2
Engine Symptom – Vibration Noises from the Engine Compartment (SY 62/23)
Vehicle Type:
718 Cayman GTS 4.0 (982)
718 Boxster GTS 4.0 (982)
25 Years of the Boxster (982)
718 Spyder (982)
718 Cayman GT4 (982)
Model Year:
As of 2019 up to 2024
Concerns:
Piezo injection valve
Symptom:
Customers complain of an audible vibrating noise from the engine compartment. The noise is
particularly noticeable when the vehicle is stationary or the engine is idling.
Cause:
Piezo injection valves are installed in 718 model line vehicles with a 4.0-liter flat-6 engine, which cause a
certain noise pattern and are significantly more perceptible due to the mid-engine concept.
Remedial
Action:
Inform customer that the use of piezo injection valves can generally lead to acoustic excitation in the fuel
high-pressure system and thus to these noise abnormalities (state of the art).
Information
Since replacing the fuel injectors or the fuel high-pressure pump is not expedient in this fault pattern, and
other measures also do not ensure that the noise can be reduced, proceed in steps as follows in case of a
customer complaint:
1
First explain the acoustic characteristics of piezo injection valve technology to the customer. See
the corresponding description in the section  Technical Information 'Explanations of acoustic characteristics of piezo injection valve technology'.
2
If the customer continues to complain about a particularly loud vibration noise, first assess the noise
using a comparison vehicle from the 718 model line with a 4.0-liter flat-6 engine. For procedure, see
 Technical Information 'Assessing vibration noise using a comparison vehicle'.
3
If the fuel injector vibration noise in the vehicle in question is significantly louder than in a comparison
vehicle, loosen and refasten the fuel collection pipe. For procedure, see  Technical Information
'Loosening and fastening fuel collection pipe'.
4
If, despite loosening and rethreading the fuel collection pipe, the vibration noise is still significantly
louder than in the comparison vehicle, replace the fuel collection pipe. For procedure, see 
Technical Information 'Replacing fuel collection pipe'.
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Explanations of acoustic characteristics of piezo injection valve technology
Information
In contrast to 718 model line vehicles with 4 cylinder Boxer engines, piezo injection valves are used
instead of the conventional solenoid injection valves for derivatives with 4.0-liter flat-6 engine.
Piezo injection valves have a directly actuated and outwardly opening nozzle in conjunction with the
piezo actuator, enabling extremely short switching times (up to four times shorter than with solenoid
valves), making high-precision fuel dosing possible. With up to five injections per working cycle, highly
flexible injection technologies are implemented, optimizing combustion and ultimately reducing fuel
consumption.
Compared to motors with solenoid valve injectors, the piezo injection system is characterized by a
metallic impact noise in the range of 3 kHz. This frequency range is perceived particularly intensely by
humans.
Particularly in the lower load and engine speed range, when engine and driving noises move into the background, the injection system’s impact noise can be perceived as dominant. Operating states such as
idling, starting off and manoeuvring are particularly noticeable. As the load and engine speed increases,
the sound of the fuel injectors fades into the background due to the increased noise level of the engine,
exhaust system as well as rolling and wind noises.
Propagation of sound waves is particularly encouraged by the installation position of the flat engine. Due
to the low position in the vehicle, the sound radiates in the direction of the road and the wheel housing.
The sound waves are reflected and diffused in the vehicle surroundings.
Efficiently absorbing sound via acoustic insulation in the engine compartment is difficult due to the center
or rear engine configuration compared to the front engine. In addition, some vehicles are also operated
on the race circuit. The resulting high thermal loads make a complete acoustic engine compartment
encapsulation impossible.
On 718 model line vehicles with a 4.0-liter flat-6 engine, piezo injection valves were deliberately chosen,
as the emission benefits outweigh possible acoustic drawbacks while at the same time maintaining high
specific power.
Assessing vibration noise using a comparison vehicle
Work
Procedure:
If customers continue to complain about a particularly loud vibration noise, this must be assessed using a
comparison vehicle from the 718 model line with a 4.0-liter flat-6 engine.
Assessment
Action
Vibration noise identical to comparison vehicle.
No action required.
If necessary, inform customer again about the special
features of the piezo injection valve.
Vibration noise much louder than comparison
vehicle.
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Continue by  Technical Information 'loosening and
fastening fuel collection pipe'.
AfterSales
Symptom-based workshop manual
Service
62/23
ENU
2440
2
Loosening and fastening fuel collection pipe
Information
The remedial action described below entails considerable work, and reduced noise cannot be guaranteed.
Please inform the customer about this in advance and coordinate the next steps with them.
Parts Info:
Materials:
Tools:
Part No.
Designation
– Location
Number
N 91257801
 Hexagon-head bolt, M8 x 80
– Fuel collection pipe
6 pieces
982251261
 Seal
– Exhaust manifold/cylinder head
2 pieces
982251263B
 Seal
– Exhaust manifold/particle filter
2 pieces
9A700384201
 Hexagon nut
– Exhaust manifold at cylinder head
18 pieces
Required materials (usually already available in the Porsche Center):
•
•
•
•
•
•
•
•
•
•
Part No.
Designation
– Location
Quantity
00004330508
 Mounting paste (100 gram/ 3.52 oz tube)
– Wheel centring surface to wheel hub
As required
Torque spanner, 6–50 Nm (4.5–37 ftlb.), e.g. V.A.G 1331A - torque spanner, 6–50 Nm
(4.5–37 ftlb.)
Torque spanner 40–200 Nm (30–148 ftlb.), e.g. V.A.G 1332A - Torque spanner 40–200 Nm
(30–148 ftlb.)
9961/2 - Guide pins
P90013 - Guide pins
9769 - Retainer plate
9769/1 - Support
9769/2 - Support
VAS 6832 - Master Gear unit elevating platform
VAS 6931 - Transmission and gearbox jack
Nr.90 Pos.3 - Torque spanner
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Nr.98-1 Pos.3 - Insert adapter with universal joint
Nr.96-3 - Open-end/ring spanner
VAS 261 021 - Ring spanner insert, SW 22
•
•
•
Additional required tool for vehicles with central wheel bolts (I-no. 1PJ):
Torque spanner, 150–800 Nm (111–592 ftlb.), e.g. V.A.G 1601 - torque spanner, 150–800 Nm
(111–592 ftlb.)
9796 - Socket spanner
9794 - Assembly aid
VAS 6266A - Wheel fitting trolley
•
•
•
•
Work Procedure:
Information
The fuel lines on the fuel collection pipes are not loosened.
1
2
Loosen and fasten fuel collection pipe screw connections. For instructions, see
 Workshop Manual '243019 Removing and installing fuel collection pipe (with injector valves)'
Assess the vibration noise again using a comparison vehicle.
Assessment
Action
Vibration noise identical to comparison vehicle.
No further action required.
Vibration noise much louder than comparison
vehicle.
Continue by replacing  Technical Information
'243019 fuel collection pipe'.
Replacing fuel collection pipe
Information
The remedial action described below entails considerable work.
Replacing the fuel collection pipe may compensate for unfavorable component tolerances, which may
contribute to additional acoustic excitation, thus reducing noise complaints. However, this action does
not ensure that the noise abnormality can be reduced.
Please inform the customer about this in advance and coordinate the next steps with them.
Parts Info:
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Part No.
Designation
– Location
Number
0PB128373J
 Fuel collection pipe cylinders 1-3
1 piece
0PB128374J
 Fuel collection pipe cylinders 4-6
1 piece
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Symptom-based workshop manual
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62/23
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2440
N 91257801
 Hexagon-head bolt, M8 x 80
– Fuel collection pipe
6 pieces
0PB127219
 Spacer ring
– Fuel collection pipe
6 pieces
PAF006121
 O-ring
– Fuel collection pipe
6 pieces
0PB127291
 Retaining ring
– Fuel collection pipe
6 pieces
0PB128071
 Support ring
– Fuel collection pipe
6 pieces
0PB127199
 Circlip
– Fuel collection pipe
6 pieces
0PB127404
 Sealing ring (Teflon)
– High-pressure injector
6 pieces
0PB127269
 Sealing ring
– High-pressure injector
6 pieces
0PB825411
 Seal
– High-pressure injector
6 pieces
0PB128626
 Retaining clip
– High-pressure injector
6 pieces
982251261
 Seal
– Exhaust manifold/cylinder head
2 pieces
982251263B
 Seal
– Exhaust manifold/particle filter
2 pieces
9A700384201
 Hexagon nut
– Exhaust manifold at cylinder head
18 pieces
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Materials:
Tools:
ENU
Symptom-based workshop manual
62/23
Required materials (usually already available in the Porsche Center):
Part No.
Designation
– Location
Quantity
00004330508
 Mounting paste (100 gram/ 3.52 oz tube)
– Wheel centring surface to wheel hub
As required
00004320935
 Lubricant (400 ml/ 13.52 oz spray can)
– Fuel collection pipe thread
As required
9900 - PIWIS Tester 3/4
Battery charger with a current rating of at least 90 A, VAS 5908 - battery charger 90 A
9961 - Puller
9961/1 - Assembly tool
9961/3 - Assembly tool
•
•
•
•
•
Work Procedure:
Information
The fuel injectors are not replaced.
1
Replace fuel collection pipe and rebuild fuel injectors. For instructions, see
 Workshop Manual '243019 Removing and installing fuel collection pipe (with injector valves)'
Labor position and PCSS encryption
Labor position:
APOS
Labour operation
I No.
24304942
Loosening and fastening fuel collection pipe
24304943
Removing and installing fuel collection pipe
PCSS encryption:
Location (FES5)
24400
Injection valve
Damage type (SA4)
1111
Adjustment error
Important Notice: Technical Bulletins issued by Porsche Cars North America, Inc. are intended only for use by professional automotive technicians who have attended Porsche service training
courses. They are written to inform those technicians of conditions that may occur on some Porsche vehicles, or to provide information that could assist in the proper servicing of a vehicle. Porsche special
tools may be necessary in order to perform certain operations identified in these bulletins. Use of tools and procedures other than those Porsche recommends in these bulletins may be detrimental to the
safe operation of your vehicle, and may endanger the people working on it. Properly trained Porsche technicians have the equipment, tools, safety instructions, and know-how to do the job properly and
safely. Part numbers listed in these bulletins are for reference only. The work procedures updated electronically in the Porsche PIWIS diagnostic and testing device take precedence and, in the event of a
discrepancy, the work procedures in the PIWIS Tester are the ones that must be followed.
© 2023 Porsche Cars North America, Inc.
Jul 11, 2023
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