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Porsche 996 TT Repair Manual

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Summary of Contents for Porsche 996 TT

Page 1 einordnung...
Page 2: Table Of Contents
einordnung Table of Contents Information on handling of the GT2 scope.......................1 0 Technical data..............................2 Engine..............................3 Engine design............................4 Engine cooling............................5 Engine lubrication............................5 Engine control............................5 Heating..............................6 Fuel system..............................6 Electrical system............................6 Exhaust system............................7 Emission control............................7 Transmission............................7 Clutch...............................7 Transmission............................8 Body designs............................9 Running gear............................9 Brakes..............................10 Wheels and tyres............................11 Spare wheel............................11...
Page 3 einordnung Table of Contents 0 Body Refrigerant circuit..........................26 Component arrangement, Airbag System B05..................26 0 Electrics................................28 Fuse assignments...........................28 0 Power supply..............................31 Work instructions after disconnecting the battery.................31 Control module memories........................31 Supply voltage fault entry........................32 Test drive after connecting the battery ....................32 2470 DME control module........................32 3730 Tiptronic ............................33 6452 Power windows..........................33...
Page 4 einordnung Table of Contents 01 Activating/deactivating the parking aid Deactivating the parking aid without PST 2..................48 Activating the parking aid with PST 2 ....................48 Selecting door mirror to be lowered, left/right..................49 Adjusting the lowering angle for the passenger door mirror..............49 Deactivating the parking aid with PST 2....................50 01 Removing transport lock (spring strut locking devices) Turbo and GT2...........51...
Page 5 einordnung Table of Contents 03 Changing the engine oil and oil filter......................68 03 Changing the engine oil (without oil filter)....................72 03 Replacing spark plugs ..........................74 Removing spark plugs...........................74 Installing spark plugs..........................75 03 Checking cooling system ..........................77 Coolant: checking level, antifreeze content and leaks................77 03 Replacing air cleaner element........................79 Removing air cleaner..........................79 Installing air cleaner ..........................81...
Page 6 einordnung Table of Contents 03 Changing transmission oil in front wheel drive..................103 Changing transmission oil in front wheel drive...................103 Tightening torques..........................103 03 Changing transmission oil − GT2......................105 Changing transmission oil − GT2......................105 Topping up transmission oil − GT2.....................105 Tightening torques..........................106 03 Steering gear: fluid level and bellows .......................107 Power steering: checking the fluid level....................107 General............................107...
Page 7 einordnung Table of Contents 03 Checking lid and doors Function test, checking door lock......................122 Functional inspection of the tank cap lock..................123 Checking door and lid tightening torques....................123 Checking inner release of luggage compartment (Trunk Entrapment) ..........123 Tightening torques..........................124 03 Checking seat belts.............................125 Functional inspection...........................125 Condition inspection..........................125 03 Inspecting the airbag system........................126...
Page 8 einordnung Table of Contents 03 Additional maintenance − USA − as of MY 2004...................141 Additional maintenance, replacing spark plugs...................141 Additional maintenance every 60,000 mls/96,000 km................141 Additional maintenance every 90,000 mls/144,000 km..............142 Maintenance every 2 years ........................142 Maintenance after 4, 8, 10 then every 2 years..................142 03 Additional maintenance ..........................144 Additional maintenance, replacing spark plugs...................144 Additional maintenance every 80,000 km/48,000 mls................144...
Page 9 einordnung Table of Contents 5 Plug location plan Side of front end ...........................160 Bottom of lower side member and floor....................161 Top of lower side member and floor ....................161 Bottom of rear end..........................162 Top of rear end.............................162 Side of rear end............................163 Seam seals................................164 Accessories............................164 Front lid............................165...
Page 10 einordnung Table of Contents 5 Safety notes Safety instructions for sticking......................185 Safety instructions for Teromix−6700 two−component adhesive..........185 Safety instructions for installation work....................186 Safety instructions for sharp−edged body and unit parts..............186 Safety instructions for airbag system....................186 Safety instructions for door......................186 Safety instructions for corrosion protection ..................187 Safety instructions for plug location plan (body)................187 Safety instructions for water drains (body)...................187 5 General information and quality notes......................188...
Page 11 Exterior paintwork metallic/pearl .....................231 Special colours.............................232 6 Processing of Porsche 2−component window bonding agents..............234 Overview of tools and materials......................234 Preparing the adhesive surfaces......................235 Combined procedure (handling double cartridge press)..............236 7 Special notes for the care of soft−look paint surfaces ................239 Light soiling (e.g.
Page 12 einordnung Table of Contents 9 Work instructions after disconnecting the battery Test drive after connecting the battery ....................243 2470 DME control module........................243 6452 Power windows...........................244 90 25 Instrument cluster ........................244 9030 Clock............................244 9023 Fuel level display........................244 9120 Radio............................245 9110 PCM............................245 30 Clutch: checking fluid levels........................247 General..............................247 Checking Pentosin CHF 11 S hydraulic fluid in the engine compartment and luggage...
Page 13 einordnung Table of Contents 44 Suspension alignment, complete.......................264 Vehicle height/wheel load ........................265 Wheel−alignment corrections......................265 Rear axle............................265 Front axle ............................266 General procedure for suspension alignment ..................266 Vehicle height (vehicle height check) ....................267 General............................267 Preliminary work...........................267 Front axle ............................268 Rear axle............................268 Wheel alignment .
Page 14 Further to 4b: Fine balancing of the rear wheels................290 Balancing weights..........................291 Affixing the adhesive weights.......................291 45 ABS/PSM 5.7 check with Porsche System Tester 2................292 Test with Porsche System Tester 2......................292 46 Checking brake light switch setting......................293 Brake light switch setting........................293 Checking brake light switch setting.....................293...
Page 15 einordnung Table of Contents 69 Safety regulations for vehicles with airbag and belt tensioner..............309 Assembly and adjustment work......................310 Handling airbag and belt tensioner......................311 Dangers for persons and the environment..................311 Protective measures and rules of behaviour..................311 Behaviour in cases of malfunction or danger................312 Materials............................313 General information..........................313 Component exchange after airbag triggering................314...
Page 16 einordnung Table of Contents 40 09 Front−axle cross member − permissible combinations Impermissible combination......................337 Permissible combinations......................337 Impermissible combination......................338 40 Disassembling and assembling front spring strut...................339 Tools..............................339 Disassembly and assembly instructions....................341 Disassembly ...........................341 Distinguishing feature of coil springs and dampers..............342 Preliminary work and notes on assembly..................342 Assembly............................343 42 71 Disassembling and assembling rear spring strut −...
Page 17 einordnung Table of Contents 87 03 Safety regulations when handling refrigerant R134a................364 92 66 Non−adjustable spray nozzles ......................365 94 23 Bulb table and installation instructions....................366 Bulb table.............................366 Installing bulbs.............................366 96 22 Bulb table and installation instructions....................367 Bulb table.............................367 Installing bulbs.............................367 97 68 Optical waveguide −...
Page 18 einordnung Table of Contents 13 10 19 Removing and installing pistons (includes removing and installing cylinders)......411 Tools..............................411 Removing pistons and cylinders......................412 Removing pistons..........................414 Installing pistons and cylinders ......................415 13 19 21 Removing piston rings........................423 Tools..............................423 Removal...............................423 13 19 23 Installing piston rings........................427 Tools..............................427 Installation............................427 13 48 37 Disassembling and assembling crankshaft..................431...
Page 19 einordnung Table of Contents 15 05 19 Removing and installing camshafts engine removed ..............474 Tools..............................474 Component overview and tightening torques..................475 Removing camshafts..........................477 Installing camshafts..........................481 15 20 37 Disassembling and assembling intermediate shaft ................487 15 55 19 Removing and installing hydraulic valve ..................489 Removing the hydraulic valve......................489 Installing the hydraulic valve.......................491 15 70 21 Removing cylinder head........................494...
Page 20 einordnung Table of Contents 19 50 19 Removing and installing coolant pump (engine installed)............529 Tools..............................529 Removal...............................529 Installation............................534 19 62 19 Removing and installing coolant hose at front left (Y−type coolant distributor)......538 Tools..............................538 Removal...............................538 Installation............................540 20 02 01 Checking fuel pressure........................543 20 10 19 Removing and installing fuel tank....................546 Removing fuel tank..........................548 Installing fuel tank..........................553...
Page 21 einordnung Table of Contents 21 67 05 Checking and adjusting the bypass flap control boxes on the turbocharger Check and adjust (cylinder bank 4 − 6)....................586 21 67 19 Removing and installing bypass flap control box on the turbocharger − Engine installed..588 Removing bypass flap control box on the turbocharger..............588 Installing bypass flap control box on the turbocharger ................589 21 75 20 Removing and installing oil container for exhaust turbocharger −...
Page 22 einordnung Table of Contents 24 73 19 Removing and installing oxygen sensors behind catalytic converter Installing oxygen sensors behind the catalytic converter..............634 26 01 05 Exhaust system leak test........................635 Tools..............................635 Leak test...............................636 26 33 19 Removing and installing rear mufflers..................637 Removing rear mufflers........................637 Installing rear mufflers .........................639 26 65 19 Removing and installing secondary air pump................641...
Page 23 einordnung Table of Contents 30 01 01 Checking clutch booster circuit 2.2 Checking the valve (pressure−regulating valve) in the upper part of the expansion tank..664 30 01 07 Bleeding clutch operation........................666 Disposal of Pentosin..........................667 30 27 19 Removing and installing clutch pressure hose − Engine installed ..........668 Removing clutch pressure hose......................668 Installing clutch pressure hose......................669 30 30 19 Removing and installing clutch slave cylinder................671...
Page 24 einordnung Table of Contents 32 50 19 Removing and installing torque converter..................698 Tools..............................698 Removing the torque converter ......................698 Installing the torque converter......................699 03 26 00 Major maintenance − USA ......................700 03 26 00 Major maintenance − as of MY 2003.....................702 03 26 00 Major maintenance −...
Page 25 einordnung Table of Contents 03 50 00 Annual maintenance − USA......................727 03 50 00 Annual maintenance − as of MY 2004...................729 03 50 00 Annual maintenance − USA − as of MY 2004................730 37 02 35 Checking and topping up the ATF....................731 Tools..............................731 Checking and topping up the ATF.......................731 Tightening torques..........................733...
Page 26 einordnung Table of Contents 38 77 37 Disassembling and assembling electrohydraulic control unit ............759 Tools..............................759 Overview..............................759 Disconnecting hydraulic and electrical control unit................761 Removing solenoid and control valve ....................761 Installing solenoid and control valve....................761 Reassembling the hydraulic and electrical control unit...............761 40 41 19 Removing and installing the front drive shaft ................763 Tools..............................763 Removal...............................763...
Page 27 einordnung Table of Contents 45 30 19 Removing and installing hydraulic unit ..................784 Replacing the hydraulic unit........................784 Removal...............................785 Installation............................786 45 59 19 Removing and installing rate−of−turn sensor................788 Removal...............................789 Installation............................790 45 59 31 Conversion of rate−of−turn sensor....................791 Overview of rate−of−turn sensor conversion..................792 Removal...............................794 Fitting..............................796 45 60 19 Removing and installing steering angle sensor................799...
Page 28 einordnung Table of Contents 46 53 19 Removing and installing the rear brake disc .................822 Removal...............................822 Installation............................822 46 83 16 Adjusting the parking brake shoes ....................824 Check the free play of the parking brake lever..................824 Adjusting the parking brake.........................824 46 83 19 Removing and installing the parking brake shoes................826 Removal...............................826 Installation............................826 47 01 07 Bleeding brakes (vehicle with PSM)....................829...
Page 29 einordnung Table of Contents 55 10 37 Disassembling and assembling release for front lid Removing and installing support for cap release.................861 55 17 19 Removing and installing front lower part of lid lock ..............863 Removing and installing bowden cable for lock actuation..............865 55 22 19 Removing and installing front lid....................868 55 22 37 Disassembling and assembling front lid ..................870 55 25 19 Removing and installing front lid hinge ..................873...
Page 30 einordnung Table of Contents 60 28 19 Removing and installing frame for sliding roof Tightening torques .........................916 60 28 37 Disassembling and assembling frame for sliding roof..............917 Disassembling frame for sliding roof....................917 Assembling frame for sliding roof.......................919 60 40 19 Removing and installing sliding roof panel...................921 Additional instructions for removing the inner panels................924 Additional instructions for fitting the inner panels................925 63 10 19 Removing and installing front bumper..................927...
Page 31 einordnung Table of Contents 64 86 19 Removing and installing rear window...................961 Removing rear window........................961 Preparing the window section for installation..................963 Installing rear window.........................964 Overview of tools and materials......................967 66 13 19 Removing and installing air inlet ....................969 Removing air inlet..........................969 Installing air inlet..........................970 66 36 19 Removing and installing roof joint strip..................973 Removing roof joint strip........................973...
Page 32 einordnung Table of Contents 69 54 19 Removing and installing the contact unit..................1006 Installing contact unit .........................1006 Installing contact unit .........................1006 69 58 19 Removing and installing the driver's airbag unit...............1008 Removing driver's airbag unit ......................1008 Installing driver's airbag unit......................1008 69 59 19 Removing and installing the passenger's airbag unit..............1010 Removing passenger's airbag unit .
Page 33 einordnung Table of Contents 70 59 19 Removing and installing door trim panel Tightening torque..........................1046 70 65 19 Removing and installing oddments compartment lid..............1047 Removing and installing oddments compartment lid................1047 70 84 19 Removing and installing roof lining.....................1050 Removing roof lining.........................1050 Installing roof lining..........................1052 80 23 19 Removing and installing heat exchanger..................1055 Removing heat exchanger........................1055...
Page 34 einordnung Table of Contents 87 27 19 Removing and installing the magnetic coupling.................1076 Removing the magnetic coupling......................1076 Installing the magnetic coupling......................1076 Checking the air gap of the magnet coupling................1077 87 34 19 Removing and installing the compressor..................1078 Removing the compressor ........................1078 Installing the compressor........................1079 Running−in regulations for new compressor................1080 87 50 19 Removing and installing the condenser..................1081...
Page 35 Table of Contents 90 12 15 Setting ahead the total mileage counter in the instrument cluster..........1091 Setting ahead with the Porsche System Tester 2................1091 90 25 37 Disassembling and assembling instrument cluster..............1092 90 50 19 Removing and installing horn.......................1093 Removing horn..........................1093...
Page 36 einordnung Table of Contents 92 15 19 Removing and installing the wiper motor...................1109 Removing wiper motor........................1109 Installing wiper motor........................1109 92 19 19 Removing and installing the wiper link..................1111 Removing wiper link.........................1111 Installing wiper link...........................1111 92 27 19 Removing and installing the wiper blades...................1113 92 30 19 Removing and installing rear window wiper system..............1114 Removing rear window wiper system ....................1114 Installing rear window wiper system....................1114...
Page 37 einordnung Table of Contents 94 15 15 Left / right traffic conversion for Xenon headlights..............1127 Converting Xenon headlights......................1127 Installation............................1127 94 15 19 Removing and installing the main headlights................1129 94 23 19 Removing and installing gas discharge lamp (Xenon headlights)..........1130 Removing gas discharge lamp (Xenon headlights)................1130 Installing gas discharge lamp (Xenon headlights)................1130 94 27 19 Removing and installing bulb for parking light................1132 Removing bulb for parking light.......................1132...
Page 38 einordnung Table of Contents 94 78 19 Removing and installing front angle sensor for headlight beam adjustment ......1142 Removing front angle sensor for headlight beam adjustment............1142 Installing front angle sensor for headlight beam adjustment.............1142 94 79 19 Removing and installing rear angle sensor for headlight beam adjustment......1144 Removing rear angle sensor for headlight beam adjustment.............1144 Installing rear angle sensor for headlight beam adjustment .
Page 39 einordnung Table of Contents 96 72 19 Removing and installing signal converter/immobilizer..............1158 Removing signal converter/immobilizer ....................1158 Installing signal converter/immobilizer.....................1159 96 85 19 Removing and installing passenger compartment monitoring sensor........1160 Removing and installing passenger compartment monitoring sensor..........1160 Removing and installing passenger compartment monitoring sensor..........1160 97 09 41 Repair of main wiring harness ......................1162 Removing main wiring harness......................1162 Installing main wiring harness......................1163...
Page 40 einordnung Table of Contents 24 70 19 Removing and installing DME control module Programming the new DME control module − GT2 and version X51..........1208 Programming the DME control module 911 Turbo (996)..............1209 Programming DME control module − GT2 and version X51............1210 Version (data records) 911 Turbo (996)....................1212 Version (data records) −...
Page 41 einordnung Table of Contents 37 04 19 Removing and installing selector knob..................1240 Removing selector knob........................1240 Installing selector knob........................1240 37 30 19 Removing and installing Tiptronic control module..............1242 Removing the control module ......................1242 Installing the control module......................1244 Coding the Tiptronic control module ....................1245 Tightening torques..........................1246 Tools..............................1246 39 02 19 Removing and installing cardan shaft ..................1248...
Page 42 einordnung Table of Contents 39 58 19 Removing and installing lid for front wheel drive Tightening torques..........................1263 39 58 19 Removing and installing lid for front wheel drive..............1264 Tools..............................1264 Removing the lid for front wheel drive ....................1264 Installing the lid for front wheel drive....................1265 Tightening torques..........................1265 39 59 19 Removing and installing sealing ring for flanged shaft (front wheel drive)......1266 Tools..............................1266...
Page 43 einordnung Table of Contents 39 82 19 Removing and installing sealing ring for cardan flange .............1288 Tools..............................1288 Removing sealing ring for cardan flange...................1288 Installing sealing ring for cardan flange....................1289 Tightening torques..........................1290 39 82 19 Removing and installing sealing ring for cardan flange .............1291 Tools..............................1291 Removing and installing sealing ring for cardan flange..............1291 Removing sealing ring for cardan flange..................1291...
Page 44 einordnung Table of Contents 45 46 19 Removing and installing front ABS lead..................1320 Removing front ABS lead ........................1320 Installing front ABS lead........................1322 Tightening torques..........................1324 Tools..............................1324 45 46 19 Removing and installing rear ABS lead (Turbo & GT2)............1325 Removing rear ABS lead........................1325 Installing rear ABS lead........................1327 Tightening torques..........................1330 Tools..............................1330...
Page 45 einordnung Table of Contents 50 10 55 Replacing closing panel Tools and materials..........................1352 50 14 55 Replacing front wall ........................1353 Cutting out front wall .........................1353 Preparing front wall for installation and fitting.................1355 Welding in front wall.........................1357 Tools and materials..........................1358 50 74 55 Replacing wheel housing.......................1359 Removing wheel housing, lower shell and outer side member from the body........1359 Preparing wheel housing, lower shell and outer side member for installation and fitting ....1361...
Page 46 einordnung Table of Contents 51 45 55 Replacing lower side member − Cabriolet ...................1401 Cutting out lower side member......................1401 Preparation for installation of lower side member and fitting............1403 Welding in lower side member......................1405 Tools and materials..........................1406 51 63 19 Removing and installing deformation element ................1407 Removing deformation element .
Page 47 einordnung Table of Contents 57 51 19 Removing and installing door.......................1446 57 51 37 Disassembling and assembling door.....................1450 Disassembling door ..........................1450 Assembling door..........................1456 57 51 37 Disassembling and assembling door.....................1462 Diagram: sheetmetal clips and grommets..................1462 Basic setting of door lock........................1463 Basic setting of the door lock before installation................1464 Standardising the system........................1465 Standardising the power windows ....................1465...
Page 48 einordnung Table of Contents 64 75 19 Removing and installing side window Test and adjusting values........................1492 Tightening torques..........................1492 64 75 19 Removing and installing rear side window (Cabriolet)..............1493 Removing side window........................1493 Installing side window........................1493 Tightening torques..........................1494 Test and adjusting values........................1494 64 76 19 Removing and installing side window seal .
Page 49 einordnung Table of Contents 66 72 37 Disassembling and assembling pump unit Removing wiring harness......................1533 Installing wiring harness......................1534 Removing and installing micro switches for rear spoiler............1536 Removing micro switches......................1536 Installing micro switches......................1537 Troubleshooting..........................1537 Tools and materials..........................1538 66 85 19 Removing and installing micro switches for rear spoiler............1539 Remove micro switches........................1539 Installing micro switches........................1540 Tools..............................1540...
Page 50 einordnung Table of Contents 69 11 19 Removing and installing front three−point belt................1573 Removing front three−point belt ......................1573 Installing front three−point belt......................1575 69 11 19 Removing and installing front three−point belt − Cabriolet.............1577 Removing front three−point belt ......................1577 Installing front three−point belt......................1579 69 11 01 Checking seat belts.........................1581 Checking belt strap..........................1581...
Page 51 einordnung Table of Contents 69 77 19 Removing and installing frame for roll−over protection system..........1610 Removing and installing frame for roll−over protection system............1610 Tightening torques..........................1612 70 05 19 Removing and installing front luggage compartment trim ............1613 Removing and installing trims units....................1613 Removing and installing carpet lining....................1615 Tools and materials..........................1616 70 18 19 Removing and installing the instrument panel and instrument panel bracket −...
Page 52 einordnung Table of Contents 72 21 19 Removing and installing cushion carrier..................1658 Removing front cushion carrier......................1658 Installing front cushion carrier......................1660 72 36 19 Removing and installing motor for the lumbar support............1662 Removing lumbar adjustment device for the lumbar support ............1663 Removing motor for the lumbar support...................1664 Removing electrical line for the lumbar....................1664 Removing lumbar support.........................1664...
Page 53 Removing display and operator control unit (PCM) ................1712 Installing display and operator control unit (PCM)................1712 Connecting and switching on the Porsche System Tester 2............1712 Device code input........................1713 91 10 19 Removing and installing display and operator control unit (PCM 2) − as of MY 2003..1714 Removing display and operator control unit (PCM 2) .
Page 54 einordnung Table of Contents 91 20 02 Checking complaints about car radio system Tools..............................1732 91 24 19 Removing and installing the car radio − as of MY 2003............1733 Tools..............................1733 Removing the car radio........................1733 Installing the car radio........................1735 Teaching the car radio ........................1735 91 42 19 Removing and installing rear loudspeakers, Bose sound package..........1738 Removing rear loudspeakers......................1738 Installing rear loudspeakers.......................1739...
Page 55 97 Circuit diagram for 911 Turbo (996), '03 model ...................1789 97 Circuit diagram for 911 Turbo (996), '04 model ...................1791 97 Circuit diagram for 911 Turbo (996), '05 model ...................1793 Preconditions for using workshop documentation for Porsche vehicles..........1795 01 Mobile roofs: checking function......................1797 Checking sliding roof .........................1797 Checking convertible top........................1797...
Page 56 einordnung Table of Contents 01 Interior equipment: visual inspection for damage and soiling............1801 01 Removing transport protection......................1802 1 Removing external transport protection ..................1802 1 Removing internal transport protection..................1803 01 Installing air guides for PCCB brake discs − GT2................1804 Installing front air guides........................1804 Installing rear air guides ........................1804 01 Fitting front lip GT2..........................1806...
Page 57 einordnung Table of Contents 4 Tests / notes Spoiler setting............................1821 Racing camber values........................1822 44 Alignment card − GT2..........................1823 Suspension alignment − GT2........................1825 Suspension alignment, complete ......................1825 Driving onto measuring platform .......................1825 Tools..............................1825 Deviating points for GT2........................1826 Notes on height changes/wheel−load changes ...................1827 Vehicle height GT2..........................1828 Wheel alignment..........................1829 Front−axle camber setting......................1830...
Page 58 einordnung Table of Contents 30 50 19 Removing and installing clutch − GT2 ..................1855 Tools..............................1855 Removing clutch..........................1855 Installing clutch ..........................1856 Tightening torques..........................1856 30 50 37 Disassembling and assembling clutch − GT2................1857 34 01 55 Changing transmission oil − GT2....................1858 Changing transmission oil − GT2......................1858 Topping up transmission oil −...
Page 59 einordnung Table of Contents 34 55 37 Disassembling and assembling front transmission cover Disassembling outer bearing race ....................1878 Assembling front transmission case cover ..................1879 Fitting reverse idler gear ......................1879 Fitting cylindrical−roller bearing....................1879 Fitting outer bearing race......................1880 Tightening torques..........................1880 34 72 19 Removing and installing transmission oil pump − GT2.............1881 Tools..............................1881 Removing transmission oil pump......................1881 Installing transmission oil pump......................1882...
Page 60 einordnung Table of Contents 39 40 19 Removing and installing differential and differential lock − GT2. Tightening torques..........................1906 39 40 37 Assembling and disassembling differential and differential lock − GT2........1907 Tools..............................1907 Overview............................1907 Disassembling GKN differential lock ....................1909 Assembling GKN differential lock....................1909 Tightening torques..........................1910 46 16 24 Installing air ducts for PCCB brake discs −...
Page 61 einordnung Table of Contents 34 35 37 Disassembling transmission − GT2 Overview.............................1936 Removing shafts..........................1937 Disassembling output shaft........................1938 Overview.............................1938 Disassembling shaft ........................1939 Dismantling input shaft ........................1939 Overview.............................1939 Disassembling shaft ........................1941 34 35 37 Assembling transmission − GT2....................1942 Tools..............................1942 Assembling input shaft........................1942 Assembling shafts ........................1943 Tightening torques ........................1944...
Page 62 einordnung Table of Contents 63 15 19 Removing and installing front spoiler GT2 ................1969 Removing front spoiler........................1969 Installing front spoiler........................1971 63 15 37 Disassembling and assembling front spoiler GT2..............1973 Disassembling front spoiler.......................1973 Removing front spoiler ........................1975 Installing front spoiler........................1976 Installing front spoiler.........................1977 66 58 19 Removing and installing rear spoiler GT2................1979 Removing rear spoiler........................1979...
Page 63 einordnung Table of Contents 55 90 37 Disassembling and assembling rear lid Carrera 4S Removing and installing additional brake light.................2022 Installing rubber covering − Cabriolet....................2023 Removing and installing reflector cover....................2024 Removing and installing wiring harness....................2024 Replacing the model logo........................2025 Test and adjustment values........................2025 Tightening torques..........................2026 Materials and tools..........................2026 55 91 19 Removing and installing rear lid hinges −...
Page 64: Information On Handling Of The Gt2 Scope
Information on handling of the GT2 scope. This supplement represents the basic edition for the vehicle 911 GT2. The GT2 is recorded with the 911 Turbo in one file and is separated with a cardboard cover sheet. This supplement should be filed behind the 911 Turbo material in the file Group 3 "Transmission, manual transmission"...
Page 65: Technical Data
0 Technical data Engine Engine design Engine cooling Engine lubrication Engine control Heating Fuel system Electrical system Exhaust system Emission control Transmission Clutch Transmission Body designs Running gear Brakes Wheels and tyres Spare wheel Wheel alignment Dimensions Weights according to DIN 700 20 Filling capacities Performance data Climbing performance...
Page 66: Engine
einordnung top of page Engine Engine Engine type M96/70 No. of cylinders Bore 100 (3.94) mm (in.) Stroke 76.4 (3.01) mm (in.) Cubic capacity 3600 (219.7) (cu.in.) Compression ratio 9.4 : 1 Max. engine power 309 (420) kW (HP) as per 80/1269/EEC Net power as per SAE J1349 Engine...
Page 67: Engine Design
einordnung at engine speed 6000 Max. torque 560 (57.08) Nm (ftlb.) as per 80/1269/EEC Net torque as per SAE J1349 ftlb. at engine speed 2700 to 4600 Max. litre output 85.8 (116.6) kW/l (HP/l) HP/l (115.3) Engine speed limitation by fuel cutoff at 6750 Idle speed 740 ±...
Page 68: Engine Cooling
Camshaft adjustment Porsche VarioCam Plus with 30° adjustment Valve clearance Hydraulic valve clearance compensation Valve timing with 1 mm valve travel and zero clearance Inlet opens at 10° before TDC (kinetic clearance of the operating plunger taken Inlet closes at 20° after BDC into account, basic inlet camshaft setting early) Outlet opens at 41°...
Page 69: Heating
einordnung Ignition timing control Via DME (ECM) Spark plugs Bosch FR 5 LOC Beru 14−FR 5 LDU Electrode gap mm (in) 1.6 ± 0.2 (0.06 ± 0.008) E−gas Electronic throttle actuator control via DME ME 7.8 USA version On−Board Diagnosis II Boost pressure control Absolutely pressure−guided turbocharger control top of page...
Page 70: Exhaust System
einordnung Exhaust system Exhaust system 2−pipe, 3−way catalytic converter exhaust system, rear mufflers top of page Emission control Emission control EURO III Stereo oxygen sensor closed−loop control and 3−way catalytic converter system, each with a 2−stage catalytic converter on left+right, secondary air system, Europe OBD USA LEV Stereo oxygen sensor closed−loop control and 3−way catalytic converter system,...
Page 71: Transmission
einordnung top of page Transmission Transmission Manual Tiptronic Z front axle transmission transmission A 96.50 G 96.50 Z 96/00 Number of gears, forward/reverse Internal designation, transmission ratios (i) 1st gear 3.82 3.59 2ndgear 2.05 2.19 3rd gear 1.41 1.41 4th gear 1.12 1.00 5th gear...
Page 72: Body Designs
Running gear Front axle Spring strut axle Wheels individually suspended by control arms with trailing arms and spring struts (McPherson design, optimised by Porsche) Springs One truncated cone spring per wheel, with vibration damper inside spring Spring constant 33 N/mm Spring wire diameter 12.6 to 14.0...
Page 73: Brakes
Lining area per wheel 85 (13.08) (sq.in) Running gear control systems Standard Porsche Stability Management (PSM) with ABS, Traction Control (TC), ABD, MSR (engine drag torque control), FZR (vehicle regulator) and EBV (electronic brake distributor). Passive switching possibility for TC, FZR and MSR.
Page 74: Wheels And Tyres
einordnung Wheels and tyres Wheels and tyres Summer tyres RO (mm) Tyre size, front on wheel 225/40 ZR 18 −8 J x 18 Tyre size, rear on wheel 295/30 ZR 18 − 11 J x 18 Winter tyres ** RO (mm) Tyre size, front on wheel 225/40 R 18 88H M + S −...
Page 75: Dimensions
12.0* degrees Overhang angle, rear 13.0* degrees for USA 13.5* degrees * Design position according to Porsche definition in acc. with PN 230 top of page Weights according to DIN 700 20 Weights according to DIN 700 20 Wheel alignment...
Page 76: Filling Capacities
Permissible towed weight none none Permissible drawbar load none none Permissible roof load, kg (lbs.) with Original Porsche Roof Transport System 75 (165) 75 (165) top of page Filling capacities Note • Measurement of the engine oil level by instrument or oil dipstick! •...
Page 77: Performance Data
einordnung Manual transmission with 3.8 (0.82) l (Imp. gal.) differential Automatic transmission with torque Approx. 9,0 (1,95) l (Imp. gal.) converter Differential 1.2 (0.26) l (Imp. gal.) Specification for transmission oil Manual transmission Tiptronic (first filling) SAE 75 W90 Shell ATF 3403−M115 Mobilube PTX Specification for differential SAE 85 W 90 or...
Page 78: Climbing Performance
einordnung Climbing performance Climbing performance Manual transmission Tiptronic 1st gear 89.3 79.3 2nd gear 89.5 70.4 3rd gear 50.9 38.1 4th gear 37.4 24.3 5th gear 29.0 17.9 6th gear 21.9 − top of page Specific power Specific power Manual transmission Tiptronic 4.98 5.12...
Page 79: Entire Vehicle General
0 Entire vehicle General Lifting the vehicle top of page Lifting the vehicle CAUTION Danger of material damage if the vehicle is raised incorrectly or if the vehicle is driven incorrectly onto the lifting platform! Lift the vehicle only at the take−up points shown in the figure! •...
Page 80: Power Unit
Power unit Engine M96/70 Engine Engine design Engine cooling Engine lubrication Engine control top of page Engine M96/70 top of page Power unit...
Page 81: Engine
einordnung Engine Engine Engine type M96/70 No. of cylinders Bore 100 (3.94) mm (in.) Stroke 76.4 (3.01) mm (in.) Cubic capacity 3600 (219.7) (cu.in.) Compression ratio 9.4 : 1 Max. engine power 309 (420) kW (HP) as per 80/1269/EEC Net power as per SAE J1349 at engine speed 6000 Max.
Page 82: Engine Cooling
From the crankshaft via a gear wheel to the intermediate shaft, and from there to the exhaust and inlet camshafts via one double chain each. Camshaft adjustment Porsche VarioCam Plus with 30° adjustment Valve clearance Hydraulic valve clearance compensation Valve timing with 1 mm valve travel and zero clearance Inlet opens at 10°...
Page 83: Engine Control
einordnung Oil pressure at n = 5000 rpm Approx. 6.5 bar at 90° C Oil pressure indicator Oil pressure indicator light plus instrument Oil consumption Max. 1.0l/1000km top of page Engine control Engine control Engine control module Bosch ME 7.8 Ignition DME, individual spark coils, knock control Firing order...
Page 84: Transmission
0 Transmission 6−speed manual transmission G 96.50 Front wheel drive Z 96.00 top of page 6−speed manual transmission G 96.50 Type Code letter Equipment Installed in Model year G 96.50 − 6−speed 911 Turbo (996) 2001 General data Manual transmission G 96.50 Transmission ratios Z1 : Z2 = Z2 : Z1 1st gear...
Page 85: Front Wheel Drive Z 96.00
einordnung top of page Front wheel drive Z 96.00 Type Code letter Equipment Installed in Model year Z 96.00 − − 911 Turbo (996) world−wide 2001 General data Front−axle final drive Z 96.00 Transmission ratio, final drive (Z2 : Z1 = i) 31 : 9 = 3.44 Final drive Bevel gear drive without hypoid offset...
Page 86: Body
0 Body Body of high−strength steel 1 Body of high−strength steel 2 Water drainage plan Coupé Refrigerant circuit Component arrangement, Airbag System B05 top of page Body of high−strength steel 1 The indicated body parts are made by welding together plates of differing thicknesses and characteristics and then deep−drawing these parts.
Page 87: Body Of High−Strength Steel 1
• The use of high−strength steels for the body has an effect on body repairs. For this reason, only Original Porsche parts must be used for repair work. • Body repairs by means of reshaping are not possible if these body parts are correspondingly deformed.
Page 88: Water Drainage Plan Coupé
einordnung top of page Water drainage plan Coupé 1 Water drainage: Rear of sliding roof 2 Water drainage: Front of sliding roof 3 Water drainage: Evaporator of heating and air−conditioning system 4 Water drainage: Tank tray 5 Water drainage: Radiator tank top of page Body of high−strength steel 2...
Page 89: Refrigerant Circuit
einordnung Refrigerant circuit 1 Compressor 2 Condenser 3 Fluid tank 4 Expansion valve 5 Evaporator top of page Component arrangement, Airbag System B05 Refrigerant circuit...
Page 90 einordnung 1 Triggering unit 2 Passenger's airbag unit 3 Warning light 4 Driver's airbag unit 5 Side airbag 6 Contact unit 7 Side−airbag sensor 8 Belt buckle, driver/passenger 9 Plug connection, child restraint system 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651 Component arrangement, Airbag System B05...
Page 91: Electrics
0 Electrics Fuse assignments top of page Fuse assignments A to E Fuses (rows A...E or 1...10) Switch for retractable spoiler Replacement fuses Gripper Load Amperage rating Row A High beam headlight, right High beam headlight, left Side lights, right Side lights, left Number plate light, instrument lighting Seat heating...
Page 92 einordnung Instrument cluster, Tiptronic, PSM/ASR button, diagnosis, convertible−top drive Hazard warning light Horn Engine−compartment fan Reversing lights, convertible−top drive control module, mirror and mirror memory Direction indicator light, power window touch−control enabling Brake lights, cruise control Control modules for central locking system, alarm system, DME, Tiptronic Control module for ABS/ASR/PSM, Traction Control Instrument cluster, diagnosis, headlight beam adjustment Row C...
Page 93 einordnung Row E Terminal 86 S, instrument cluster, radio, daytime driving light, control modules for central locking, alarm system, information system, roll−over sensor Control module for seat memory Control module memory for seat adjustment, left Control module memory for seat adjustment, right Information system Terminal 30, telephone, navigation control module Air conditioning...
Page 94: Power Supply
0 Power supply Work instructions after disconnecting the battery Control module memories Supply voltage fault entry Test drive after connecting the battery 2470 DME control module 3730 Tiptronic 6452 Power windows 90 25 Instrument cluster 9030 Clock 9023 Fuel level display 9120 Radio 9110 PCM top of page...
Page 95: Supply Voltage Fault Entry
einordnung top of page Supply voltage fault entry Problem Remedy The entry "supply voltage" could be stored in various control Delete the "supply voltage" modules if the battery has been completely discharged. entry from the control modules in question. top of page Test drive after connecting the battery Note •...
Page 96: Tiptronic
einordnung top of page 3730 Tiptronic Problem Remedy The stored pressure adaptation values are lost if the power Carry out a test drive and drive the supply to terminal 30 is interrupted. This can result in poor vehicle with different loads and at shifting quality and rough shift operations during the different speeds so that all shift adaptation phase.
Page 97: Fuel Level Display
2. If the code card is unavailable, the radio code can also be read from the DME control module (under "Vehicle data"). 3. This code is also available from the Porsche IPAS. top of page 9110 PCM Problem Remedy...
Page 98 PCM code can also be read from the DME disconnected and is thus no longer control module (under "Vehicle data"). ready for operation. 2. This code is also available from the Porsche IPAS. • When the power supply is 3. Switch on the PCM with a free panoramic disconnected, the built−in GPS...
Page 99: General Maintenance: Test Drive
01 General maintenance: Test drive Note Note The following test items are included in the test drive. • Checking footbrake operation and actuation travel. Actuating clutch, checking operation. Actuating steering, checking operation. Shifting gear, checking operation. Parking assistant: Selecting reverse gear and checking operation. Activating the automatic cruise control during the test drive and checking operation.
Page 100: Diagnostic System: Read Out Fault Memory And Activate Systems
The work procedure is menu−prompted, the Tester instructions have highest priority, further actuation is specified using the arrow symbols e.g., >> . 1. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch on ignition. Press >> to continue.
Page 101: Load Navigation
einordnung • All control modules are read out automatically one after the other. 2. Control modules showing an error have an asterisk in front of their designation >> *DME. 3. Select these control modules, select Read out fault memory menu. 4.
Page 102: Battery: Checking The Charge State
01 Battery: checking the charge state Tools Checking charge state with battery tester top of page Tools Item Designation Source Remarks Battery rapid−start charger see Workshop Equipment Manual, Chapter 3 top of page Checking charge state with battery tester Note •...
Page 103: Windscreen Wiper/Washer System, Headlight Washer
01 Windscreen wiper/washer system, headlight washer Caution Mix ratio of fluids for windscreen washer system CAUTION Danger of material damage if headlights are cleaned incorrectly! • Use only soapy water to clean the exterior lights and the plastic headlight lenses! Never use chemical cleaning agents! •...
Page 104: Checking The Function Of The Vehicle's Lights And The Headlight Setting
01 Checking the function of the vehicle's lights and the headlight setting Checking the adjustment of the headlights Adjusting the main headlights Adjusting the main headlights, USA version Fog light adjustment Vehicle lights: • Switch on the ignition, and switch through all exterior and interior light functions in turn. Check the function of the exterior lighting with the help of a second person.
Page 105: Adjusting The Main Headlights
einordnung 2. To do this, line up the left, horizontal section of the light/dark limit (when driving on the right) with the dotted horizontal line of the adjustment unit. Note • The distance between the headlights and the adjustment unit should be as small as possible! It should not exceed 30 cm, because if the distance is greater, it is no longer possible to define the •...
Page 106: Adjusting The Main Headlights, Usa Version
einordnung • Only the lower screw may be turned for height adjustment; for lateral adjustment the upper and lower screws must be turned in the same direction and for the same number of rotations! 5. Make the adjustment with the vehicle ready for driving (fuel tank full, driver's seat occupied by a person or 75 kg, the tyre pressure must correspond to the stipulated values) using a headlight adjustment unit.
Page 107 einordnung Make the adjustment with the vehicle ready for driving (fuel tank full, driver's seat occupied by a person or 75 kg, the tyre pressure must correspond to the stipulated values) using a headlight adjustment unit. C Fog light adjustment Note •...
Page 108: Checking The Function Of Electrical Equipment, As Well As The Indicator And Warning Lights
01 Checking the function of electrical equipment, as well as the indicator and warning lights Turn ignition key and check function of warning and indicator lights (visual inspection). Actuate power windows and check operation. Check that rear window heater is in working order. Adjust heater blower and fans to high and low and check the air vents for air throughput.
Page 109: Alarm System: Checking Operation Of Indicators
01 Alarm system: checking operation of indicators Vehicle must be unlocked and the sales check step − Diagnostic system: systems activated and fault • memory read out − must be carried out. 1. Lock vehicle with the remote control. Shortly after locking, the alarm system horn should not issue a warning tone.
Page 110: Activating/Deactivating The Parking Aid
01 Activating/deactivating the parking aid Note General Activating the parking aid without PST 2 Deactivating the parking aid without PST 2 Activating the parking aid with PST 2 Selecting door mirror to be lowered, left/right Adjusting the lowering angle for the passenger door mirror Deactivating the parking aid with PST 2 Note •...
Page 111: Deactivating The Parking Aid Without Pst 2
einordnung • The parking aid is activated for the respective seat position saved! Activation of the parking aid must be carried out individually for every seat position! • top of page Deactivating the parking aid without PST 2 1. Switch ignition on. 2.
Page 112: Selecting Door Mirror To Be Lowered, Left/Right
einordnung top of page Selecting door mirror to be lowered, left/right Note • The door mirror (left/right) can be adjusted with the PST 2 only! 1. Connect the PST2 with the ignition off, then switch the ignition on. 2. Switch on the PST2 and wait for the start−up screen. 3.
Page 113: Deactivating The Parking Aid With Pst 2
einordnung • The lowering angle is now set! top of page Deactivating the parking aid with PST 2 1. Connect the PST2 with the ignition off, then switch the ignition on. 2. Switch on the PST2 and wait for the start−up screen. 3.
Page 114: Removing Transport Lock (Spring Strut Locking Devices) Turbo And Gt2
The spring strut locking devices must be removed before a test drive and before the vehicle is handed over to the customer! Note • Send the removed spring strut locking devices to the Porsche Warranty Test Office in Ludwigsburg! • Include the spring strut locking devices with the normal warranty goods consignment! top of page...
Page 115 einordnung 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841 Removing spring strut locking devices...
Page 116: Technical Data Gt2
Technical Data Engine Engine design Engine cooling Engine lubrication Engine control Fuel system Electrical system Exhaust system Emission control top of page Technical Data...
Page 117: Engine
einordnung Engine Engine Engine type M96/70 S Bore mm (in.) 100 (3.94) Stroke mm (in.) 76.4 (3.01) Cubic capacity cm³ (cu. in.) 3600 (219.7) Compression ratio 9.4:1 Max. engine power as per 80/1269/EEC at engine speed 5700 Max. torque Nm (ftlb.) 620 (63.20) at engine speed 3500 −...
Page 118: Engine Cooling
einordnung Timing with 1 mm valve travel Inlet closes 20° after BDC Outlet opens 41° before BDC Outlet closes 9° before TDC Intake system Tuned−intake system top of page Engine cooling Engine Water cooling; 3 radiators ahead of the front wheels. Two electric fans, controlled in cooling three stages top of page...
Page 119: Fuel System
einordnung top of page Fuel system Injection ME 7.8 (Digitale−Motor−Electronic) Injection valves controlled sequentially Fuel supply 1 electrical internal gear pump with 2 additional sucking jet pumps Fuel required RON 98 unleaded top of page Electrical system Radio interference suppression ECE−R 10 and 95/54/EC Rated voltage 12 V...
Page 120: Technical Data
Technical data Engine Engine design Engine cooling Engine lubrication Engine control Fuel system Electrical system Exhaust system Emission control top of page Technical data...
Page 121: Engine
einordnung Engine Engine Engine type M96/70 Bore mm (in.) 100 (3.94) Stroke mm (in.) 76.4 (3.01) Cubic capacity cm³ (cu. in.) 3600 (219.7) Compression ratio 9.4:1 Max. engine power as per 80/1269/EEC at engine speed 6000 Max. torque Nm (ftlb.) 560 (57.08) at engine speed 2700−4600...
Page 122: Engine Cooling
einordnung Timing with 1 mm valve travel Inlet closes 20° after BDC Outlet opens 41° before BDC Outlet closes 9° before TDC Intake system Tuned−intake system top of page Engine cooling Engine Water cooling; 3 radiators in front of the front wheels. Two electric fans, controlled in cooling three stages top of page...
Page 123: Fuel System
einordnung top of page Fuel system Injection ME 7.8 (Digitale−Motor−Electronic − engine control module ECM) Injection valves controlled sequentially Fuel supply 1 electrical internal gear pump with 2 additional sucking jet pumps Fuel ROZ 98 required top of page Electrical system Radio interference suppression ECE−R 10 and 95/54/EC Rated voltage...
Page 124: Precautionary Measures When Working On Fuel System
Precautionary measures when working on fuel system Caution CAUTION Danger of fire and injury! Danger of fire due to escaping fuel, e.g. on hot engine components or due to electrostatic charge. • • Danger of fire due to naked flame and flying sparks, e.g. during welding or sanding work •...
Page 125: Diagnostic System: Reading Out Fault Memory
Reading out fault memory The method of reading out the fault memory is described in the operating instructions for the Porsche System Tester 2. The operating instructions are supplied with each Tester. The Porsche System Tester 2 is connected to the vehicle via a 16−pin diagnosis socket.
Page 126: General Maintenance: Test Drive
03 General maintenance: test drive Note Note The following test items are included in the test drive. • Actuating the remote control of the central locking and checking operation. Front seats: Checking adjustment possibilities for operation. Checking footbrake operation and actuation travel. Starting engine, checking operation.
Page 127: Removing And Installing Drive Belt
03 Removing and installing drive belt Removal overview of the drive belt (engine installed) Installation overview of the drive belt (engine installed) To check the drive belt, it must be removed and installed. Procecedure is described below. top of page Removal overview of the drive belt (engine installed) 1 Removing air cleaner assembly 2 Loosening servo pump wheel...
Page 128: Installation Overview Of The Drive Belt (Engine Installed)
einordnung 3 Relieving drive belt 4 Removing servo pump wheel 5 Removing drive belt Check the drive belt for any cracks, flaws, and other damage. Replace if necessary. Note • The drive belt must be replaced at 60,000 miles for USA vehicles, and at 80,000 km or 48,000 miles for RoW vehicles, according to the maintenance plan.
Page 129 einordnung 1 Fitting the drive belt 2 Positioning servo pump wheel 3 Tensioning the drive belt 4 Tightening the fastening screws on servo pump 5 Installing the air cleaner assembly 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651 Installation overview of the drive belt (engine installed)
Page 130: 56 19 Removing And Installing Bulb For Direction Indicator Light
94 56 19 Removing and installing bulb for direction indicator light Removing bulb for direction indicator light Installing bulb for direction indicator light top of page Removing bulb for direction indicator light 1. Switch off light. Remove main headlight. 2. Turn bulb socket counter−clockwise and remove from the headlight housing. 3.
Page 131: Changing The Engine Oil And Oil Filter
03 Changing the engine oil and oil filter Caution WARNING Danger of scalding from draining oil! • Wear protective equipment specified. 1. Undo the oil drain plug on the crankcase and drain off the engine oil. 2. Undo the oil drain plug on the oil container and drain off the oil. An open−ended wrench must be used to counter it in order to avoid damage to the oil container.
Page 132 einordnung 4. Loosen the oil filter with special tool release key 9204 . 5. Change the oil filter element. To do this, pull the oil filter element out and replace the filter element and the two O−rings. 1 Oil filter cover 2 O−ring 71.5 x 3.5 3 O−ring 10 x 2 4 Oil filter element...
Page 133 einordnung Remove the remaining quantity of oil from the oil filter housing by suction. 6. Clean oil drain plugs. Always replace the sealing rings. Make sure that the sealing ring on the oil container is 2 mm thick. Tighten the drain plug on the crankcase to 70 Nm (52 ftlb.) those on the oil container to 60 Nm (44 ftlb.), and the drain plugs on the turbocharger to 30 Nm (22 ftlb.).
Page 134 einordnung • The vehicle must not be moved during the check Location Thread Tightening torque Nm (ftlb.) Oil drain plug on crankcase M20 x 1.5 70 (52) Oil drain plug for oil container M20 x 1.5 60 (44) Oil drain plug for turbocharger M18 x 1.5 30 (22) Oil filter cover...
Page 135: Changing The Engine Oil (Without Oil Filter)
03 Changing the engine oil (without oil filter) Caution WARNING Danger of scalding from draining oil • Wear protective clothing specified! 1. Undo the oil drain plug on the crankcase −arrow− and drain off the engine oil. Then equip the drain plug with a new sealing ring and tighten to a torque of 70 Nm (52 ftlb.).
Page 136 einordnung 5. Check engine oil level. Check engine oil level on the instrument cluster. Top up engine oil until the 7th segment of the on−board computer display lights up. The following conditions must be maintained for the measurement. • Vehicle horizontal •...
Page 137: Replacing Spark Plugs
03 Replacing spark plugs Removing spark plugs Installing spark plugs top of page Removing spark plugs CAUTION Danger of material damage if the vehicle is raised incorrectly or if the vehicle is driven incorrectly onto the lifting platform! • Lift the vehicle only at the take−up points shown in the figure! •...
Page 138: Installing Spark Plugs
einordnung 4. Remove heat shield. Remove the heat shields located above the exhaust system. 5. Remove shield. Remove the shields above the plug coils. Unscrew the two hexagon head bolts for this purpose. 6. Undo hexagon socket head bolts −arrows− of the ignition coils. 7.
Page 139 einordnung Tighten spark plugs with commercially available tool spark plug socket wrench No.14 . 3. Push on the ignition coils again. 4. Tighten hexagon socket heat bolts −arrows− for the ignition coils to 10 Nm (7.5 ftlb.). 5. Fit shields. Reinstall the shields above the ignition coils and tighten the screws to 10 Nm (7.5 ftlb.). 6.
Page 140: Checking Cooling System
• Only original Porsche antifreeze should be used when changing or topping up the coolant. 1. Check antifreeze content: Open the lid on the coolant expansion tank and check the antifreeze content with a frost protection testing device.
Page 141 einordnung Workshop Equipment Manual, Chapter 2.4, No. 160 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651 Coolant: checking level, antifreeze content and leaks...
Page 142: Replacing Air Cleaner Element
03 Replacing air cleaner element Removing air cleaner Installing air cleaner top of page Removing air cleaner 1. Pull off hot film mass air flow sensor. Push the plug downwards and press the grooved surface at the sides. Pull the plug up and off at the same time.
Page 143 einordnung Refit the retaining clips immediately. 3. Undo hose clamp. Undo the hose clamp −arrow− between the air cleaner housing and the intake pipe. 4. Remove air cleaner housing. Unscrew the fastening screw M6 x 34 at the rear of the air cleaner housing.
Page 144: Installing Air Cleaner
einordnung 7. Open air cleaner housing. To do this, open the screws −arrows− and pull the two housing halves apart. 8. Take out the cleaner element. c. Take out the air cleaner element. d. Wipe out the two housing halves with a cloth.
Page 145 einordnung 1. Insert filter element. a. Insert the filter element into the cleaned air cleaner housing. b. Retighten the two air cleaner housing halves with the screws −arrow− 2. Clip in hot film mass air flow sensor cable. Insert the cable into the omega clip on the left air cleaner housing side and then close the clip.
Page 146 einordnung 3. Place the air cleaner housing in the engine compartment as shown and move into installation position. c. Turn the housing to the right by approx. 90° and push the rubber hose over the flange. d. Swivel the housing downwards by 90°.
Page 147 einordnung 6. Attach the connecting hose between the left turbocharger and the intake distributor. Note • The hose must engage audibly! 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651 Installing air cleaner...
Page 148: Replacing The Fuel Filter
03 Replacing the fuel filter 1. Disconnect plug on the hot film mass air flow meter. To do this, push the plug downwards and press on the grooved surface at the sides. Pull the plug up and off at the same time. 2.
Page 149 einordnung 7. Pull off the ground cable from the fuel filter. 8. Undo fuel pressure line. Make sure to counter with a wrench when doing this. Collect emerging fuel. 9. Disconnect the plug connection and collect the residual fuel. Protect open lines against dirt. 10.
Page 150 einordnung 12. Push the new fuel filter into the restraining strap and tighten again. Position the filter in such a way that the mark −arrows− on the filter is aligned with the outer edge of the holder in installation position. 13.
Page 151 einordnung Clip in hot film mass air flow sensor cable. To do this, insert the cable into the omega clip on the left air cleaner housing side and then close the clip. 18. Place the air cleaner housing in the engine compartment as shown and move into installation position.
Page 152: Clutch: Checking The Play And Pedal End Position
03 Clutch: checking the play and pedal end position Checking clutch free play Checking the pedal end position (pedal return/return force) top of page Checking clutch free play The clutch master cylinder has an inner stop. The push rod and the clutch pedal are always pressed against this stop by the boost spring.
Page 153: Changing Transmission Oil
Changing transmission oil Note • Top up only with transmission oil approved by Porsche. See Parts Catalogue! Filling capacity: 3.8 litres Change quantity: 3.0 litres 1. Place oil collection pan under the transmission. 2. Unscrew the oil filler screw and drain plug and drain the oil with the vehicle horizontal.
Page 154: Checking And Topping Up The Atf
Tools Item Special tool designation Remarks Connection hose 9507/1 top of page Checking and topping up the ATF Note • Top up only with ATF approved by Porsche. See Parts Catalogue! 03 Checking and topping up the ATF...
Page 155 • The vehicle must stand horizontally. 1. Place oil collection pan under the transmission. 2. Connect the Porsche System Tester 2 and call up the ATF temperature. Note • The ATF temperature must not be higher than 40 °C at the start of the test.
Page 156: Tightening Torques
einordnung with step 10. Note • The control screw must be closed no later than when an ATF temperature of 45 °C is reached. 5. If no ATF escapes from the control bore even though approx. 40 °C has been reached, the ATF must be topped up.
Page 157: Replacing Atf
Replacing ATF fluid Note • Top up only with ATF approved by Porsche. See Parts Catalogue! Filling capacity: approx. 9.0 litres Change quantity: approx. 4.5 litres 1. Place oil collection pan under the transmission. 03 Replacing ATF...
Page 158 einordnung 2. Unscrew drain screw −A− and drain ATF. Note • Without ATF, the engine must not be started and the vehicle must not be towed. 3. Replace sealing ring for drain plug and screw in plug. Tightening torque: 22 Nm (16 ftlb.) 4.
Page 159: Tightening Torques
7. Connect the Porsche System Tester 2 and call up the ATF temperature. 8. Move selector lever to position "P" and allow engine to idle. 9. With engine running, top up ATF again until excess ATF emerges from the bore of the ATF control screw −B−...
Page 160: Removing And Installing Atf Filter
03 Removing and installing ATF filter Tools Removing ATF filter Installing ATF filter Tightening torques top of page Tools Item Special tool designation Remarks Connection hose 9507/1 top of page Removing ATF filter 1. Remove underbody panels, rear and centre. 2.
Page 161: Installing Atf Filter
einordnung 3. Disengage cable on the retaining clips of the ATF pan. 4. Place oil collection pan under the transmission. 5. Unscrew drain screw −A− and drain ATF. Note • Without ATF, the engine must not be started and the vehicle must not be towed. 6.
Page 162: Tightening Torques
einordnung top of page Tightening torques Location Thread Tightening torque Nm (ftlb.) Drain plug to ATF pan M 10 22 (16) ATF pan to transmission 8 (6) Transmission cross member to body M 10 65 (48) 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651 Installing ATF filter...
Page 163: Replacing And Checking Transmission Oil In Final Drive
Special tool designation Remarks Filling system V.A.G 1924 top of page Changing transmission oil in final drive Note • Use only oils approved by Porsche. See Parts Catalogue! Filling capacity: 1.2 litres 03 Replacing and checking transmission oil in final drive...
Page 164 einordnung 1. Unscrew oil filler plug −A− . 2. Unscrew oil drain plug −arrow− . Drain oil with vehicle standing horizontally. 3. Clean the drain plug and filler plug. 4. Replace sealing rings for the drain plug and filler plug. Note •...
Page 165: Tightening Torques
einordnung Tightening torques Location Thread Tightening torque Nm (ftlb.) Oil drain plug M21 x 1.5 25 (19) Oil filler plug M18 x 1.5 22 (16) 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651 Tightening torques...
Page 166: Changing Transmission Oil In Front Wheel Drive
Tightening torques top of page Changing transmission oil in front wheel drive Note • Use only oils approved by Porsche. See Parts Catalogue! Filling capacity: approx. 1.5 litres 1. Remove underbody cover (front). 2. Unscrew oil filler plug −A− .
Page 167 einordnung 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651 Tightening torques...
Page 168: Changing Transmission Oil − Gt2
Tightening torques Total capacity: 3.7 + 0.1 litres Oil change quantity: 3.2 + 0.1 litres Note Use only oils approved for this type by Porsche. See Parts Catalogue. • top of page Changing transmission oil − GT2 1. Remove rear, centre and left underbody trim.
Page 169: Tightening Torques
einordnung Tightening torques Location Thread Tightening torque Nm (ftlb.) Oil filler plug M22 x 1.5 30 (22) Oil drain plug M22 x 1.5 30 (22) 996840, 996841 Tightening torques...
Page 170: Steering Gear: Fluid Level And Bellows
03 Steering gear: fluid level and bellows Power steering: checking the fluid level Steering gear: visual inspection of the bellows top of page Power steering: checking the fluid level General Damage to the power steering is caused by a shortage of oil in the hydraulic system. Even small leaks can cause the fluid to escape and damage the servo pump as a result of the high oil pressure occurring in the hydraulic circuit.
Page 171 einordnung • There are two marks on the dipstick located on the reservoir cap. One side bears the mark Cold for a cold engine (approximately 20° C) and the other Hot for a hot engine (approximately 80° C). • Check the fluid level (Pentosin CHF 11 S) with the engine stationary and cold (approx. 20 °C). CAUTION Danger of damage to property if too much Pentosin CHF 11 S is filled or if it comes in contact with the coolant hoses when topping up or filling in.
Page 172: Steering Gear: Visual Inspection Of The Bellows
einordnung Steering gear: visual inspection of the bellows Note • The bellows on the steering gear can be damaged by outside influences for example, by stone damage or during assembly work. • The steering gear can become leaky if dirt or moisture enter a leaky bellows. Visually inspect the bellows for damage.
Page 173: Axle Joints/Drive Shafts
03 Axle joints/drive shafts Tie rod ends: checking the play and dust bellows Axle joints: checking the play and dust bellows Drive shafts: visual inspection of the boots top of page Tie rod ends: checking the play and dust bellows Note The rubber dust bellows and bellows on the steering gear and on the tie rods can be damaged by •...
Page 174: Drive Shafts: Visual Inspection Of The Boots
einordnung 3. Inspect the dust bellows of the axle joints (ball joints) on the suspension (front and rear) as follows: Put the vehicle onto a lifting platform with the steering lock disengaged. • • Perform a visual inspection after cleaning. Note •...
Page 175: Running Gear Adjustment/Storage Of Assemblies
03 Running gear adjustment/storage of assemblies Running gear adjustment (wheel alignment values) Storage of assemblies and running gear top of page Running gear adjustment (wheel alignment values) Check that the screw connections of the running gear adjustment facility (wheel alignment values) at the front and rear are secure.
Page 176: Tyres And Spare Wheel: Checking Condition And Tyre Pressure
03 Tyres and spare wheel: checking condition and tyre pressure Checking condition Tyre pressure for cold tyres (approx. 20 °C) top of page Checking condition Tyres are a safety element that fulfil the demands placed on them only if they have the correct air pressure and a sufficient tread depth.
Page 177 einordnung • 911 GT2 M002 = road version 911 GT2 M003 = Club Sport version • 18−inch wheels, summer and winter tires Front 2.2 bar overpressure Rear 2.7 bar overpressure Collapsible wheel not present • Spare wheel/collapsible wheel not available! However there is a tyre repair kit in the luggage compartment which can be used to repair the damaged tyre in the event of damage.
Page 178: Checking And Changing The Brake Fluid
03 Checking and changing the brake fluid Checking the brake fluid level Changing the brake fluid top of page Checking the brake fluid level 1. Visually inspect brake fluid level. Note • The brake fluid level must be between min. and max.. •...
Page 179 einordnung 3. Switch on the bleeding device. Bleeding pressure is approximately 2.0 bar. Note • Drain brake fluid on every brake caliper on both bleeder valves. • Use a transparent hose and a collecting bottle to check the escaping brake fluid accurately for cleanliness, lack of air bubbles and to determine the brake fluid used.
Page 180: Parking Brake: Checking The Free Play Of The Parking Brake Lever
03 Parking brake: checking the free play of the parking brake lever Parking brake: checking the free play of the parking brake lever top of page Parking brake: checking the free play of the parking brake lever Checking the free play of the handbrake lever. The parking brake has asbestos−free brake linings.
Page 181 einordnung 6. Repeat the procedure on the other wheel. 7. Pull up the parking brake lever by 2 teeth and adjust the adjustment nut of the turnbuckle until both wheels can be turned manually with difficulty. 8. Release the parking brake lever and check whether both wheels can be turned freely.
Page 182: Visual Inspection: Brake Lines/Brake Pads/Brake Discs
03 Visual inspection: brake lines/brake pads/brake discs Brake hoses and lines Brake system: visual inspection of the brake pads and brake discs for wear top of page Brake hoses and lines Carry out visual inspection for leaks, damage, routing and corrosion.
Page 183 einordnung 2. Visually inspect the brake pads for wear (wear limit 2 mm). 3. Carry out visual inspection of the brake discs for wear. 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841 Brake system: visual inspection of the brake pads and brakediscs for wear...
Page 184: Checking The Wheel Mounting
03 Checking the wheel mounting Use suitable commercially available tools (wrench size 19 mm) together with a tested torque wrench , • covering the range of 130 Nm (96 ftlb.). Never use an impact bolter. • Do not loosen the wheel bolts to check the tightness. Tighten the wheel bolts or check for tightness (tightening torque 130 Nm (96 ftlb.)).
Page 185: Checking Lid And Doors
03 Checking lid and doors Checking lid lock, front and rear Checking safety hook, front lid Function test, checking door lock Functional inspection of the tank cap lock Checking door and lid tightening torques Checking inner release of luggage compartment (Trunk Entrapment) Tightening torques top of page Checking lid lock, front and rear...
Page 186: Functional Inspection Of The Tank Cap Lock
Check whether the upper part of the lock automatically disengages from the lower part of the lock. 1. Engage the upper part of the lock No. 996 551 051 02 = tool (Porsche spare part) in the lower part of the lock −direction of arrow−...
Page 187: Tightening Torques
einordnung Tightening torques Tightening torque Location Illustration Thread [Nm] (ftlb.) Fastening screws of upper part of the lid lock on front 10 (7.5) cover (ftlb.) Fastening screws of lower part of the lid lock on front 10 (7.5) closing panel (ftlb.) Fastening screws on door lock on the doors 20 +2 (15 +...
Page 188: Checking Seat Belts
03 Checking seat belts Functional inspection Condition inspection top of page Functional inspection It must be possible to unroll the belt strap smoothly from the belt retractor via the deflector fitting by • pulling evenly, and the tongue of the seat belt must engage audibly in the buckle •...
Page 189: Inspecting The Airbag System
Danger of injury and damage to property as a result of incorrect handling of airbag units! Always observe the safety regulations for handling airbag units ’ 6, 69 Safety regulations for handling airbag and belt tensioner units . Connect and switch on the Porsche System Tester. Switch on ignition.
Page 190 einordnung control module. Read out fault memory: No fault stored. Pull off fuse according to the circuit diagram. Fault present after approx. 30 seconds >> Airbag warning light<<. Insert E1 fuse again. Clear fault memory. Read out fault memory again after approx. 30 seconds: No fault stored.
Page 191: Passenger Protection Maintenance: Checking Roll−Over Protection System
> Repairs to the roll−over bar and actuators are not permitted. Note • The roll−over bar must be triggered every two years at the latest, using the Porsche System Tester. • Perform the function test on the roll−over protection system only with >> the hardtop and covering cap removed <<...
Page 192: Particle Filter: Replacing The Filter Element
03 Particle filter: replacing the filter element Removing particle filter Installing particle filter Replacing filter element (with and without carbon). Note • The particle filter is installed on the right in front of the heating/air−conditioning system! top of page Removing particle filter 1.
Page 193: Checking The Function Of The Vehicle's Lights
03 Checking the function of the vehicle's lights Adjusting the main headlights Setting Adjusting the main headlights, USA version Fog light adjustment Removing main headlight Installing main headlight top of page Adjusting the main headlights 1. Open the luggage compartment lid. 2.
Page 194: Setting
einordnung 5. Make the adjustment with the vehicle ready for driving (fuel tank full, driver's seat occupied by a person or 75 kg, the tyre pressure must correspond to the stipulated values) using a headlight adjustment unit. A Lateral adjustment B Height and lateral adjustment C Fog light adjustment top of page...
Page 195: Adjusting The Main Headlights, Usa Version
einordnung Adjusting the main headlights, USA version Note • A new adjustment may only be made in the case of accident repairs or replacement of the main headlights! Vertical and horizontal adjustment must be carried out with a headlight adjustment unit.
Page 196: Installing Main Headlight
einordnung 1. Release the side carpet by unscrewing plastic nut −A− −arrow− . 2. Pull rubber stopper −B− off the release opening. 3. Place the socket wrench from the tool kit on the release axle. 4. The toggle of the socket wrench should point horizontally to the rear. 5.
Page 197 einordnung 1. Insert the headlight into the guide rails and push it fully into the wing −arrow− . 2. Press the headlight to the rear, turning the socket wrench at the same time until the wrench points horizontally to the rear −arrow C− . In the process, the headlight lock must engage with an audible and perceptible click.
Page 198: Windscreen Wiper/Washer System, Headlight Washer
03 Windscreen wiper/washer system, headlight washer Caution CAUTION Danger of material damage if headlights are cleaned incorrectly! Use only soapy water to clean the exterior lights and the plastic headlight lenses! • • Never use chemical cleaning agents! • To avoid scratches, do not rub with dry or only damp cloths, paper towels or insect−removal sponges! Note •...
Page 199: Checking The Function Of Electrical Equipment, As Well As The Indicator And Warning Lights
03 Checking the function of electrical equipment, as well as the indicator and warning lights Turn ignition key and check function of warning and indicator lights (visual inspection). Actuate power windows and check operation. Check that rear window heater is in working order. Adjust heater blower and fans to high and low and check the air vents for air throughput.
Page 200: Additional Maintenance − Usa
03 Additional maintenance − USA Caution Additional maintenance, replacing spark plugs Additional maintenance every 60,000 mls/96,000 km Additional maintenance every 90,000 mls/144,000 km Maintenance every 2 years Maintenance after 4, 8, 10 then every 2 years WARNING Damage is possible if the wrong maintenance schedules are used for reimported vehicles! These maintenance schedules are invalid for RoW (rest of world) vehicles and for vehicles reimported •...
Page 201: Additional Maintenance Every 90,000 Mls/144,000 Km
Final drive, front: change oil => Changing transmission oil in front wheel drive top of page Maintenance every 2 years Maintenance every 2 years Change brake fluid (use only original Porsche brake fluid) => Checking and changing the brake fluid Condition report preparing long−life guarantee...
Page 202: Additional Maintenance − As Of My 2004
03 Additional maintenance − as of MY 2004 Note Additional maintenance, replacing spark plugs Additional maintenance every 80,000 km/48,000 mls Additional maintenance every 160,000 km/96,000 mls Maintenance every 2 years Maintenance after 4, 8, 10 then every 2 years Note •...
Page 203: Maintenance Every 2 Years
Maintenance every 2 years Maintenance every 2 years Change brake fluid (use only original Porsche brake fluid) => Checking and changing the brake fluid Check roll−over protection system (only 911 Turbo Cabrio) => Passenger protection maintenance&colon; checking roll−over protection system Condition report preparing long−life guarantee...
Page 204: Additional Maintenance − Usa − As Of My 2004
03 Additional maintenance − USA − as of MY 2004 Caution Additional maintenance, replacing spark plugs Additional maintenance every 60,000 mls/96,000 km Additional maintenance every 90,000 mls/144,000 km Maintenance every 2 years Maintenance after 4, 8, 10 then every 2 years WARNING Damage is possible if the wrong maintenance schedules are used for reimported vehicles! These maintenance schedules are invalid for RoW (rest of world) vehicles and for vehicles reimported...
Page 205: Additional Maintenance Every 90,000 Mls/144,000 Km
Maintenance every 2 years Maintenance every 2 years Change brake fluid (use only original Porsche brake fluid) => Checking and changing the brake fluid Check roll−over protection system (only 911 Turbo Cabrio) => Passenger protection maintenance&colon; checking roll−over protection system Condition report preparing long−life guarantee...
Page 206 einordnung 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841 Maintenance after 4, 8, 10 then every 2 years...
Page 207: Additional Maintenance
03 Additional maintenance Note Additional maintenance, replacing spark plugs Additional maintenance every 80,000 km/48,000 mls Additional maintenance every 160,000 km/96,000 mls Maintenance every 2 years Maintenance after 4, 8, 10 then every 2 years Note • Not valid for USA. •...
Page 208: Maintenance Every 2 Years
Final drive, front: change oil => Changing transmission oil in front wheel drive top of page Maintenance every 2 years Maintenance every 2 years Change brake fluid (use only original Porsche brake fluid) => Checking and changing the brake fluid Condition report preparing long−life guarantee...
Page 209: Technical Data
3 Technical data 6−speed manual transmission G 96.50 Front wheel drive Z 96.00 top of page 6−speed manual transmission G 96.50 Type Code letter Equipment Installed in Model year G 96.50 − 6−speed 911 Turbo (996) 2001 General data Manual transmission G 96.50 Transmission ratios Z1 : Z2 = Z2 : Z1 1st gear...
Page 210: Manual Transmission Tightening Torques
einordnung Manual transmission tightening torques Location Thread Tightening torque Nm (ftlb.) Drain plug for transmission oil 30 (22) Filler plug for transmission oil 30 (22) Transmission on engine 45 (33) Air flanges on transmission 10 (7.5) Slave cylinder on transmission M10 x 35 45 (33) Bracket for slave cylinder on transmission...
Page 211: Front−Axle Drive Tightening Torques
einordnung General data Front−axle final drive Z 96.00 Transmission ratio, final drive (Z2 : Z1 = i) 31 : 9 = 3.44 Final drive Bevel gear drive without hypoid offset Filling capacity approx. 1.5 l Front−axle drive tightening torques Location Thread Tightening torque Nm (ftlb.) Screw plug, oil drainage and oil filling...
Page 212: Technical Data
3 Technical data 5−speed Tiptronic transmission A 96.50−150 Front wheel drive Z 96.00 top of page 5−speed Tiptronic transmission A 96.50−150 Type Code letter Equipment Installed in Model year A 96.50−150 − 5−speed 911 Turbo (996) 2001 Note • In order to protect the converter components from excessive centrifugal forces with the vehicle stationary, this car has been equipped with torque converter centrifugal force protection .
Page 213: Tightening Torques For Tiptronic Transmission
einordnung 4th gear 1.00 5th gear 0.83 Reverse gear 1.93/3.16 Final drive Bevel gear drive Final drive ratio (without spur gear) 9 : 34 = 3.77 Filling capacity, rear−axle final drive 1.2 l Automatic section: new filling (with torque approx. 9.0 l converter) Change quantity approx.
Page 214: Front Wheel Drive Z 96.00
einordnung Front wheel drive Z 96.00 Type Code letter Equipment Installed in Model year Z 96.00 − − 911 Turbo (996) world−wide 2001 General data Front−axle final drive Z 96.00 Transmission ratio, final drive (Z2 : Z1 = i) 31 : 9 = 3.44 Final drive Bevel gear drive without hypoid offset Filling capacity...
Page 215 einordnung Diagonal braces to body and front−axle cross member 100 (74) Tank strap to body M8 x 40 23 (17) Pipe holder to transmission support 7 (5) 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651 Front−axle drive tightening torques...
Page 216: Removing Transport Lock (Spring Strut Locking Devices) Turbo And Gt2
The spring strut locking devices must be removed before a test drive and before the vehicle is handed over to the customer! Note • Send the removed spring strut locking devices to the Porsche Warranty Test Office in Ludwigsburg! Include the spring strut locking devices with the normal warranty goods consignment! • top of page...
Page 217 einordnung 2. Remove spring strut locking devices from all spring struts. To do this, pull spring strut locking devices off the springs. 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841 Removing spring strut locking devices...
Page 218: Lifting The Vehicle
4 Lifting the vehicle Lift the vehicle top of page Lift the vehicle CAUTION Danger of material damage if the vehicle is raised incorrectly or if the vehicle is driven incorrectly onto the lifting platform! Lift the vehicle only at the take−up points shown in the figure! •...
Page 219: Tests/Notes For All−Wheel Drive
When fine balancing wheels on the vehicle, all four wheels must be raised and must be able to turn freely. If a fault occurs in PSM (Porsche Stability Management), read out fault memory before fine balancing. After fine balancing, the fault memory of the PSM control unit must be erased.
Page 220: Switching Off Psm
Switching PSM back on Characteristic features of Tiptronic vehicles (slip upshift) Note • The PSM (Porsche Stability Management) is automatically operational/switched on after each engine start! top of page Switching off PSM Press the PSM OFF logo of the rocker switch. The PSM switches off after a short delay.
Page 221: Characteristic Features Of Tiptronic Vehicles (Slip Upshift)
einordnung Characteristic features of Tiptronic vehicles (slip upshift) • When a maximum permissible speed difference between front and rear axle is exceeded, an integrated slip monitoring shifts into the next highest gear. This increases the driving stability on slippery roads. •...
Page 222: Plug Location Plan
5 Plug location plan Caution Top of front end Bottom of front end Side of front end Bottom of lower side member and floor Top of lower side member and floor Bottom of rear end Top of rear end Side of rear end CAUTION Danger of material damage (corrosion) due to entry of water when removing plugs! •...
Page 223: Bottom Of Front End
einordnung Bottom of front end Plug hole Ø 20 top of page Side of front end A Rubber grommet hole Ø 20 mm B Rubber grommet hole Ø 30 mm top of page Bottom of front end...
Page 224: Bottom Of Lower Side Member And Floor
einordnung Bottom of lower side member and floor A Rubber grommet hole Ø 20 mm C Plug hole Ø 10 mm D Plug hole Ø 10 mm E Plug hole Ø 15 mm top of page Top of lower side member and floor A Rubber grommet hole Ø...
Page 225: Bottom Of Rear End
einordnung top of page Bottom of rear end A Rubber grommet hole Ø 20 mm D Plug hole Ø 10 mm E Plug hole Ø 15 mm F Plug hole Ø 20 mm top of page Top of rear end Top of lower side member and floor...
Page 226: Side Of Rear End
einordnung A Rubber grommet hole Ø 20 mm B Rubber grommet hole Ø 30 mm L Plug hole Ø 55 mm top of page Side of rear end A Rubber grommet hole Ø 20 mm D Plug hole Ø 10 mm 996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841 Top of rear end...
Page 227: Seam Seals
Seam seals Accessories top of page Accessories Note • Due to modifications to the spare part range, in the case of repair work accessories must be sealed before assembly (painting) according to the following illustrations. • The sealing material 000 043 204 38 can be applied directly to the accessories coated with KTL paint (cathodic dipbath coating).
Page 228: Front Lid
einordnung • The seam seal can be painted over when it has reached approx. 70 % hardness (approx. 4 − 5 h at 20 °C, 50 % relative air humidity). (Higher air humidity or dampening with water accelerates the hardening process). •...
Page 229: Sliding Roof Panel
einordnung Sliding roof panel 996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841 Sliding roof panel...
Page 230: Work Sequence For Accident Repair
5 Work sequence for accident repair Work sequence for accident repair Determine scope of damage “ Expose the area to be repaired “ Make an economic or technical decision. Should parts be repaired or replaced? “ Determine the scope of replacement parts and have the parts obtained ’...
Page 231 einordnung Paint the repaired area “ If necessary, touch up the undersealing “ Seal cavities “ Fit accessories 996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841 5 Work sequence for accident repair...
Page 232: Work Sequence For Determining Scope Of Damaged Vehicles Involved In An Accident
5 Work sequence for determining scope of damaged vehicles involved in an accident Note Note • A body is constructed so that it has deformable zones in the front and rear area. These deformable zones enable absorption of impact energy due to their special construction. The bearing structure in these areas is adapted by a specific cross section reduction to provide optimum energy reduction in the event of an impact.
Page 233 einordnung Visual inspection of the structural parts on the Check accessories for paint abrasion connection points for gaping plate connections (e.g. (accessories which have been in contact entry area on the side member under the rubber seal of during the impact) the door) “...
Page 234: Corrosion Protection Measures During Repairs
Prerequisite for ensuring vailidity of the long−life guarantee Porsche long−life guarantee conditions • All body repair work must be carried out correctly and according to the specific Porsche instructions for sheetmetal, paint and corrosion protection/preservation work. • To prevent jeopardising the long−life guarantee, a Paint Condition Report is made out 2 years after delivery of the vehicle.
Page 235: Vehicle Identification Number
5 Vehicle identification number Imprinting new vehicle identification number Materials, tools After replacing the body or the sheetmetal parts in the area of the vehicle identification number (firewall), the original vehicle identification number must be reimprinted onto the new body or the new sheet metal part. The documentation of the imprinted vehicle identification number in the vehicle supplementary document or legally permissible treatment can be obtained from the importer of the respective country.
Page 236: Materials, Tools
Stamp the vehicle identification number to be replaced into the spacer with an 8 mm number embossing tool and the Porsche star. b. Mask imprinted vehicle identification number. c. Apply exterior paintwork. d. Remove the vehicle identification number mark.
Page 237: Change Identification Data Plate
5 Change identification data plate After exchanging sheetmetal parts, side section, or doors, a new indentification data plate must be attached. The identification data plate must be ordered from the importer of the respective country. When ordering the indentification data plate, the item number −1− and vehicle identification number −2− must be specified.
Page 238 einordnung 5. Identification data plate Canada a. Item number b. Vehicle identification number 996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431 5 Change identification data plate...
Page 239: Undersealing
5 Undersealing Note Overview diagram, lower front of vehicle Overview diagram, bottom of lower side member and floor Overview diagram, lower rear end Tools and materials Note In the case of repairs, before painting or the installation of ancillaries, the standard stone •...
Page 240: Overview Diagram, Bottom Of Lower Side Member And Floor
einordnung A 0.6 mm to 0.8 mm B 0.4 mm to 0.6 mm C 1 mm to 1.3 mm top of page Overview diagram, bottom of lower side member and floor A 0.6 mm to 0.8 mm B 0.4 mm to 0.6 mm C 1 mm to 1.3 mm top of page Overview diagram, lower front of vehicle...
Page 241: Overview Diagram, Lower Rear End
einordnung Overview diagram, lower rear end A 0.6 mm to 0.8 mm B 0.4 mm to 0.6 mm C 1 mm to 1.3 mm top of page Tools and materials Item Special tool designation Remarks −1− Recommendation Terostat multi−functional sealant 9320 Sprayable Manufacturer: Henkel seam and compartment sealant Teroson GmbH...
Page 242: Water Drainage Plan Cabriolet
5 Water drainage plan Cabriolet 1 Water drainage: Drainage panel 2 Water drainage: Drip tray 3 Water drainage: Drainage tube 4 Water drainage: Water channel, side section 5 Water drainage: Evaporator for heating and air−conditioning system 6 Water drainage: Tank tray 7 Water drainage: Radiator tank 8 Water drainage: Inner panel of convertible top compartment lid 996630, 996631, 996620, 996621, 996650, 996651...
Page 243: Check Dimensions For Body Repair − Cabriolet Structure
5 Check dimensions for body repair − Cabriolet structure Structure dimensions for cabriolet top of page Structure dimensions for cabriolet 5 Check dimensions for body repair − Cabriolet structure...
Page 244 einordnung Note • All dimensions are measured on the body shell (with units removed) middle hole or middle screw connection point. The dimensions are measured directly and, therefore, are oblique dimensions. Refer to the relevant vehicle views for the positions of the measuring points. The measuring points are identified for the right or left side in relation to the direction of travel (viewed from above).
Page 245 einordnung Measuring point Designation −P1L− Convertible−top positioning screwed point (thread M6) −P1R− Convertible−top positioning screwed point (thread M6) −P2L− Locking screwed point (thread M6) −P2R− Locking screwed point (thread M6) −P3L− Convertible−top support/B−pillar Screwed point (thread M8) −P3R− Convertible−top support/B−pillar Screwed point (thread M8) Convertible−top support/inner front side section −P4L−...
Page 246: Safety Notes
5 Safety notes Safety instructions for raising vehicles Safety instructions for welding Safety instructions for sticking Safety instructions for installation work Safety instructions for corrosion protection top of page Safety instructions for raising vehicles Danger of injury when raising vehicles DANGER Risk of fatal injury due to vehicles slipping or tilting off lifting platforms! Risk of injury due to vehicles slipping or tilting off lifting platforms may be caused by improper...
Page 247: Safety Instructions For Welding
einordnung top of page Safety instructions for welding Dangers of injury when welding DANGER Risk of fatal injury from high voltage during electric welding. Danger of explosion and fire when welding in the area of highly inflammable materials. Irritation to respiratory tracts from toxic zinc oxide emitted when welding galvanized steel! Danger of injury from weld spatters and UV light when welding! Danger of injury from false releases of pyrotechnical safety components! •...
Page 248: Safety Instructions For Fuel Tank
einordnung Safety instructions for fuel tank CAUTION Danger of fire due to fuel tank or fuel−carrying parts heating up during grinding and welding work! • When carrying out grinding and welding work near the fuel tank or fuel−carrying parts, make sure that these parts do not heat up! •...
Page 249: Safety Instructions For Installation Work
einordnung Safety instructions for installation work Safety instructions for sharp−edged body and unit parts CAUTION Danger of injury from sharp edges on body and unit parts! • Wear protective gloves when working in the area of sharp−edged body and unit parts! Safety instructions for airbag system CAUTION Danger of injury if airbag units are triggered while ignition key is not removed!
Page 250: Safety Instructions For Corrosion Protection
einordnung CAUTION There is a danger of injury if fingers or hands are trapped by the door window when the comfort function is triggered: lower and raise door window! • When carrying out assembly work in the area of the connection piece, the door handle and the door lock, the fuse No.
Page 251: General Information And Quality Notes
Prerequisite for maintaining the long−life guarantee All body repair work must be carried out correctly and according to the specific Porsche instructions for sheetmetal, paint and corrosion protection/preservation work. To prevent jeopardising the long−life guarantee, a Paint Condition Report is made out 2 years after delivery of the vehicle. This condition report must be updated annually by every Official Porsche Centre.
Page 252: Protection Against Overvoltage
einordnung Protection against overvoltage To protect electronic control units from overvoltage during electric arc welding, the following work regulations must be observed: When welding work is extensive, the electronic control units must be removed. Ensure that there are • no electrically insulated parts between the ground connection and the welding point. •...
Page 253: Tools And Metalworking Tools For Body Repairs
5 Tools and metalworking tools for body repairs Note Straightening systems Metalworking tools Note Detailed and additional information about tools and equipment can be found in the "Workshop • Equipment" manual. top of page Straightening systems Shown on Celette type top of page Metalworking tools Electrical equipment...
Page 254: Mechanical Equipment
einordnung Drill Angle grinder, large Angle grinder, small Sander Hot−air gun Mechanical equipment 6 Hole punch 7 Edge setter Compressed−air equipment Electrical equipment...
Page 255: Welding Equipment
einordnung 9 Air chisel 10 Body saw 11 Spotweld cutter Welding equipment 12 Multispot spot welder 13 MIG welder 996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841 Compressed−air equipment...
Page 256: Diagram − Keys To Symbols For Welding Work
5 Diagram − keys to symbols for welding work Resistance spot welding Inert−gas arc welding (MAG procedure) Gas welding top of page Resistance spot welding A Spot seam, single row B Spot seam, double row C Spot seam, double row offset top of page Inert−gas arc welding (MAG procedure) A Plug weld...
Page 257 einordnung A Hard soldering 996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841 Gas welding...
Page 258: Check Dimensions For Body Repair
5 Check dimensions for body repair Floorpan check dimensions top of page Floorpan check dimensions Note • All dimensions are measured to the middle of the hole or screwed point. The dimensions are measured directly and, therefore, are oblique dimensions. Dimensions in brackets are measured horizontally.
Page 259 einordnung Dimension Measuring points Designation Dimension in mm Impact absorber / pipe front 800±2 Bearer side spare−wheel well 712±2 Front axle front, front, low 610±1 Front axle front, rear, high 731,2±1 Rational location hole, side member front 800±1 Spring strut bracket, front 985±2 Front axle front, rear 773±1...
Page 260 einordnung Bearer side spare−wheel well screwed point (M8 thread) FA, front screwed point low (thread M12 x 1.5) FA, front screwed point high (thread M14 x 1.5) Rational location hole, side member front Spring strut bracket, front FA, rear screwed point (thread M14 x 1.5) Hoist/car jack front location hole Transmission support, front screwed point...
Page 261: Water Drainage Plan
5 Water drainage plan A water drainage facility −1−2− is available on both sides of the vehicle. 1 Water drainage: Rear of sliding roof 2 Water drainage: Front of sliding roof 3 Water drainage: Evaporator of heating and air−conditioning system 4 Water drainage: Tank tray 5 Water drainage: Radiator tank 996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841...
Page 262: Diagram − Body Gap Dimensions
5 Diagram − body gap dimensions Note Gap dimensions, body front Gap dimensions, body centre Gap dimensions, body rear Gap dimensions, body rear Carrera 4S Diagram − Gap dimensions, Cabriolet Note • Set gap dimensions on the lids, doors and covers, or accessories in accordance with the gap specifications.
Page 263 einordnung Designation Dimension Note Front cover to front trim −A− mm Cover only lowered (max. 1 mm) Front cover to modular headlight −B− mm Determine gap left to right Modular headlight to front trim −C− Modular headlight to wing −D− 3.5 ±0.8 −E−...
Page 264: Gap Dimensions, Body Centre
einordnung top of page Gap dimensions, body centre Designation Dimension Note +2.5 Door to front wing −A− mm Door only lowered (max. 1 mm) Door to outer side −B− −0.5 section −C− mm Doors only lowered −D− −0.5 −E− mm Doors only lowered mm Doors only raised −F−...
Page 265: Gap Dimensions, Body Rear
einordnung −G− mm Door only raised (max. 1 mm) −0.5 Air inlet to outer side −H− mm Determine regularly all the way round section Door window to rear −J− 7 ±1 side window Side section to outer roof 25.3 −K− panel ±1 Roof joint strip to outer...
Page 266 einordnung Designation Dimension Note Side member cover to outer −A− 1.4 +0.5 mm side section −B− Rear trim to outer side section −C− 3 ±0.5 mm Gap is evident Tail light to outer side section −D− 3 ±0.5 −E− 2 −1 mm Tail light only lowered Rear trim to tail light −F−...
Page 267: Gap Dimensions, Body Rear Carrera 4S
einordnung −1.5 Rear lid to tail light −M− 4.5 ±1 mm Tail light only lowered (max. 1 mm) Rear lid to outer side section −N− 4.5 ±1 mm Rear lid only lowered (max. 1 mm). determine left to right Rear centre panel to outer side −O−...
Page 268 einordnung Designation Dimension Note Rear trim to outer side section −A− 3 ±0.5 mm Gap is evident Tail light to outer side section −B− 3 ±0.5 mm −1 −C− mm Tail light only lowered Tail light to middle side section −D−...
Page 269: Diagram − Gap Dimensions, Cabriolet
einordnung Rear lid to spoiler top section −K− 4.5 ±1 mm Rear lid only lowered (max. 1 mm). determine seam Rear window to outer roof panel −L− −2 Rear window to outer side −N− section −O− mm Determine left to right Outer side part to rear centre part −P−...
Page 270 einordnung Designation Dimension Note Cowl panel frame to fender −A− 3.5 to 7.0 Continuous transition ±1 +2.5 Windscreen to cowl panel frame −B− −1 Door window to rear window 9 ±1 −C− +2.5 Rear side section flap to side trim panel −D−...
Page 271: Diagram − Gap Dimensions, Rear Cabriolet
einordnung Diagram − Gap dimensions, rear Cabriolet Designation Dimension Note Side part to convertible−top compartment lid −A− Continuous seam −0.5 joining line −B− −C− −0.5 Convertible−top compartment lid to rear lid −D− −0.5 Convertible−top compartment lid to rear lid −E− −0.5 Diagram −...
Page 272: Diagram, Gap Dimensions, Cabriolet Rear − Carrera 4S
einordnung Diagram, gap dimensions, Cabriolet rear − Carrera 4S Designation Dimension Note Side part to convertible−top compartment lid −A− mm Continuous seam joining −0.5 line −B− −C− −0.5 Convertible−top compartment lid to rear lid −D− −0.5 Convertible−top compartment lid to spoiler top −E−...
Page 273: Diagram − Gap Dimensions, Hardtop
einordnung Diagram − Gap dimensions, hardtop Designation Dimension Note Windscreen frame to convertible top −A− 5.5 ±0.5 mm −B− mm Convertible top only lowered −2 Rear window to rear roof frame (Hardtop) −C− 10.4 −D− 3 ±1.5 Hardtop to convertible−top compartment lid −E− 5.5+2 Hardtop to convertible−top compartment lid −F−...
Page 274 einordnung 996420, 996421, 996450, 996451, 996630, 996631, 996430, 996431, 996620, 996621, 996650, 996651 Diagram − Gap dimensions, hardtop...
Page 275: Body Parts Of High−Strength Steel
5 Body parts of high−strength steel High−strength steel plates Tailored blanks Baked hardening Straightening body parts Welding work Reshaping Separation points Diagram − Body, model year 2002 The following body parts are made of high−strength steel (HS). 1 Bearer side at spare−wheel well, left and right 2 Connection bracket inner to side member front inner left and right 3 Side member front inner, left and right 5 Body parts of high−strength steel...
Page 276: High−Strength Steel Plates
Body parts −1 to 23− attain their final strength only after the production stage of cathodic immersion painting and drying! The special material properties have effects on body repair. For this reason, only "Original Porsche • parts" must be used for repair work! top of page High−strength steel plates...
Page 277: Tailored Blanks
But this also means that higher reshaping force must be applied in reshaping work. Note • Only "Original Porsche parts" must be used for repair work! top of page Tailored blanks The indicated body parts are made by welding together plates of differing thicknesses and characteristics and then deep−drawing these parts.
Page 278: Baked Hardening
Note • Only "Original Porsche parts" or sections of "Original Porsche parts" may be used! The body and floor assembly are produced in series from deep−drawn panels. For this reason, accident damage must be reshaped in the same way. Body repairs by reshaping are not possible if these body parts are correspondingly deformed.
Page 279: Welding Work
Reshaping Note • Only "Original Porsche parts" or sections of "Original Porsche parts" may be used for repair work! • The separation of damaged body parts should not take place until after reshaping against the accident direction has taken place and connection pieces have been straightened! Body repairs by reshaping are not possible if these body parts are correspondingly deformed.
Page 280: Diagram − Body, Model Year 2002
einordnung Diagram − Body, model year 2002 In the model year 2001 (model care), the following structural body parts have been used in the body for passive safety. As of model year 2002, all vehicles will be constructed with the structural parts shown in the following diagram.
Page 281 einordnung 1. Front side members (cross member double connection) 2. Interior door reinforcement (diagonal) 3. Inner lower side member 4. Inner side part 5. Sliding roof reinforcement frame 6. Seat well cross tube 7. Gusset plate and reinforcement plate of belt height adjuster 8.
Page 282: Safety Notes
6 Safety notes Safety instructions for work on car windows Safety instructions for installation work top of page Safety instructions for work on car windows Danger of injury when working on car windows WARNING Danger of cut injuries when removing and installing car windows! •...
Page 283: Safety Instructions For Installation Work
einordnung In order to ensure that the bonded joint is sufficiently strong, the following boundary conditions must be adhered to: • Curing time: 3 hours • Temperature: at least 10°C • Fixing time: approx. 1 hour top of page Safety instructions for installation work Safety instructions for airbag system CAUTION Danger of injury due to unintentional activation of airbag units!
Page 284: Safety Instructions For The Pump Unit Hydraulic System Of The Rear Spoiler
einordnung Safety instructions for the pump unit hydraulic system of the rear spoiler DANGER Danger of injury/damage during assembly work on the hydraulic system! • The hydraulic system is under approx. 30 bar pressure when extended Do not smoke during work, avoid open flames. Danger of fire! •...
Page 285: General Information On Installing And Removing Car Windows
6 General information on installing and removing car windows Removing glass with cutting wire separator top of page Removing glass with cutting wire separator Note • The following instructions describe the general procedure for removing car windows with the glass separating tool VAG 1474 B.
Page 286 einordnung −A3− Spooling device −A8− Handle −A4− −A9− Square cutting wire −A5− Guide rails Note • It is generally possible to remove the windscreen with the cutting wire and the optional cutting thread contained in the tool set. • In contrast to cutting threads, however, the cutting wire has the following disadvantages: •...
Page 287 einordnung 2. Applying protective film to the dashboard a. Select the appropriate film −1− and insert between windscreen and damping mat. Note • The film −1− protects the damping mat against damage when removing the glass. 3. Inserting cutting thread into the passenger compartment Note In order to prevent damage, make sure that the vehicle identification number −C−...
Page 288 einordnung 4. Inserting cutting thread into the gap in the glass g. Pull cutting thread −B− in the direction of the arrow through the gap between the glass and the body. Use filler −A6− if necessary. Note • The cutting thread should be positioned under the rim as far as possible. The sealing lip must be raised slightly in the upper part of the glass in order to pull the cutting thread through.
Page 289 einordnung k. Attach cutting thread −B− firmly with the clamping screw −3− 7. Installing spooling device and deflection rollers on the glass l. Position spooling device −A3− diagonally in the centre of the glass. m. Press spooling device −A3− with the fastening intakes firmly against the glass. n.
Page 290 einordnung 10. Separating glass as far as P2 t. Position deflection roller in the lower right corner. u. Press deflection roller with fastening intake firmly against the glass. v. Fix fastening intake onto the glass by moving the actuating lever. w.
Page 291 einordnung 12. Repositioning spooling device ae. Release spooling device. af. Release the upper fastening intake on the spooling device. ag. Pull cutting thread through onto the other side of the fastening intake. ah. Fix fastening intake onto the glass by moving the actuating lever. 13.
Page 292: Cutting Power When Removing Glass With Cutting Thread
einordnung 14. Separating glass as far as P5 an. Release spooling device. ao. Position deflection roller in the lower left corner. ap. Press deflection roller with fastening intake firmly against the glass. aq. Fix fastening intake onto the glass by moving the actuating lever. ar.
Page 293 einordnung High cutting power Unfavourable angle (strong traction required) Average cutting power Favourable angle (average traction required) Low cutting power Optimum angle (minimum traction required) 996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431 Cutting power when removing glass with cutting thread...
Page 294: Overview Of Exterior Colours
6 Overview of exterior colours Note Exterior paintwork solid Exterior paintwork metallic/pearl Special colours Note • As from model year '02, the same colour code will be used for water−based paints and for conventional paints. top of page Exterior paintwork solid Model year Colour designation...
Page 295: Special Colours
einordnung Arctic silver metallic Lapis blue metallic Rainforest green metallic Orient red metallic 1) 2) Carmona red metallic Zanzibar red pearl effect Meridian metallic Seal grey metallic 1) 2) Atlas grey metallic Midnight blue metallic 1) 2) Lagoon green metallic Water−based Conventional top of page...
Page 296 einordnung 1) 2) GT silver metallic Slate metallic Midnight blue metallic Zanzibar red pearl effect Water−based Conventional 996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431 Special colours...
Page 297: Processing Of Porsche 2−Component Window Bonding Agents
Overview of tools and materials Item Designation Source Remarks −A− Double cartridge gun VAS 5237 See Workshop Equipment Manual, Chapter 3.5 −B− Pipette VAG 1344 See Workshop Equipment Manual, Chapter 3.5 6 Processing of Porsche 2−component window bonding agents...
Page 298: Preparing The Adhesive Surfaces
einordnung −C− Special electric cutter (fine) VAG 1561 See Workshop Equipment Manual, Chapter 3.5 −D− Flashing knife, U−type 639.031.130.22 −H− 2−component window bonding agent Contains set 000.043.300.94 components H1−H8 Item Designation Item Designation −H1− Cleaning solution −H5− Cartridge, component A −H2−...
Page 299: Combined Procedure (Handling Double Cartridge Press)
einordnung Cut back adhesive bead −Cleaner− “ “ Clean flange surface “ −Activator− −Primer− “ “ Activate adhesive bead Prime rim (ceramic layer) (only necessary if car is idle for a long period) “ “ Apply adhesive Install glass top of page Combined procedure (handling double cartridge press) CAUTION •...
Page 300 einordnung 2. Screwing on processing nozzle −H8− b. Screw processing nozzle −H8− onto the mixing nozzle −H7− 3. Screwing on mixing nozzle −H7− c. Screw both cartridges onto the mixing nozzle. 4. Placing mixing cartridge in the double cartridge gun d.
Page 301 einordnung 6. Affixing car window Note • The bonding material has an open time of −15 min− , which means that the bonding material must be applied and the car window must be assembled within this period of time. • In order to ensure that the substance is completely mixed, apply a 30 mm long adhesive bead of fresh adhesive to a piece of cardboard before processing.
Page 302: Special Notes For The Care Of Soft−Look Paint Surfaces
CAUTION Damage to the soft−look paint coat if the cleaning agents or solvents available as accessories for cleaning the vehicle interior are used. This also applies to the use of plastic polish 999.901.021.41 from the Porsche care set. The contents of these agents etch the paint coat (paint swells, rubber−like texture). Consequently, the paint coat can fall off the substratum when a mechanical load is applied.
Page 303 Interior window cleaner (from Porsche care set) Note Observe cleaning instructions, wipe down with clear water if necessary Soft, lint−free cloth Solvent naphtha Note: Use solvent naphtha only, other solvents are not permissible! 996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841...
Page 304: Air Conditioning
8 Air conditioning Technical data for the air−conditioning system top of page Technical data for the air−conditioning system Note When installing the refrigerant lines, the screw connections and the O−rings must be wetted with • refrigerant oil! • The refrigerant oil must be disposed of as special−category waste! Compressor type 7 SB 16 Refrigerant quantity 900 g Refrigerant R 134a...
Page 305: Work Instructions After Disconnecting The Battery
9 Work instructions after disconnecting the battery Effect of disconnection or total discharge of the battery on electrical systems in the vehicle, subsequent measures Control module memories Supply voltage fault entry Test drive after connecting the battery 2470 DME control module 6452 Power windows 90 25 Instrument cluster 9030 Clock...
Page 306: Supply Voltage Fault Entry
einordnung discharged. out before the battery is disconnected. top of page Supply voltage fault entry Problem Remedy The entry "supply voltage" could be stored in various control Delete the "supply voltage" modules if the battery has been completely discharged. entry from the control modules in question.
Page 307: Power Windows
einordnung This completes the adaptation of the throttle adjusting unit. top of page 6452 Power windows Problem Remedy The limit positions of the power windows are deleted from Manually close each power window as the control module when the battery is disconnected and far as it will go, then press the rocker connected.
Page 308: Radio
PCM code can also be read from the DME function when the battery is control module (under "Vehicle data"). disconnected and is thus no longer 2. It is also possible to gain this code from the Porsche ready for operation. IPAS. •...
Page 309 einordnung 6. The telephone is enabled again when the telephone PIN code is entered with the SIM telephone card inserted. 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841 9110 PCM...
Page 310: Clutch: Checking Fluid Levels
30 Clutch: checking fluid levels General Checking Pentosin CHF 11 S hydraulic fluid in the engine compartment and luggage compartment Checking Pentosin CHF 11 S hydraulic fluid in the engine compartment Checking Pentosin CHF 11 S hydraulic fluid in the luggage compartment top of page General CAUTION...
Page 311: Checking Pentosin Chf 11 S Hydraulic Fluid In The Engine Compartment
einordnung • The supply tank for the power steering and the clutch booster circuit is located in the engine compartment! • The second supply tank for the clutch actuating circuit is secured under a cover in the luggage compartment! top of page Checking Pentosin CHF 11 S hydraulic fluid in the engine compartment Note...
Page 312: Checking Pentosin Chf 11 S Hydraulic Fluid In The Luggage Compartment
einordnung top of page Checking Pentosin CHF 11 S hydraulic fluid in the luggage compartment WARNING Danger of damage and injury if the wrong fluid is filled in after the caps have been changed! If fluid is being filled into several tanks in the luggage compartment (brake fluid / water / Pentosin), •...
Page 313 einordnung Front tank 1 Brake fluid reservoir / black cap with yellow marking. 2 Pentosin reservoir for clutch actuation / green cap 3 Washer fluid container / blue cap. 2. If the fluid level in the transparent container −2− does not lie between the Min. and Max. marking, screw off the cap.
Page 314: Tightening Torques For Front Axle
40 Tightening torques for front axle Cross member/side member (1 component) Diagonal brace Control arm Spring strut/wheel carrier Front−axle final drive/drive shaft (Turbo) Stabilizer Steering Wheel fastening top of page Cross member/side member (1 component) Location Thread Tightening torque Nm (ftlb.) Cross member/side member on body (front and rear) M14 x 1.5...
Page 315: Spring Strut/Wheel Carrier
einordnung 911 GT2 Bssic camber setting on 2−part control arm 27 (20) top of page Spring strut/wheel carrier Location Thread Tightening torque Nm (ftlb.) Spring strut to wheel carrier (shock−absorber tube clamp) Turbo M12 x 1.5 100 (74) 911 GT2 M12 x 1.5 85 (63) Spring seat clamp (Turbo)
Page 316: Stabilizer
einordnung Rear front−axle transmission support to body Front front−axle transmission support to front−axle cross 65 (48) member Stud to front−axle cross member 20 (15) Front−axle transmission support at front to final drive 65 (48) Tank strap to body 23 (17) top of page Stabilizer Location...
Page 317 einordnung facing the wheel. If heavily contaminated, clean bolts first with a lint−free cloth. 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841 Wheel fastening...
Page 318: Tightening Torques For Rear Axle
42 Tightening torques for rear axle Carrier side section/cross member Axle strut Wheel carrier Spring strut Drive shaft/stabilizer Unit mount top of page Carrier side section/cross member Location Thread Tightening torque Nm (ftlb.) Carrier side section to body 12 x 1.5 110 (81) Studs for carrier side section to body only screw−in torque M12 x 1.5...
Page 319: Wheel Carrier
einordnung top of page Wheel carrier Location Thread Tightening torque Nm (ftlb.) Wheel bearing to wheel carrier (lid) 37 (29) Speed sensor to wheel carrier 10 (7.5) Brake cover plate to wheel carrier 10 (7.5) Brake disc to wheel hub 10 (7.5) * 1) Brake caliper to wheel carrier...
Page 320: Drive Shaft/Stabilizer
einordnung Drive shaft/stabilizer Location Thread Tightening torque Nm (ftlb.) Drive shaft to transmission 81 (60) to wheel hub M22 x 1.5 460 (340) Stabilizer to carrier side section 23 (17) Stabilizer mount to stabilizer and spring strut Turbo 46 (34) 911 GT2 M10 / 10.
Page 321: Conversion Table For Wheel Alignment Values
(division in 60 units) to decimal degrees (division in 100 units) by presseing a key (special function)! This function is standard for the electronic wheel alignment testers approved by Porsche. Using the conversion table, minutes (') can be converted into decimal degrees and decimal degrees •...
Page 322 einordnung form the coordinates again. Line to the left = 40' and line upwards = 1' (amounts to 40' + 1'). 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841 Conversion from decimal degrees to minutes (examples)
Page 323: Adjusting Values For Suspension Alignment − Turbo And Gt2
Danger of injury and damage to property due to malfunctions in the PSM control range if the steering angle sensor is not calibrated or is calibrated incorrectly! • Calibrate steering angle sensor with wheels in straight−ahead position with the Porsche System Tester 44 Adjusting values for suspension alignment − Turbo and GT2...
Page 324 einordnung • The steering angle sensor actual value must be checked after a suspension alignment where no changes were made to the wheel alignment values! Note The following values relate to the empty weight, i.e., full fuel tank, vehicle with spare •...
Page 325: Alignment Card − Turbo
44 Alignment card − Turbo Porsche measurement of running gear Customer: Rep. Order No.: Street: Vehicle Ident No.: Place: Licence number: Telephone: Date of first registration: Odometer reading: km/miles Measurement made by: Date / signature: Vehicle: 911 Turbo (996) Model: Measurement prerequisite (vehicle weight): Empty weight as in DIN 70020.
Page 326 einordnung Note • In practice this means that alignment cards cannot be ordered! • The alignment cards can be used for all 911 Turbo (996), USA and RoW! 1. Prepare copies of the corresponding alignment card shown. 2. Before measurement, enter the general data, vehicle model and the missing nominal values into the copied alignment card.
Page 327: Suspension Alignment, Complete
The quick−clamping holders present can be retrofitted by replacing the clamping units on the left and right. Supplier: Messrs. Beissbarth. These converted quick−clamping holders can also be used retroactively for the other Porsche models. The order number for the new clamping units will be included in the Workshop Equipment Manual.
Page 328: Vehicle Height/Wheel Load
Because of the different equipment versions (additional equipment), a greater wheel−load difference between the left and right is permissible than previously was the case in Porsche suspension alignment for the 911 Carrera (996) (over 20 kg is possible). This is partly the result of heavier components compared with standard equipment and partly results from additional components that are asymmetrically arranged.
Page 329: Front Axle
• Calibrate steering angle sensor with wheels in straight−ahead position with the Porsche System Tester The steering angle sensor actual value must be checked after a suspension alignment which resulted in • no changes being made to the wheel alignment values! Note •...
Page 330: Vehicle Height (Vehicle Height Check)
einordnung the following points should be given special attention: Empty weight of vehicle in accordance with DIN 70020, i.e. car ready for the road, with full fuel tank, • spare wheel (collapsible wheel) and tools. • Ball−joint and wheel−bearing play in order (wheel−bearing play cannot be adjusted). •...
Page 331: Front Axle
• Calibrate steering angle sensor with wheels in straight−ahead position with the Porsche System Tester • The steering angle sensor actual value must be checked after a suspension alignment which resulted in...
Page 332: Rear Axle
• Calibrate steering angle sensor with wheels in straight−ahead position with the Porsche System Tester • The steering angle sensor actual value must be checked after a suspension alignment which resulted in...
Page 333: Adjusting Toe
• Calibrate steering angle sensor with wheels in straight−ahead position with the Porsche System Tester • The steering angle sensor actual value must be checked after a suspension alignment which resulted in...
Page 334: Front Axle
• Calibrate steering angle sensor with wheels in straight−ahead position with the Porsche System Tester • The steering angle sensor actual value must be checked after a suspension alignment which resulted in no changes being made to the wheel alignment values! The camber is adjusted by moving the spring strut transversely.
Page 335: Adjusting Toe
• Calibrate steering angle sensor with wheels in straight−ahead position with the Porsche System Tester The steering angle sensor actual value must be checked after a suspension alignment which resulted in •...
Page 336 • Calibrate steering angle sensor with wheels in straight−ahead position with the Porsche System Tester • The steering angle sensor actual value must be checked after a suspension alignment which resulted in...
Page 337: Toe−Difference Angle
einordnung Toe−difference angle The toe−difference angle is not adjustable. 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651 Toe−difference angle...
Page 338: Wheel Rims And Tires
Danger of injury and damage to property as a result of modified handling behavior if tires are used which do not correspond to Porsche−specific requirements! The stated air pressures are minimum pressures and must never be fallen below, since in addition to •...
Page 339: Overview Of Tires And Wheels (Series)
When replacing summer tires, pay close attention to the tire specification number! The specification • characters N1, N2, N3 or N0 distinguish the summer tires specially authorised by Porsche from other models of the same tire type and size! Note •...
Page 340: Tyres
44 Tyres Mounting instructions Balancing weights Navigation system Wheel storage Tyre age top of page Mounting instructions General Note • Always use new valves when changing tyres! Steel valves (part no. 993.361.073.00) −1− are used for 18−inch Turbo II wheels and rubber valves −2− for 18−inch Turbo−Look II wheels. Steel valve assembly ’...
Page 341: Uncontrolled Matching
einordnung • Customers should be informed that the full performance of new or newly mounted tyres is achieved only after a distance of 100 to 200 km (60 to 120 miles) has been driven. Extreme driving manoeuvres (acceleration, braking) should be avoided. •...
Page 342: Balancing Weights
The overview of summer and winter tyres is included in Technical Information (TI), Group 4. The specification code N1, N2, N3 or N0 distinguishes summer tyres expressly approved by Porsche from other versions of the same tyre type and size.
Page 343: Tyre Age
Optimum conditions for proper storage of the complete wheels are provided by the Original Porsche storage stand (trolley), part number 000.044.000.38. Tyres age due to physical and chemical processes, which can impair their function. If they are stored for an extended period, they will harden and become brittle faster than do tyres that are in continual use.
Page 344: Checking Disc Wheels
44 Checking disc wheels Checking the radial and lateral runout top of page Checking the radial and lateral runout Note Straightening and welding work on light alloy wheels is not permissible! • Maximum permissible radial runout and lateral runout of the light alloy wheels = 0.7 mm. Maximum permissible radial runout and lateral runout of the wheel with tyre = 1.25 mm.
Page 345: Tyre Mounting
44 Tyre mounting Note Tools Notes on removing/mounting tyres Removal Fitting Note The mounting machine described here is particularly suitable for the tyre combinations used on the • 911 Turbo (996). • All parts in contact with the wheel and the tyres are made of plastic. •...
Page 346: Notes On Removing/Mounting Tyres
einordnung Mounting lever commercially available top of page Notes on removing/mounting tyres Note • When fitting tyres, the direction of rotation and the inner and outer sides should be noted! • Use only TIP TOP Universal, order No. 593 0601 (3.5 kg bucket) or Contifix as the mounting paste. •...
Page 347: Fitting
einordnung 2. When pushing off the tyre, ensure that the bead press−off tool is set to the exact inch graduation. If this is not the case, the rim flange may be damaged by the press−off rollers. 3. The wheel must be turned anti−clockwise when pressing the tyre off the rim. Otherwise, excessive forces occur on the fastening bolts of the machine which can lead to bolt breakage.
Page 348 • Do not use commercially available steel valves! The Porsche valves (part No. 993.361.073.00) are shorter; dimension −X− . Dimension −X− is 43 mm • for the Porsche version! 1. Free the wheel from the abraded rubber particles and check for damage.
Page 349 einordnung 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841 Fitting...
Page 350: Balancing/Optimising Wheels
44 Balancing/optimising wheels General Balancing/optimising wheels Balancing weights top of page General Excessive wheel imbalance not only produces vibrations and causes the steering wheel to shake, but also results in increased wear on various parts of the running gear. Even if the wheels are correctly balanced, excessive geometry errors (radial and axial runout) and misshapen tyres, e.g.
Page 351: Further To 1: Mounting The Tyre On The Rim
Centre (clamp) the wheel from the inside with centring clamping device refer to Workshop Equipment Manual, Chapter 3. This centring clamping device fits on all wheel balancing machines approved by Porsche. Check radial and axial runout during the 1st measuring run. Values less than 1.0 mm better around 0.5 mm are desirable.
Page 352: Further To 3: Mounting The Wheel On The Vehicle
einordnung A value of 80/80 g should not be exceeded. A greatly different distribution, e.g. 30/70 g is very unfavourable; this usually indicates incorrect mounting. Problem wheels of this kind often have pronounced radial and axial runout values. This can be remedied by matching (use correct mounting paste). Improvement is possible with uncontrolled matching (manual);...
Page 353: Further To 4A: Fine Balancing Of The Front Wheels
einordnung Affix balancing weights on the outer plane (uniform procedure / could also be distributed or affixed on the inner plane). Under no circumstance remove the weights affixed during stationary balancing. Mark the balancing weight required by electronic fine balancing using a prick punch in order to distinguish it. Read out and erase the PSM fault memory after fine balancing.
Page 354: Balancing Weights
einordnung The imbalance values shown here in this speed range are not real values. They are actually max. 1/4 to 1/3 of the indicated values. The subjective impression in the vehicle is the decisive criterion here. The balancing process is complete only when no more vibrations caused by imbalance are perceptible! top of page Balancing weights...
Page 355: Abs/Psm 5.7 Check With Porsche System Tester 2
(Drive links/Actual values)! • The Porsche System Tester 2 is connected to the diagnositic socket in the front left footwell in the same way as for the 911 Carrera (996)! Entry takes place through the ABS system (automatic status...
Page 356: Checking Brake Light Switch Setting
46 Checking brake light switch setting Brake light switch setting Checking brake light switch setting Adjusting switch if pedal travel is too small top of page Brake light switch setting The switch travel of the brake light switch is designed so that the brake light lights up before braking pressure builds up.
Page 357: Adjusting Switch If Pedal Travel Is Too Small
einordnung top of page Adjusting switch if pedal travel is too small There are two possibilities to adjust the switch if the pedal travel to the switching point is too small. 1st possibility: 1. Press the brake pedal and pull out the switch plunger. 2.
Page 358: Tightening Torques For Mechanical Brake
46 Tightening torques for mechanical brake Location Thread Tightening torque Nm (ftlb.) * 1) Brake caliper * to front and rear axles M12 x 1.5 85 (63) Brake disc to wheel hub (front and rear axles) 10 (7.5) Brake cover plate to front and rear axles 10 (7.5) Speed sensor to front and rear axles 10 (7.5)
Page 359: Technical Data/Brake Wear Limit − Turbo
Total brake pad area 568 cm 1) * Porsche Stability Management (PSM) standard with ABS, Traction Control (TC), ABD, MSR (engine drag torque control), FZR (vehicle regulator) and EBV (electronic brake distributor). Passive switching 46 Technical data/Brake wear limit − Turbo...
Page 360: Wear Limit Technical Data − Turbo With Cast Iron Brake Discs
einordnung possibility for TC, FZR and MSR. 2) ** EBV = electronic brake distributor (brake proportioning control). As a result, no screw−in brake proportioning valves are required! top of page Wear limit technical data − Turbo with cast iron brake discs Depending on the wear of cast iron brake discs, two condition criteria can make replacement necessary: 1.
Page 361: Checking The Thickness Of The Disc Brake Pads − Turbo And Gt2
However, if only the plastic part of the warning contact is worn, there is no need to replace it! CAUTION Vehicles with PCCB (Porsche Ceramic Composite Brake): Danger of material damage during wheel removal/installation (danger of damage to brake discs)! •...
Page 362 einordnung 1. To check the brake pads, remove the wheels. Screw the 2 assembly aids (assembly pins), instead of 2 wheel bolts, into the wheel hub before wheel removal/installation. During removal, first remove the 3 remaining wheel bolts and remove the wheel carefully, without touching the brake discs. 2.
Page 363: Technical Data/Brake Wear Limit − Turbo With Pccb
Total brake pad area 696 cm 1) * Porsche Stability Management (PSM) standard with ABS, Traction Control (TC), ABD, MSR (engine drag torque control), FZR (vehicle regulator) and EBV (electronic brake distributor). Passive switching 46 Technical data/Brake wear limit − Turbo with PCCB...
Page 364: Wear Limit Technical Data − Turbo With Ceramic Brake Discs (Pccb)
einordnung possibility for TC, FZR and MSR. 2) ** EBV = electronic brake distributor (brake proportioning control). As a result, no screw−in brake proportioning valves are required! top of page Wear limit technical data − Turbo with ceramic brake discs (PCCB) Designation Note, dimensions...
Page 365: Tightening Torques For Brake Hydraulics
47 Tightening torques for brake hydraulics Tightening torque Nm Location Thread (ftlb.) Brake pressure line to brake master cylinder, brake hose, distributor, brake caliper and hydraulic unit M10 x 1 12−14 (9−10) M12 x 1 20 (15) Hydraulic unit on holder 12 (9) Hydraulic unit to body 10 (7.5)
Page 366: Tightening Torques For Steering
48 Tightening torques for steering Location Thread Tightening torque [Nm] (ftlb.) * 1) Steering gear to cross member M10/10.9 65 (48.8) Tie rod (ball joint) to steering arm M12 x 1.5/10 75 (56.3) ** 2) Universal joint (steering shaft) to steering gear 23 (17.3) Tie rod to ball joint (lock nut) M14 x 1.5...
Page 367: Test And Assembly Work On Power Steering
48 Test and assembly work on power steering General Checking hydraulic fluid of power steering and servo clutch Bleeding the steering system top of page General Damage to the power steering is caused by a shortage of oil in the hydraulic system. Even small leaks can cause the fluid to escape and damage the servo pump as a result of the high oil pressure occurring in the hydraulic circuit.
Page 368: Bleeding The Steering System
einordnung on one side and the "Hot max" symbol on the other side. Pentosin reservoir Check the fluid level (Pentosin CHF 11 S) with the engine stationary and cold (approx. 20 °C). CAUTION Danger of damage to property if too much Pentosin CHF 11 S is filled or if it comes in contact with the coolant hoses when topping up or filling in! •...
Page 369 einordnung turned. 5. Switch off engine. 6. Wipe off the dipstick. Close and then reopen the cap. The fluid level should be in the designated "Cold range" (min./max. level at 20 °C). Top up with Pentosin if necessary. Do not add too much Pentosin! In warmed−up condition, the fluid level must not exceed the "Hot max"...
Page 370: Assessment Of Steering Gear After Accident Damage
48 Assessment of steering gear after accident damage Fundamentals top of page Fundamentals Various kinds of damage can be caused to the steering gear in the event of accidents or driving conditions resembling accidents. In cases where the steering gear shows no external damage it can be difficult and costly to detect damage.
Page 371: Exceptional Regulation / Order Handling
einordnung replaced. Exceptional regulation / order handling If a workshop's intended exchange of steering gear is refused by a customer or insurer for reasons of costs, an expert or if this is impossible abroad, the importer should be called in at the cost of the refusing party. If the decision contradicts the guideline, we recommend that a memorandum be drawn up on the point and that it be countersigned by the expert.
Page 372: Safety Regulations For Vehicles With Airbag And Belt Tensioner
69 Safety regulations for vehicles with airbag and belt tensioner Note Assembly and adjustment work Handling airbag and belt tensioner General information Note As from model year 2002, the front three−point belt will be fitted with a belt tensioner as standard. •...
Page 373: Assembly And Adjustment Work
As long as the airbag triggering unit is not locked, the warning light lights up continuously. • The triggering unit is locked with the Porsche System Tester. WARNING Danger of injury and damage to property as a result of incorrect handling of airbag units! Please observe the following point: •...
Page 374: Handling Airbag And Belt Tensioner
Injury caused by incorrect triggering due to manipulation of the short circuit bridge. Protective measures and rules of behaviour Note Assembly work only by trained staff. • • Carry out tests only with the Porsche System Tester diagnostic module; do not use test lamps, voltmeters or ohmmeters. Handling airbag and belt tensioner...
Page 375: Behaviour In Cases Of Malfunction Or Danger
einordnung • Do not bring into contact with grease, solvents or cleaning agents. Do not expose to temperatures above 100°C. • • Keep the unfolding area of the airbag clear; e.g. do not hang test devices over the steering wheel. When carrying, hold the airbag with the blow−out direction facing away from the body.
Page 376: Materials
Exchanged airbag units or airbag modules must be taken into possession by the Porsche Centre or by • a dealer authorised by Porsche and must not be handed over to the customer (customer has no right to possess them). They must be destroyed, disposed of or returned to the manufacturer in accordance with the explosives ordinance and the hazardous materials ordinance! •...
Page 377: Component Exchange After Airbag Triggering
Because it is difficult to visually determine if one or both belt tensioners has been triggered, check the following points. • Read out the airbag fault memory with the Porsche System Tester. • Check plug connection on the belt tensioner for damage.
Page 378: Nominal Values For Pressures And Temperatures
87 Nominal values for pressures and temperatures Note General test prerequisites Note • The temperature of the air from the centre dashboard vents must lie within the prescribed tolerance range within 5 minutes, depending on the ambient temperature! top of page General test prerequisites Close doors, windows and sliding roof.
Page 379: High Pressure In Cold Circuit As A Function Of Ambient Temperature
einordnung High pressure in cold circuit as a function of ambient temperature Low pressure in cold circuit as a function of ambient temperature Centre vent temperature as a function of ambient temperature...
Page 380 einordnung 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841 Low pressure in cold circuit as a function of ambient temperature...
Page 381: Retrofitting Mobile Communication Systems
Mobile two−way radios (telephones) that are retrofitted must have a type approval for this vehicle and be identified with an 'e'. In the Driver's Manual of its vehicles, Porsche has approved mobile telephones and two−way radios with a maximum transmission power of 10 W. Porsche permits the installation and operation of two−way radios over 10 W for the radio services listed below under the following preconditions:...
Page 382 • In this case it is necessary to have EMV experts inspect the Porsche in order to observe the protective goals! • The optimum range of the two−way radios can only be reached with an external antenna! • Excessive electro−magnetic fields can occur in the vehicle from the operation of mobile phones and two−way radios without an external antenna or with an external antenna that is incorrectly installed...
Page 383: Additional Alarm System M 536
96 Additional alarm system M 536 Note Removing alarm siren and tilt sensor Note • Vehicles for Great Britain and Belgium are equipped with an alarm siren and tilt sensor in addition to the standard alarm system! • M 590 (lid release locks) is also standard equipment in these vehicles! top of page Removing alarm siren and tilt sensor 1.
Page 384: Measurement Of Closed−Circuit Current
97 Measurement of closed−circuit current Tools Preparations on the vehicle Measurement top of page Tools Closed−circuit current should be measured using an analog ammeter or a digital multimeter with a long integration time (to filter out voltage peaks). Item Special tool designation Remarks −1−...
Page 385: Measurement
einordnung ground which is always available for RHD or LHD versions. 3. Remove ground strap from the body and secure against contact with the body. The on−board current now flows via the ammeter. top of page Measurement • Select a measuring range which ensures that the pointer of the instrument is in the upper third of the scale, as far as possible.
Page 386 einordnung Passenger compartment monitoring/tilt sensor M No. 534 Power windows, front Standard Tiptronic* M No. 249 Standard Radio CD changer M No. 692 Amplifiers, audio M No. 490 Navigation information system M No. 662 Navigation computer PCM2 as from MY '03 Telephone as from MY '03 Both seat memeories M No.
Page 387: 06 Battery
27 06 Battery Note Battery − handling notes Removing and installing battery Remove battery Install battery Visual inspection Check acid level Checking gravity of electrolyte Open−circuit voltage measurement Battery load test Charging battery Note To prevent contact corrosion, only approved screws, nuts, discs etc. should be used. These elements •...
Page 388: Warning Notes And Safety Regulations For Hydrocyanic Acid Batteries
einordnung Warning notes and safety regulations for hydrocyanic acid batteries 1. −1− Fire, sparks, naked flames and smoking are forbidden: Avoid sparking when using cables and electrical devices Avoid short circuits. In batteries with central venting, there is an increased detonating gas concentration. The vent hose should not be bent or blocked by dirt.
Page 389: Remove Battery
einordnung • The battery is located in the radiator tank. In order to avoid triggering the alarm siren (installed on right next to the battery) of vehicles with M • 536, the battery must be disconnected with the ignition on! •...
Page 390: Install Battery
einordnung 2. Open turn−lock fasteners −A− . 3. Remove battery cover. 4. First disconnect the ground strap of the battery on the negative battery terminal. Unscrew hexagon nut and remove terminal. 5. Undo hexagon nut on the positive battery terminal and remove terminal. 6.
Page 391: Visual Inspection
einordnung 23 Nm (17 ftlb.) 3. Push on vent hose −A− . 4. First connect the positive cable then the negative − otherwise there is a danger of a short−circuit! Tightening torque: 5 Nm (3.5 ftlb.). 5. Put on the battery cover and lock with the turn−lock fasteners. 6.
Page 392: Checking Gravity Of Electrolyte
einordnung 2. Remove battery cover. 3. Unscrew battery plugs. 4. Shine a torch into the battery. The electolyte level of the battery must be at the protruding lug . If the acid level is too low, refill distilled water using the battery filling bottle. 5.
Page 393: Open−Circuit Voltage Measurement
einordnung Battery charging condition in Spec. gravity tropical climatic zone (hot in kg/dm³ countries) discharged 1.08 half charged 1.16 well charged 1.23 The gravity of electrolyte must be at least 1.24 kg/dm³. If the gravity of electrolyte is too low, charge battery. After charging the battery, repeat the electrolyte gravity test.
Page 394: Battery Load Test
einordnung If the hand−held multimeter shows a battery voltage below 12.5V: Charge battery. top of page Battery load test Note • The electrolyte gravity test provides information about the state of the battery in connection with the battery load test. •...
Page 395: Charging Battery
einordnung top of page Charging battery WARNING The battery plugs must always be screwed in correctly when charging and during the voltage measurement and the load measurement. Rooms in which batteries are being charged, should not be entered with a naked flame or when smoking. Gases form through the charging process in the batteries which are highly flammable.
Page 396 einordnung Set charge current at maximum 5% of the battery capacity, ie. with a 80 Ah battery the charge current is a max. 4 A. 8. Charge battery. 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841 Charging battery...
Page 397: 06 Electrical Emergency Release
27 06 Electrical emergency release, front cover Note Emergency release, front cover Note • In the event of a flat battery, the release engines of both covers can be supplied with electricity, via a battery jump lead. • A red marked emergency power unit is located on the fuse box in the driver's footwell. •...
Page 398 einordnung 4. Connect second auxiliary wire (negative) onto the vehicle ground (e.g. onto the lock bar of the B−pillar). 5. Connect auxiliary wire to an appropriate electricity source (e.g. separate vehicle battery). 6. Actuate the cover switch on the side member panel and open the cover.
Page 399: 09 Front−Axle Cross Member − Permissible Combinations
40 09 Front−axle cross member − permissible combinations New front−axle cross member − as of model '02 Allocating the front−axle cross member to the body top of page New front−axle cross member − as of model '02 As of model '02, the front−axle cross member is attached to the body at the rear fastening with two •...
Page 400: Impermissible Combination
einordnung Impermissible combination Front−axle cross member with one fastening bore −F1− and body with two fastening points −K2− . • Attention: Impermissible combination! Permissible combinations Front−axle cross member with one fastening bore −F1− and body with one fastening point −K1− . •...
Page 401: Impermissible Combination
einordnung Impermissible combination The combination − front−axle cross member with two fastening bores and (F2) and body with one fastening point (K1) − is not possible! 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841 Impermissible combination...
Page 402: Disassembling And Assembling Front Spring Strut
40 Disassembling and assembling front spring strut Tools Disassembly and assembly instructions top of page Tools Item Designation of Explanation the special tool Spring clamp Commercially available in accordance with Technical Equipment Manual, Chapter 2.4, No. 12. Clamping range of spring holder up to 165 mm spring diameter on one side and 195 mm spring diameter on the other side.
Page 403 einordnung Designation Qty. Removal Installation Fastening nut Before loosening the fastening nut, Use new fastening nut. Tighten M 14 x 1 tension coil spring with the spring to 80 Nm (59 ftlb.). clamp. Counter at the piston rod when loosening the nut. Stop plate Mount in correct position (No.
Page 404: Disassembly And Assembly Instructions
einordnung Spring plate Observe allocation as per Spare (compensation Parts Catalogue. part) Coil spring Observe allocation as per Spare Parts Catalogue. Stop plate Mount in correct position (No. 7 and No. 2 are identical parts). Cup washer Mount in correct position. Additional spring 1 Mount on protective bellows (No.
Page 405: Distinguishing Feature Of Coil Springs And Dampers
einordnung 1. Tension the coil spring with the spring clamp until the piston rod is relieved. 2. Remove all parts from the piston rod. Note • Disassemble back−up ring −4− and mount −4A− only in the case of replacement. 3. Lever out the mount with a small screwdriver. Distinguishing feature of coil springs and dampers A Identification of the running gear version (spring constant/spring length) by two different coloured lines (for example, 1 x blue and 1 x white).
Page 406: Assembly
einordnung • If the coil springs are exchanged, it might be necessary to use a different spring plate than before! 1. Replace nut for fastening the piston rod on the spring strut mount. The following spring plates (compensation parts) are available: 1 white line = 3.0 mm thick compensation part 1 green line = 6.5 mm thick compensation part 2.
Page 407 einordnung • Spring seats for the right and left sides are different! The distinguishing feature of the spring seat is a cast lug on the left spring seat! Also, a different cast number is stamped on the bottom of the spring seat! Example: 996 343 508 02 even number for right side.
Page 408 einordnung Note • Use a socket wrench insert open on one side to tighten the fastening nut on the spring strut mount! In this way the specified tightening torque can be adhered to exactly! It is also possible to counter at the piston rod with countering tool 9630 at the same time! 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651 Assembly...
Page 409: 71 Disassembling And Assembling Rear Spring Strut − Turbo
42 71 Disassembling and assembling rear spring strut − Turbo Tools Disassembling and assembling rear spring strut Disassembly and assembly instructions top of page Tools Item Designation of the tool Remarks Spring clamp (e.g. from Klann) Commercially available, clamping range of spring holder up with spring holder to 165 mm spring diameter top of page...
Page 410 einordnung No. Designation Qty. Removal Installation Fastening nut Before loosening the fastening nut, Use new fastening nut. Tighten to 58 M 12 x 1.5 tension coil spring with the spring Nm (43 ftlb.). First position clamp. spring−strut mount 3. Support at the piston rod with an open−ended wrench (7 mm) when loosening the nut.
Page 411: Disassembly And Assembly Instructions
einordnung part) plate No. 5. Spring plate Stop plate Mount in correct position (No. 2 and No. 6 are identical parts). Washer Additional Mount on protective bellows (No. 9) spring Protective bellows 10 Coil spring Observe allocation as per Spare Parts Catalogue.
Page 412 einordnung 1. Tension the coil spring with the spring clamp until the piston rod is relieved. 2. To undo the connection (piston rod to spring strut mount) counter at the piston rod with a 7mm open−ended wrench. 3. Remove all parts from the piston rod. 4.
Page 413: Distinguishing Feature Of Coil Springs And Dampers
einordnung 6. Fit protective bellows on additional spring. Distinguishing feature of coil springs and dampers A Identification of the running gear version (spring constant/spring length) by two different coloured lines (for example, 1 x gold and 1 x red). Refer to the Parts Catalogue for the allocation. B Identification of the coil spring tolerance group (load group) for determination of the compensation part (spring plate) thickness.
Page 414 einordnung 3. Slide the washer −7− and stop plate −6− (No. 6 in correct position) as far as they will go onto the piston rod. 4. Place the spring strut mount (assembly of spring strut mount / intermediate part / spring plate) onto the piston rod so that the end of the coil spring lies against the stop of the spring plate.
Page 415 einordnung • The mount is positioned correctly if one of the 3 fastening pins is aligned with the holder on the damper tube! 7. Position the spring strut mount for installation (correctly position spring strut mount with respect to the damper). 8.
Page 416: 27 Instructions For Collapsible Wheel/Spare Wheel − Turbo With Pccb
The collapsible wheel is mounted at the front or rear axle wheels using the standard wheel bolts −A− M14 x 1.5 (length 45 mm) dimension −X− ! WARNING Vehicles with PCCB (Porsche Ceramic Composite Brake): Danger of injury and material damage through impaired brake function exists if brake discs are damaged during the mounting/removal of wheels. •...
Page 417: Placing Collapsible Spare Wheel In To The Vehicle − Turbo With Pccb
einordnung top of page Placing collapsible spare wheel in to the vehicle − Turbo with PCCB 1. After using the collapsible spare wheel, release the air by unscrewing the valve case. Note It takes several hours for the tyre to resume its original form! It can only be stowed in the spare wheel •...
Page 418: 60 Steering Angle Sensor
Steering angle sensor position The steering angle sensor has no defined zero position when new. The position for "straight ahead" direction of travel must be programmed. This is done by calibrating with the Porsche System Tester 2 with the wheels in straight−ahead position.
Page 419: Calibrating Steering Angle Sensor
Calibration description in following text. 3. Select the "Calibrate steering angle sensor" menu with the Porsche System Tester 2 in the PSM system. Entry to the PSM system takes place through the ABS system (automatic status change after PSM).
Page 420: Check The Steering Angle Sensor Actual Value In The Following Cases
2. As a check after steering angle sensor calibration. Checking the steering angle sensor actual value 1. Connect the Porsche System Tester 2 to the diagnostic socket. 2. Select vehicle type and then enter PSM system. Entry takes place through the ABS system (automatic status change after PSM).
Page 421: 72 Assignment Of Spoiler Drive, Relays And Instrument Cluster
66 72 Assignment of spoiler drive, relays and instrument cluster Note Variants of the spoiler drive Note In the case of the 911 Turbo (996), it is essential when replacing the spoiler drive, the relay no. 9 or • the instrument cluster to note that only the variants listed in the table below can be installed together. •...
Page 422: 59 Disposal Of Airbag And Belt Tensioner Units
• In the case of airbag units which cannot be ignited or if the conditions for safe ignition are insufficient, always return the airbag units to Porsche or the respective importer in their original packaging! top of page...
Page 423: Tools
einordnung • Ignition and preparations may only be carried out by skilled staff, supervised by a second responsible person! Other normal accident prevention regulations must also be observed! • • Ignite airbag units only in their securely installed, original condition! •...
Page 424: Connecting Ignition Tool
einordnung Ignition cable 9567 For driver's airbag Ignition cable 9566 For passenger's airbag Ignition cable 9257/2 For side airbag Ignition cable 9257/3 For belt tensioner * Order if required top of page Connecting ignition tool Driver's side Connect the ignition device 9257 with the adapter cable 9567 directly to the 2−pin plug of the driver's airbag contact unit (under the steering column).
Page 425: Belt Tensioner
einordnung Connect the ignition device 9257 with the adapter cable 9257/2 to the side airbag plug connection. Place the ignition device in front of the vehicle through the door gap. Belt tensioner Connect the ignition device 9257 with the adapter cable 9257/3 to the belt tensioner. Place the ignition device in front of the vehicle through the door gap.
Page 426 einordnung Note • The driver's and passenger's airbags and side airbags and the belt tensioner must be ignited separately! Attach the ignition device to a vehicle battery and press the button. 996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841 Ignition...
Page 427: 03 Safety Regulations When Handling Refrigerant R134A
87 03 Safety regulations when handling refrigerant R134a The refrigerant R 134a which is used is known as a safety refrigerant. This means that this refrigerant is non−flammable, non−explosive, non−toxic, non−irritating, odorless and tasteless. Despite this, you should still follow the points below: WARNING Danger of injury as a result of contact with liquid or gaseous refrigerants! •...
Page 428: 66 Non−Adjustable Spray Nozzles
92 66 Non−adjustable spray nozzles Note Note The new spray nozzles for the windscreen washer system are not adjustable! • Sharp objects (needles) must not be inserted in the nozzle holes! • • Do not install old and new spray nozzles together! A Old version (adjustable) B New version (non−adjustable) 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841...
Page 429: 23 Bulb Table And Installation Instructions
94 23 Bulb table and installation instructions Bulb table Installing bulbs top of page Bulb table Lamp Shape, Output High beam headlight, dipped beam headlight D2S, 35 W Auxiliary high beam headlight H 11, 55 W Fog light H 3, 55 W Direction indicator light PY, 21 W Rear fog light...
Page 430: 22 Bulb Table And Installation Instructions
96 22 Bulb table and installation instructions Bulb table Installing bulbs top of page Bulb table Shape, Output Interior light, door warning light W 5 W Luggage compartment light K 10 W Bulbs 1.5 W top of page Installing bulbs Note •...
Page 431: 68 Optical Waveguide − Most Bus
97 68 Optical waveguide − MOST bus Note Specifications on handling the optical waveguide Plug connectors Removing and installing optical contacts Optical waveguide modules Tools Note • The optical waveguide will be used as from model year 2003. top of page Specifications on handling the optical waveguide •...
Page 432: Repairs
einordnung • Maximum permissible tensile load: 60 N • Minimum bending radius after and during installation in vehicle: 25 mm Maximum number of torsions: 10 torsions per m • The following points must be observed when installing optical waveguides and wiring harnesses containing optical waveguides: •...
Page 433: Control Module Plug Connector (Wiring Harness Side)
einordnung By actuating the lock −arrow− , the protective dust cap can be pulled off. • The protective dust cap must be replaced after every test of an optical waveguide. During or after removal of the protective dust cap, do not touch the exposed contact surfaces, because •...
Page 434: Removing And Installing Optical Contacts
einordnung top of page Removing and installing optical contacts Disconnecting plug connector at PCM: • Remove PCM ’ 9, 911019 Removing and installing control unit (PCM2) . Disconnecting plug connector at amplifier: • Remove cover for brake booster. Disconnecting connector in front luggage compartment: Connectors...
Page 435: Removing Optical Contacts On Plug Side
einordnung Disconnecting plug connector at CD changer: Remove CD changer. • Disconnecting plug connector of control module for telephone: • Remove passenger's seat ’ 7, 720119 Removing and installing front seat . Remove holder for control module for telephone ’ 9, 919019 Removing and installing control module •...
Page 436: Installing Optical Contacts On Plug Side
einordnung 2. Position tool at the primary lock and raise the lock. −A− Optical contact, grey −B− Optical contact, black 3. Pull carefully on the optical waveguide, e.g. −B− in the −direction of the arrow− . If it is not possible to pull out the optical waveguide, check again whether the secondary lock has been completely unlocked and whether the primary lock has been raised far enough.
Page 437: Removing Optical Contacts On Bushing Side
einordnung 2. Close the secondary lock −arrow− and check for proper seating of the optical contacts. Removing optical contacts on bushing side 1. Unlock and remove the spring cap on both sides using the press−out tool => Tools. 2. Remove the optical waveguide module from the plug. 3.
Page 438: Optical Waveguide Modules
einordnung 1. Push the optical contacts −B− and −A− into the module until they engage perceptibly. Check for proper seating of the optical contacts. 2. Connect the module to the connector on the bushing side. 3. Push the spring cap on to the connector until it engages perceptibly −arrow− . top of page Optical waveguide modules At least one transmitter diode and one receiver diode is installed in all MOST control modules.
Page 439: Tools
einordnung 1 MOST control modules: −A− Radio/PCM, lead −1− in connection with amplifier or CD changer without telephone. −A− Radio/PCM, lead −2− in connection with telephone without amplifier and CD changer. −A− Radio/PCM, lead −3− in connection with telephone and amplifier or CD changer. −B−...
Page 440: Sales Check
01 Sales check Working position 01 01 00 00 Working instruction to order no. Workshop no. Vehicle Ident. No. Check conformity of vehicle Ident. No. on vehicle, data bank, vehicle registration documents and on−board literature => Checking the Vehicle Ident. No. Remove transport locks, transport protection =>...
Page 441 Diagnostic system: read out or erase fault memory => Diagnostic system&colon; Read out fault memory and activate systems OK = functioning correctly Not OK = not functioning correctly Stamp of Official Porsche Centre 996430, 996431, 996420, 996421, 996450, 996451, 996840, 996841 01 Sales check...
Page 442: 24 00 Minor Maintenance
03 24 00 Minor maintenance Note Note Not valid for USA. • The engine oil and oil filter must be changed every 10,000 km (6,000 mls) on vehicles which are • operated in countries where the fuel has a high sulphur content (country coding M 150 in the control module).
Page 443 einordnung Vehicle lighting: check function; all headlights: check adjustment; horn: check operation => Checking the function of the vehicle's lights Windscreen washer, headlight washer: check fluid level and nozzle settings, pay attention to antifreeze protection in the winter months => Windscreen wiper/washer system, headlight washer All other electrical equipment as well as warning and indicator lights: check operation =>...
Page 444: 26 00 Major Maintenance
03 26 00 Major maintenance Note Note Not valid for USA! • The engine oil and oil filter must be changed every 10,000 km (6,000 mls) on vehicles which are • operated in countries where the fuel has a high sulphur content (country coding M 150 in the control module).
Page 445 einordnung Steering gear: visually inspect the bellows for damage => Steering gear&colon; fluid level and bellows Checking the tie rod end play and dust bellows => Axle joints/drive shafts Axle joints: check play, visual inspection of dust bellows for damage => Axle joints/drive shafts, check screw connections of running gear adjustment facility, front and rear, for secure fit =>...
Page 446: 50 00 Annual Maintenance
03 50 00 Annual maintenance Note Note Not valid for USA. • The engine oil and oil filter must be changed every 10,000 km (6,000 mls) on vehicles which are • operated in countries where the fuel has a high sulphur content (country coding M 150 in the control module).
Page 447 einordnung Vehicle lighting: check function; all headlights: check adjustment; horn: check operation => Checking the function of the vehicle's lights All other electrical equipment as well as warning and indicator lights: check operation => Checking the function of electrical equipment, as well as the indicator and warning lights Test drive: Remote control, front seats, foot and parking brakes (also actuation travel), engine, clutch, steering, transmission, ParkAssist, automatic speed control, PSM switch, heating, air−conditioning...
Page 448: 01 00 Tightening Torques For M 96/70 Engine
10 01 00 Tightening torques for M 96/70 engine Crankshaft/crankcase Cylinder, cylinder head and camshaft housing top of page Crankshaft/crankcase Note • The fastening screw of the belt pulley must always be replaced. Tightening torque Nm Location Thread (ftlb.) Initial tightening of connecting−rod screws M9 x 1.25 30 Nm [22 ftlb.] ±...
Page 449 einordnung Location Thread Tightening torque Nm (ftlb.) Cylinder head nut (coat thread and sealing 30 Nm (22 ftlb.), then unscrew; 20 Nm (15 surface of the nuts with engine oil) ftlb.) (joining torque); then retighten all screws to 20 Nm (15 ftlb.); final tightening with 120°...
Page 450: 10 37 Disassembling And Assembling Crankcase
10 10 37 Disassembling and assembling crankcase Tools Adapting engine holder Left crankcase half (cylinder bank 1 Right crankcase half (cylinder bank 4 − 6) Disassembling the crankcase Assembling the crankcase. top of page Tools Item Designation Special tool Explanation Engine holder Holder P 201 Fasten to the right half of the crankcase (cyl.
Page 451 einordnung Note • If the special tool is to be screwed into position for the first time with the engine holder P 201, two threaded bores must be provided in addition. Item Designation Special tool Explanation Engine holder (adapter) Engine holder 9667 Additional fastening of the crankcase via four studs.
Page 452 einordnung Retaining device Retaining device For bracing the tension rod bolts 9662 when tightening Surface seal Drei Bond Silicon Type 1209 Retainer plate Retainer plate P Screw the crankshaft to the 209a retainer plate with internal serration screws Part No. 928.102.151 01.
Page 453: Adapting Engine Holder
einordnung Adapting engine holder Note • The threaded bores must only be provided if the adapter ring is used for the first time. Procedure Instructions Centring adapter on engine holder Centring engine holder Reworking engine holder Fastening adapter on engine holder Engine holder with adapter half Adapting engine holder...
Page 454 einordnung Mounting adapter half on crankcase 1. Centring adapter on engine holder. Fasten the adapter half with the already made bores −arrows− with two auxiliary screws M10 x 60 onto the engine holder. Spot−drill or countersink the engine holder slightly through the bores in the adapter ring using a drill bit Ø 6.5. The adapter ring serves as the drilling template.
Page 455: Left Crankcase Half (Cylinder Bank 1 3)
einordnung 5. Mount engine holder with adapter half. Screw engine holder with screwed in adapter half onto the crankcase half of the cylinder bank 4 − 6. 6. Mount the second adapter half on crankcase. Screw the screw sleeves onto the studs and tighten by hand. Screw in connecting screws of the adapter half and tighten with 10 Nm (7.5 ftlb.).
Page 456 einordnung Note: No. Designation Qty. Removal Installation Hexagon−head bolt M8 x Holder 2a Fastening nut M8 Hexagon−head bolt M6 x Hexagon−head bolt M6 x Sensor holder Plug Tightening torque 70 Nm (52 ftlb.) Sealing ring A22 x 27 Always replace Threaded insert M20 x 1.5 1 Left crankcase half (cylinder bank 1...
Page 457: Right Crankcase Half (Cylinder Bank 4 − 6)
einordnung Screw−in flanges (oil Tightening torque 70 Nm (52 ftlb.) return) 10 Sealing ring A22 x 27 Always replace 11 Screw plug for oil pressure Tightening torque 50 Nm (37 ftlb.) relief valve M18 x 24 12 Sealing ring A18 x 24 Always replace 13 Compression spring 14 Piston for excess pressure...
Page 458 einordnung Note: Designation Qty. Removal Installation Screw plug Tightening torque 50 Nm (37 ftlb.) Piston Compression spring Guide sleeve Spacer ring Sealing ring A18 x 24 Replace omitted omitted omitted Fastening nut M8 Washer 8.4 Right crankcase half (cylinder bank 4 − 6)
Page 459: Disassembling The Crankcase
einordnung Hexagon−head bolt M8 x 45 Fastening nut M8 Replace Fastening nut Replace Washer Hexagon−head bolt M8 x 55 Hexagon−head bolt M8 x 45 Crash support Tension rod bolts Washer O−ring 8 x 2 Replace, oiled lightly O−ring 8.3 x 2.4 Replace Tension rod bolts Screw plug M18 x 1.5...
Page 460 einordnung 1. Position the toothed segment special tool P201b on the stud and undo the pan−head screws of the clutch pressure plate in several stages and in diametrically opposite sequence, to avoid deforming the thrust plate. 2. Fasten mounting device P238b with holder P140 onto the studs. Loosen flywheel screws and remove the flywheel.
Page 461 einordnung M6 x 20. Hexagon head bolts on pulse sender 5. Loosen belt pulley. To do this, a second person should counter with the holding wrench 9548 at the same time. Do not continue to use the hexagon−head bolt. 6. Loosen the 18 hexagon nuts (M8) of the housing screw connections. 7.
Page 462: Assembling The Crankcase
einordnung Removing tension rod bolts. 9. Crankcase half (cylinder bank 1 − 3). 10. Remove O−rings and tension rod bolts of thrust blocks 2, 3, 4 and 5. top of page Assembling the crankcase. 1. Fasten engine holder P201 to the right crankcase half (cylinder bank 4 − 6). 2.
Page 463 einordnung Pairing number on crankcase Pairing number on crankshaft gearwheel −arrow− Pairing number on the intermediate shaft gearwheel −arrow− 4. Clean crankcase halves thoroughly. Check whether there are any foreign objects (e.g. residual sealant) in the receiving bores of the tension rod bolts. 5.
Page 464 einordnung 6. Oil the bearing surfaces. Insert intermediate shaft and check for true running. 7. Insert new crankshaft bearing shell halves into the crankcase. Oil the bearing surfaces. 8. Check that the dowel sleeves are present and seated properly. 9. Insert crankshaft (excluding mount 8) into the crankcase half of the cylinder bank 4 −...
Page 465 einordnung 12. Let a second person lift the crankshaft slightly and push bearing no. 8 onto the crankshaft journal. 13. Lower the crankshaft slowly and insert crankshaft bearing no. 8 into the dowel pin. 14. Check installation position. If the mounting is correct, the centre of the bearing notch should be on the same level as the sealing surface.
Page 466 einordnung 16. Insert the complete unit, oil pump with dumb−bell shaft and intermediate shaft with both timing chains into the crankcase half. 17. Fasten new collar nuts (3 pieces). Tightening torque 23 Nm (17 ftlb.). 18. Check dumb−bell shaft. The dumb−bell shaft must be easily movable in axial direction. If necessary, re−loosen the oil pump with the intermediate shaft and shift the dumb−bell shaft.
Page 467 einordnung Prepare four tension rod bolts. Push sealing washers on to tension rod bolts. Feed lightly oiled O−rings with conical sleeve from special tool 9511 over the threaded area and push them on to the tapered section towards the head of the bolt. Observe the A side and B side on the assembly sleeve 9511.
Page 468 einordnung Cylinder sleeve application 20. Lift connecting rod of cylinder 4, 5 and 6 with restraining straps, special tool P221. Lift timing chain with tension strap. 21. Coat both sides of sealing rings on the oil pump (2 pieces) and the sealing ring on the crankcase half with vaseline and insert.
Page 469 einordnung Check the relief groove in the area of the main bearing no. 7 for foreign objects, e.g. silicone residue and clean if necessary. Insert the crankcase half carefully over the preassembled tension rod bolts of thrust blocks 2, 3, 4 and 5, at the same time having a second person pull the chain upwards through the chain space.
Page 470 einordnung 25. Insert the prepared tension rod bolts of the crankcase half 4 − 6 and hold. 26. Push the conical sleeve of special tool 9511 with an oiled O−ring to the end of the thread. 27. Push the O−ring carefully away from the conical sleeve with the A−side (thin wall) of the cylinder sleeve. View of the conical sleeve 28.
Page 471 einordnung • Cover the chain space briefly when fitting so that parts do not fall into the crankcase. 32. Mount hexagon nut M10 x 1.25 and washer A10.5 on stud, with rounded side pointing towards the hexagon nut. 33. Mount retaining device, special tool 9662, on corresponding tension rod bolts and position with holder, special tool P140.
Page 472 einordnung 35. Tighten tension rod bolts onto the flywheel side to 50 Nm (37 ftlb.). 36. Fit new self−locking hexagon nut with washers and tighten to 50 Nm (37 ftlb.). Note The self−locking nuts must always be replaced. • 37. Fit remaining crankcase screw connections. Tighten the hexagon nuts to 23 Nm (17 ftlb.). 38.
Page 473 einordnung 39. Mount new cylindrical pin so that it is flush. CAUTION Danger of injury • The holding wrench must be in contact with the belt pulley when tightening. 40. Always replace fastening screw of the belt pulley. When tightening the belt pulley, a second person must counter with the special tool 9548.
Page 474: 10 19 Removing And Installing Pistons (Includes Removing And Installing Cylinders)
13 10 19 Removing and installing pistons (includes removing and installing cylinders) Tools Removing pistons and cylinders Removing pistons Installing pistons and cylinders top of page Tools 13 10 19 Removing and installing pistons (includes removing and installing cylinders)
Page 475: Removing Pistons And Cylinders
einordnung Item Designation Special tool Explanation Assembly aid Assembly aid 9657 For positioning the restraining strap over the piston rings Restraining strap Restraining strap 9659 For mounting the pistons of cylinders 2 and 5. (Scope of delivery, 3 pieces) Piston ring restraining strap Refer to Workshop Equipment Manual, Chapter 2.4, No.
Page 476 einordnung Note: No. Designation Qty. Removal Installation Cylinder Identify, e.g. with cyl. 1 −3 or 4 − 6 Bushings Identify with cyl. 1, 2, 3, 4, 5 or 6; assign to Oil running surfaces the corresponding piston O−ring Replace on principle, mount 104.00x2.00 with special grease, do not twist...
Page 477: Removing Pistons
einordnung Piston Identify with cyl. 1, 2, 3, 4, 5 or 6, assign to Oil piston shank the corresponding bushing, do not mark or clean piston with a sharp object. Piston rings Straight pins A8, 0x14 10 Cylinder base Replace on principle, note seal installation position, "Top"...
Page 478: Installing Pistons And Cylinders
einordnung Remove O−rings of cylinder and O−rings of the bushings and dispose of. Assign bushings to the corresponding piston. top of page Installing pistons and cylinders Note • Observe installation sequence • The central pistons of cylinders 2 and 5 are mounted onto the connecting rod without bushing. •...
Page 479 einordnung 2. Oil piston liberally. Mount commercially available restraining strap. Position special tool 9659/9 on top of the piston (piston junk). 3. Align restraining strap. The restraining strap lock should be aligned between the inlet valve recesses. Note • The assembly sleeve is used to position the restraining strap. •...
Page 480 einordnung 6. Mount the piston on the connecting rod. Push in oiled piston pin as far as it will go. Note • A second person's help is recommended for pushing the circlip into the piston. Cover the opening in the crankcase below the piston so that the snap ring can not fall into the •...
Page 481 einordnung Mount new O−rings onto the bushings. Grease O−ring area liberally. Mount outer bushings in the cylinders. Align the bushings in the cylinder. The flattened areas must face towards the other bushings in longitudinal direction. The recesses on the bushing must align with the bores of the studs.
Page 482 einordnung View of the mounting tool The outer bushings can also be pushed in with an hydraulic press if necessary. Oil piston shank. Mount commercially available piston restraining strap. Push piston into the bushing. Push the piston restraining strap downwards at the same time during this procedure. Check the position of the pistons.
Page 483 einordnung 9. Mount the piston pins into the associated pistons from the inner side. The piston pin should only be inserted so far that the connecting rod can still be mounted. 10. Check pistons for correct installation position. The large valve recesses must face upwards in the installation position.
Page 484 einordnung • Check that the piston pin circlips are seated correctly! 14. Mount the piston pin and the piston pin circlip of the outer pistons from the inside (through the central cylinder opening). 15. After fitting the piston pin circlip, push the cylinder up to the spacers 9651. Secure the cylinder with the special tool, holder P 140.
Page 485 einordnung View of the special tool 19. Slowly turn belt pulley or the crankshaft clockwise until the central piston can no longer be seen in the gap between the cylinder and the crankcase. Then press the bushing into place with the pushing device until the restraining strap detaches from the piston shank.
Page 486: 19 21 Removing Piston Rings
13 19 21 Removing piston rings Tools Removal top of page Tools Item Designation Special tool Explanation Piston ring pliers Gr. Commercially available; refer to Workshop For the removing and fixing 1 No. 58 Equipment Manual, Chapter 2.4, No.: 58 of the piston rings.
Page 487 einordnung 1 Prepare piston 2 Remove pistons with piston ring pliers. 3 Remove piston rings from piston ring pliers. 4 Look for the gap of the oil scraper ring. 5 Pull apart the oil scraper spring ring. 6 Remove oil scraper spring ring. Removal...
Page 488 einordnung 1. Place the removed pistons on a clean surface and look for the gap of the piston rings. 2. Remove the piston rings starting from the piston crown. In order to do this, place the middle point of the piston ring pliers into the gap of the relevant ring. The holding arms of the piston ring pliers should clasp the piston ring from above.
Page 489 einordnung 5. Pull apart the oil scraper spring at the gap. 6. Remove the oil scraper spring from the third ring groove. 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841 Removal...
Page 490: 19 23 Installing Piston Rings
13 19 23 Installing piston rings Tools Installation top of page Tools Item Designation Special tool Explanation Piston ring pliers Gr. 1 Commercially available; refer to Workshop For the removing No. 58 Equipment Manual, Chapter 2.4, No.: 58 and installing of piston rings top of page Installation...
Page 491 einordnung 1 Open oil scraper spring. 2 Push together oil scraper spring. 3 Align the gap of the oil scraper spring. 4 Insert piston ring into the piston ring pliers. 5 Install piston rings. 6 Check that the piston ring is correctly seated and positioned. Installation...
Page 492 einordnung Open oil scraper spring. In order to do this, pull apart the oil scraper spring at the gap. The gap can be recognised by the tighter winding of the spring. 2. Insert oil scraper spring. Insert the oil scraper spring into the lowest ring groove and then push together. 3.
Page 493 einordnung of the second ring groove must be between the gap of the stepped taper faced ring. Insert the taper faced ring into the ring groove in such a way that the designation TOP is pointing toward the piston crown. 6.
Page 494: 48 37 Disassembling And Assembling Crankshaft
13 48 37 Disassembling and assembling crankshaft Tools Disassembling crankshaft Pressing ring knurled screw in and out Assembling crankshaft top of page Tools Item Designation of the special tool Explanation Retainer plate P209 a Pan−head screws SP No. 928.102.151.01 (3 ea.) Snap ring pliers Commercially available 13 48 37 Disassembling and assembling crankshaft...
Page 495 einordnung No. Designation Qty. Removal Installation Radial sealing ring Replace Bearing sleeve, Replace bearing 8 Round seal Replace, do not fit twisted Radial sealing ring Replace Snap ring Carry out insertion test Spacer ring Warm on heating plate, push on up to stop Timing gear Check toothing Note reference number, paired with intermediate...
Page 496: Disassembling Crankshaft
einordnung Connecting rod nut Replace, tightening torque: M9 x 1.25 Initial tightening: 30 Nm (22 ftlb.) Final tightening: 1 x 90° turn 10 Connecting rod Note installation position and weight. Note classification or matching number to connecting−rod bearing cap 11 Connecting rod Replace bearing shell half 12 Connecting−rod...
Page 497: Identifying The Ring Knurled Screw
einordnung 5. Remove snap ring with snap ring pliers. 6. Remove spacer ring and timing gear with a conventional puller. 7. Raise Woodruff key with side cutters and remove. 8. Remove crankshaft from retaining plate. 9. Check crankshaft for shocks, cracks and wear. 10.
Page 498: Pressing Ring Knurled Screw In And Out
einordnung Note • The visual difference between the 3−ring knurled screw and the 4−ring knurled screw can only be detected when the screw is pressed out. 1. Identify the ring knurled screw. With the screw pressed in, measure the groove diameter. Object Measured value Screw type Diameter groove 1...
Page 499: Pressing Ring Knurled Screw In
einordnung 1. Clamp the con−rod cover into a machine vice. Press both 4−ring knurled screws out at the same time. Pressing ring knurled screw in CAUTION In order to avoid damage to the joint face, always use an aluminium sleeve, e.g. from the special tool set P140 (retainer sleeves for cylinders).
Page 500 einordnung 5. Lubricate the con−rod journals with grease (Optimal Optipit) and mount the connecting rods on the crankshaft. Note • The matching numbers of the con−rods and the con−rod bearing caps must all point to the same side. 6. Tighten con−rod nuts. 7.
Page 501 einordnung • As an assembly aid, remove the timing gear from the heat source e.g. with a piston restraining strap and quickly mount or push it into place on the journal. 9. Warm the timing gear to approx. 150 − 200°C in an oil bath or on a heating plate and push it on to the crankshaft journal up to the stop.
Page 502 einordnung 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841 Assembling crankshaft...
Page 503: 73 37 Disassembling And Assembling Belt Tensioner
13 73 37 Disassembling and assembling belt tensioner Assembly note No. Designation Qty. Removal Installation Hexagon−head bolt M10 x Insert the front right hexagon−head bolt (direction of travel) with Loctite 574. Tightening torque: 65 Nm (48 ftlb.) Hexagon−head bolt M8 x Hexagon−head bolt M8 x 13 73 37 Disassembling and assembling belt tensioner...
Page 504 einordnung Hexagon−head bolt M8 x Tightening torque 23 Nm (17 ftlb.) Cover plate Deflection roller Check for smooth running or roughness before undoing Spacer O−ring Check, replace if necessary Hexagon−head bolt M8 x Tightening torque: 23 Nm (17 ftlb.) 10 Cover plate 11 Deflection roller Check for smooth running or roughness before undoing...
Page 505: Assembly Note
einordnung top of page Assembly note 1. Thread transmission lever on to tensioning lever. Tightening torque: 65 Nm (48 ftlb.) 2. Insert the front right hexagon−head bolt on the bracket with Loctite 574. 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841 Assembly note...
Page 506: 78 19 Removing And Installing Drive Belt (Engine Installed)
13 78 19 Removing and installing drive belt (engine installed) Removal overview of the drive belt (engine installed) Remove drive belt Installation overview of the drive belt (engine installed) Install drive belt top of page Removal overview of the drive belt (engine installed) 13 78 19 Removing and installing drive belt (engine installed)
Page 507: Remove Drive Belt
einordnung 1 Remove air cleaner assembly 2 Loosen servo pump wheel 3 Relieve drive belt 4 Remove servo pump wheel 5 Remove drive belt top of page Remove drive belt Removal overview of the drive belt (engine installed)
Page 508 einordnung 1. Remove air cleaner assembly Remove the complete air cleaner assembly. a. Undo hexagon−head bolt M6 x b. Undo the hose clamp on the throttle body. c. Pull off plug from hot film mass air flow sensor and remove air cleaner assembly. 2.
Page 509: Installation Overview Of The Drive Belt (Engine Installed)
einordnung 4. Remove servo pump wheel Note • Only remove the servo pump wheel when the drive belt is completely relieved! f. Remove servo pump wheel with drive belt to the rear. g. Remove the belt from all drive wheels and lift up to remove.
Page 510 einordnung 1 Fit drive belt 2 Position servo pump wheel 3 Tension drive belt 4 Tighten fastening screws on servo pump 5 Install air cleaner assembly top of page Installation overview of the drive belt (engine installed)
Page 511: Install Drive Belt
einordnung Install drive belt 1. Fit drive belt Fit the belt onto the drive wheels. 2. Position servo pump wheel a. Put on the servo pump wheel together with the drive belt. b. Slightly tighten the three fastening screws on the servo pump wheel.
Page 512 einordnung 4. Tighten fastening screws on servo pump Tighten the fastening screws of the servo pump drive wheel. Tightening torque: 23 Nm (17 ftlb.) 5. Install air cleaner assembly Install air cleaner assembly completely. e. Attach connector onto mass air flow meter.
Page 513: 03 21 Removing Camshaft Housing Engine Removed
15 03 21 Removing camshaft housing engine removed Tools Component overview and tightening torques Removing the camshaft housing top of page Tools Item Designation of the tool Remarks −A− Special tool holding wrench 9653/1 For countering the exhaust camshaft Gr. 2.2.2 ; Workshop Equipment Manual −B−...
Page 514 einordnung No. Designation Qty. Removal Installation Closure cap, green Replace; insert dry Cover with 3 Replace O−ring; tightening hexagon−head bolts M6 x torque 10 Nm (7.5 ftlb.) 20 and O−ring Oil pump with 3 Replace O−ring; tightening hexagon−head bolts M6 x torque 10 Nm (7.5 ftlb.) 35 and O−ring Hexagon−head bolt M 6 x...
Page 515 einordnung 6a O−ring for hydraulic valve 1 Replace O−ring, oil lightly if necessary (engine oil) Hexagon−head bolt M6 x 10 Nm (7.5 ftlb.) Hexagon−head bolt M 6 x (Pages 4 − 6 only 12 M6 x 35) 10 Nm (7.5 ftlb.) −...
Page 516: Removing The Camshaft Housing
einordnung Observe identification on the rotor! (cylinder bank allocation) 24 Flat−base tappets of Do not exchange Oil lightly, pay attention to exhaust camshaft cleanliness! 25 Operating plunger of inlet Do not exchange Oil lightly, pay attention to camshaft cleanliness! 26 Camshaft housing with 18 If hexagon−head bolts of Tightening torques: Initial hexagon−head bolts M8 x...
Page 517 einordnung 7. Remove camshaft housing cover. Unscrew the 15 hexagon−head bolts M6 and remove the camshaft housing cover. If this is stuck, it can be loosened by gently tapping with a plastic hammer. 8. Check engine position. The cylinder side which is to be worked on must be positioned to overlapping TDC so that the camshaft can be removed without tension.
Page 518 einordnung 9. Remove chain tensioner. To do this, unscrew the two fastening screws of the chain tensioner cover and remove the cover. Then remove the chain tensioner. 10. Remove guide rail for timing chain. Remove the three fastening screws on the short guide rail between the camshaft sprockets and remove the guide rail.
Page 519 einordnung • The oil guide housing of cylinder 1 − 3 and 4 − 6 differ in height. 12. Remove oil guide housing. Heat the three hexagon socket head bolts using a hot−air gun, unscrew and remove the housing. The fastening screws are microencapsulated and therefore must be replaced.
Page 520 einordnung 15. Remove thrust bearing cover. Unscrew the hexagon−head bolts and remove the thrust bearing cover up and off. 16. Lift camshafts up and out. WARNING Do not confuse the flat−base tappets. The flat−base tappets have been run in in their housing. Therefore, they must not be interchanged or soiled. 17.
Page 521: 03 23 Installing Camshaft Housing
15 03 23 Installing camshaft housing Refer to tools and tightening torques in Chapter "Removing camshaft housing"! 1. Replace seals. Replace the seals between the chain box/camshaft housing and the cylinder head/camshaft housing seal. The embossed recesses in the seal must face the cylinder head. 2.
Page 522 einordnung Subsequently install the camshafts => Removing and installing camshafts – engine removed. 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651 15 03 23 Installing camshaft housing...
Page 523: 05 02 Checking Camshafts (Timing) Engine Removed
15 05 02 Checking camshafts (timing) engine removed Tools Checking camshafts top of page Tools Item Designation of the tool Remarks −A− Special tool holding wrench 9653/1 For countering the exhaust camshaft Gr. 2.2.2 ; Workshop Equipment Manual −B− Special tool holding wrench 9653 For countering the inlet camshaft Gr.
Page 524: Checking Camshafts
einordnung Item Special tool designation Remarks Auxiliary chain tensioner 9401 For removing play from the timing drive mechanism Adjustment device 9661 with holding keys 9661/1 In order to fix the camshafts in the correct position top of page Checking camshafts The following prelimiminary work must be carried out: •...
Page 525 einordnung 5. Remove oil extraction pump and closure cap. The oil extraction pump flange must be held with a wrench when the oil line on the pump is loosened. Subsequently unscrew the three fastening screws of the oil extraction pump and the three fastening screws of the closure cap, then lever off the two components.
Page 526 einordnung 10. To set the timing, the respective cylinder side must be positioned to overlapping TDC. For this purpose, turn the engine at the belt pulley of the crankshaft (in operating direction) until the maximum defection (reversing point) is attained on the dial gauge. The cams of the 1st cylinder point towards each other −Figure 10.1−...
Page 527 einordnung 11. Turn camshaft adjusting element of the inlet camshafts to its left stop. Use special tool holding wrench 9653 to turn the actuating element of the inlet camshaft counter−clockwise until it meets the stop. Note Tighten the screws for the adjustment device only slightly. It must be possible to move the frame •...
Page 528 einordnung Correctly set camshafts 14. Turn the engine on the belt pulley of the crankshaft by 360° clockwise so that the second cylinder side can be checked. (Observe maximum defection of dial gauge indicator or TDC position!). Note • Camshaft adjusting element must be positioned to the left−hand stop! Use special tool holding wrench 9653 ! 15.
Page 529 einordnung Tightening torque of new spark plug 30 Nm (22 ftlb.); used spark plugs 25 Nm (19 ftlb.) 24. Install ignition coils. Insert ignition coils in spark−plug recess. Position 2 pan−head screws (hexagon socket) M6 x 25 and tighten with tightening torque. Connect cable plug. Tightening torque of pan−head screw M6 10 Nm (7.5 ftlb.) Note •...
Page 530: 05 16 Setting Camshafts (Timing) Engine Removed
15 05 16 Setting camshafts (timing) engine removed Tools Setting the camshafts (timing) top of page Tools Item Designation of the tool Remarks −A− Special tool holding wrench 9653/1 For countering the exhaust camshaft Gr. 2.2.2 ; Workshop Equipment Manual −B−...
Page 531: Setting The Camshafts (Timing)
einordnung Item Special tool designation Remarks Auxiliary chain tensioner 9401 For removing play from the timing drive mechanism Adjustment device 9661 with holding keys 9661/1 In order to fix the camshafts in the correct position top of page Setting the camshafts (timing) Preliminary work: •...
Page 532 einordnung 2. Fit auxiliary chain tensioner for both cylinder banks. Unscrew two hexagon−head bolts M6 on each chain tensioner cover and remove the covers with the chain tensioner. Subsequently screw on both auxiliary chain tensioners and then apply pretension using the hexagon−head bolt until the first ring on the piston just disappears from view.
Page 533 einordnung Note • Camshaft adjusting element must be positioned to the left−hand stop! Use special tool holding wrench 9653 ! 5. Turn camshaft adjusting element of the inlet camshafts to its left stop. Use special tool holding wrench 9653 to turn the actuating element of the inlet camshaft counter−clockwise until it meets the stop. Note •...
Page 534 einordnung Adjustment device of cylinder bank 4 − 6 8. Set camshafts on cylinder side 1 − 3 (cams of both camshafts point towards each other on cylinder 1). To do this, use a suitable open−ended wrench (a/f 30) to turn the hexagon on the camshafts until the holding key of the staking tool easily enters the slot of the camshaft.
Page 535 einordnung Turn the engine on the belt pulley of the crankshaft by 360° clockwise so that the second cylinder side can be set. (Observe maximum defection of dial gauge indicator or TDC position!). 11. Set cylinder side 4 − 6 in the same way as side 1 − 3 (cams of both camshafts on cylinder 4 point away from each other).
Page 536 einordnung Install ignition coils. Insert ignition coils in spark−plug recess. Position 2 pan−head screws (hexagon socket) M6 x 25 and tighten with tightening torque. Connect cable plug. Tightening torque of pan−head screw M6 10 Nm (7.5 ftlb.) Note Replace fastening nuts for holder of turbocharger! •...
Page 537: 05 19 Removing And Installing Camshafts Engine Removed
15 05 19 Removing and installing camshafts engine removed Tools Component overview and tightening torques Removing camshafts Installing camshafts top of page Tools Item Designation of the tool Remarks −A− Special tool holding wrench 9653/1 For countering the exhaust camshaft Gr. 2.2.2 ; Workshop Equipment Manual −B−...
Page 538: Component Overview And Tightening Torques
einordnung −D− Commercially available torque angle wrench Gr. 2.4; Workshop Equipment Manual, No. 88 716/20 top of page Component overview and tightening torques Designation Qty. Removal Installation Closure cap, green Replace; insert dry Cover with 3 hexagon−head Replace O−ring; bolts M6 x 20 and O−ring tightening torque 10 Nm (7.5 ftlb.) Oil pump with 3...
Page 539 einordnung hexagon−head bolts M6 x 35 tightening torque 10 and O−ring Nm (7.5 ftlb.) Hexagon−head bolt M 6 x 25 2 10 Nm (7.5 ftlb.) Holder for hydraulic valve Hydraulic valve for valve lift Pull out carefully, use special tool Special tool Gr.
Page 540: Removing Camshafts
einordnung Hexagon−head bolts M6 x 30 Unscrew screws from the inside Tighten in specified (10.9) sequence (description); 13 Nm (9.5 ftlb.) Camshaft bearing cap Unscrew carefully! Grease lightly; observe matching number! Hexagon−head bolts M6 x 30 13 Nm (9.5 ftlb.) (10.9) Thrust bearing cover Unscrew carefully!
Page 541 einordnung 5. Remove oil extraction pump and closure cap. The oil extraction pump flange must be held with a wrench when the oil line on the pump is loosened. Subsequently unscrew the three fastening screws of the oil extraction pump and the three fastening screws of the closure cap, then lever off the two components.
Page 542 einordnung Figure 8.2: Overlapping TDC of cylinder 4 − 2 − Inlet camshaft • • − 1 − Exhaust camshaft 9. Remove chain tensioner. To do this, unscrew the two fastening screws of the chain tensioner cover and remove the cover. Then remove the chain tensioner. 10.
Page 543 einordnung 11. Remove camshaft sprockets. The timing chain must not be loaded when the screw connection of the camshaft sprockets is loosened. To remove the sprocket wheels, the actuating element of the inlet camshaft must be countered using special tool holding wrench 9653 , and the sprocket wheel of the exhaust camshaft must be countered using speical tool holding wrench 9653/1 .
Page 544: Installing Camshafts
einordnung 14. Remove camshaft bearing covers. Lift the bearing covers up and off. The bearing covers must not be confused. 15. Remove thrust bearing cover. Unscrew the hexagon−head bolts and remove the thrust bearing cover up and off. 16. Lift camshafts up and out. top of page Installing camshafts Note...
Page 545 einordnung 1. Mount the oil guide housing. Fit the oil guide housing above the three sealing rings of the inlet camshaft. The oil guide housing should be lightly oiled for this purpose. Press the sealing rings together by hand and push the oil guide housing over them.
Page 546 einordnung 3. Insert camshafts. The bearing locations of the camshafts must be lightly greased before installation. Place the timing chain over the camshafts when inserting the camshafts. 4. Position camshafts. It must be ensured that the camshafts are correctly positioned in the bearing locations.
Page 547 9653 . New chain sprockets for the exhaust camshafts (left and right part) have been in use as of May 2001. The identical chain sprocket remains an original Porsche part − observe part numbers! Identification of the sprocket wheels...
Page 548 einordnung • Left wheel with coating and part number (identification "left" on rear side) • Right wheel with part number and identification "right" (coating on rear side) Note The contact surfaces of the sprocket wheels and camshaft flange (exhaust side) must be completely •...
Page 549 einordnung 10 Nm (7.5 ftlb.). 15. Clean sealing surface for the camshaft housing cover. 16. Install camshaft housing cover. Apply a silicone bead of a maximum 1.5 mm −Figure− (drying time of sealant approx. 5 min). Put on the camshaft housing cover and tighten the 15 fastening screws from the inside to tightening torque.
Page 550: 20 37 Disassembling And Assembling Intermediate Shaft
15 20 37 Disassembling and assembling intermediate shaft No. Designation Qty. Removal Installation Thrust bearing shell half Replace, insert in crankcase half of cylinder bank 1 − 3 Bearing shell half Replace, insert in crankcase half of cylinder bank 1 − 3 Dumb−bell shaft Check for true running without any problems;...
Page 551 einordnung Snap ring Check, replace if 13 x 1.75 necessary Bearing shell half Replace and insert into crankcase half of cylinder bank 4−6 Thrust bearing shell half Replace and insert into crankcase half of cylinder bank 4−6 Snap ring The opening of the snap ring should lie 36 x 1.75 opposite the Woodruff key groove.
Page 552: 55 19 Removing And Installing Hydraulic Valve
15 55 19 Removing and installing hydraulic valve Removing the hydraulic valve Installing the hydraulic valve top of page Removing the hydraulic valve Preliminary work: The rear spoiler and the heat shields must be removed’ 63 Removing and installing rear spoiler.
Page 553 einordnung Pull the lower connecting hose off the charge air cooler. To do so, lever the retaining clip out and pull the hose downwards. 4. Undo the front fastening. Unscrew the fastening nut and the two fastening screws. 5. Undo the bolts on the heat shield. Undo the two sheetmetal nuts on the lower end of the heat shield. Then press the heat shield out of the studs.
Page 554: Installing The Hydraulic Valve
einordnung Remove the fastening plate of the switch−over valve. To do so, unscrew the two hexagon−head bolts and remove the plate. 12. Remove the switch−over valve. To do so, disconnect the electric plug. Press the sheetmetal braces of the plug and pull the plug out at the same time. Then pull the switch−over valve out of the cylinder head. WARNING Take care of the coil spring! During removal and installation, make sure that the coil spring is present and does not remain in the camshaft...
Page 555 einordnung 2. Press the hydraulic valve into place. Insert the hydraulic valve into the camshaft housing and press it firmly into place. Place the retaining cover in place. Pay attention to the cut−out on the fastening arm. Note • In order to make it easier to position the hydraulic valve, a socket with an extension of wrench size 20 may be used.
Page 556 einordnung Reinstall the shield of the exhaust system. Tighten the two fastening nuts on the side member for this purpose. 7. Install charge air cooler. To do so, place the charge air cooler back in the vehicle. 8. Tighten the front two fastening nuts and the fastening screw in the wheel well, all to 23 Nm (17 ftlb.). 9.
Page 557: 70 21 Removing Cylinder Head
15 70 21 Removing cylinder head Removing cylinder head 15 70 21 Removing cylinder head...
Page 558 einordnung Designation Qty. Removal Installation Fastening nut Washer Cylinder−head gasket Replace, observe marking Valve keys Upper spring retainer of the exhaust spring Outer valve spring − exhaust valve Inner valve spring − exhaust valve Valve stem seal Replace Lower valve retainer − exhaust valve Spacer −...
Page 559: Removing Cylinder Head
einordnung Valve keys Upper spring retainer − inlet valve Outer valve spring − inlet valve Inner valve spring − inlet valve Valve stem seal − inlet valve Replace Lower valve retainer Spacer − inlet valve Inlet valve Inlet valve seat ring Valve guide −...
Page 560: 70 23 Installing Cylinder Head
15 70 23 Installing cylinder head 1. Replace cylinder head gasket. Replace the gasket between the cylinders and the cylinder head. The designation "TOP" must face upwards. 2. Place cylinder head in position. Uniformly push the cylinder head over the studs from above. When doing so, make sure that the sealing surface is not damaged.
Page 561 einordnung • Initial tightening to 30 Nm (22 ftlb.). • Loosen all screws again in reverse order. Tighten screws to 20 Nm (15.0 ftlb.) • • Retighten screws to 20 Nm (15.0 ftlb.) • Retighten screws with torque angle of 1 x 90°. Location Thread Tightening torque Nm (ftlb.)
Page 562: 04 19 Removing And Installing Oil Pressure Sender
17 04 19 Removing and installing oil pressure sender Removal Installation top of page Removal 1. Undo fastening screw M6x34 on the air cleaner housing. 2. Undo hose clamp between the air cleaner housing and intake manifold. 3. Tilt the complete air cleaner housing 90° upward and remove to the rear. 4.
Page 563: Installation
einordnung 5. Undo pressure pipe −middle− by removing the spring clip −5− , hose clamp −3− , hexagon−head bolts −1 & 2− and electrical plug −4− . 6. Pull off the electrical plug. Undo the fastening screws and remove the throttle body.
Page 564 einordnung 2. Install oil temperature sensor with new sealing ring. 3. Check throttle sealing ring and replace it if necessary. Fasten throttle body. Push on the electrical plug. 4. Install pressure pipe. Wet the connecting hoses between the charge air coolers and pressure pipe with water at the connecting points and fit the hoses.
Page 565: 07 19 Removing And Installing Oil Temperature Sensor
17 07 19 Removing and installing oil temperature sensor Removal Installation top of page Removal 1. Undo fastening screw M6x34 on the air cleaner housing (A/f 13). 2. Undo hose clamp between the air cleaner housing and intake manifold. 3. Pull off electrical wire connector of the hot film mass air flow meter: •...
Page 566: Installation
einordnung 5. Pull off the connecting hoses between the charge air coolers and the pressure pipe. To do this, unclip the locking clips with a screwdriver. Then return the locking clips to installation position. Additionally undo a fastening screw on the right−hand pressure pipe side. 6.
Page 567 einordnung 3. Install pressure pipe. Wet the connecting hoses between the charge air coolers and pressure pipe with water at the connecting points and fit the hoses. The hoses must audibly engage. Then re−check whether they are positioned properly by tilting and pulling on them. 4.
Page 568: 28 19 Removing And Installing Check Valve Engine Installed
17 28 19 Removing and installing check valve engine installed Removal Installation View of the check valve 17 28 19 Removing and installing check valve engine installed...
Page 569: Removal
einordnung Designation Qty. Removal Installation Oil drain plug Hold Hold; tightening torque 60 Nm (44 ftlb.) Copper sealing ring 20 x Replace Hexagon−head bolt M8 x Hexagon nut with washer Hexagon−head bolt M6 x Tightening torque 10 Nm (7.5 ftlb.) Hexagon−head bolt M8 x Check valve Check for smoothness of operation;...
Page 570 einordnung 2. Remove oll filler cap. 3. Undo the oil drain plug (a/f 19) on the oil container. Make sure to counter with a wrench (a/f 27) when doing this. Unscrew the loosened plug and drain the oil. CAUTION Danger of scalding from draining oil! •...
Page 571: Installation
einordnung 6. Undo the lower right−hand fastening point of the oil tank. 7. Loosen and remove two hexagon−head bolts (M6 x 16) on the flexible flange of the oil tank. 8. Carefully press the flexible flange off the check valve with a plastic spatula; a second person should press the oil tank to the right at the same time.
Page 572 einordnung 4. Fill in engine oil. Note • The oil change quantity (without oil filter change) is approx. 7.8 litres after a dripping time of 20 minutes! 5. Warm the engine up to operating temperature and carry out a leak test. 6.
Page 573: 40 19 Removing And Installing Oil Cooler Engine Removed
17 40 19 Removing and installing oil cooler Engine removed Removing oil cooler Installing oil cooler The following prelimiminary work must be carried out: • Remove and install oil container => Removing and installing oil container. • Remove intake distributor ’ 244619 Removing and installing intake distributor . top of page Removing oil cooler 1.
Page 574: Installing Oil Cooler
einordnung 4. Pull coolant hose −2− off the oil cooler −1− . To do so, unscrew the screw−type hose clamp from the coolant hose −2− and pull off the coolant hose. 5. Unscrew the four M6 screws −arrows− on the oil cooler and remove the oil cooler. 6.
Page 575 einordnung 3. Fasten coolant hose −2− on the oil cooler −1− . To do so, place the coolant hose −2− in position and tighten the screw−type hose clamp. 4. Install the crankcase ventilation tube. For this purpose, place the crankcase ventilation tube with the union nut −arrow−...
Page 576 einordnung 7. Install intake distributor ’ 244619 Removing and installing intake distributor . 8. Install oil container => Removing and installing oil container. 9. Check oil level and top up if necessary ’ 032000 Changing engine oil and filter . 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841 Installing oil cooler...
Page 577: 52 19 Removing And Installing Oil Container
17 52 19 Removing and installing oil container Removing oil container − removal overview Installing oil container Preliminary work: ’ 100119 Removing and installing engine top of page Removing oil container − removal overview 17 52 19 Removing and installing oil container...
Page 578 einordnung 1. Detaching oil return line and vent line a. Detach return line on the oil container. Make sure to counter with a wrench at the oil container. b. Loosen the −hose clamp− at the vent line and pull off the vent hose. Removing oil container −...
Page 579 einordnung 2. Pulling plug off oil level sender and detaching oil line c. Pull −plug− off the oil level sender and set it aside. d. Detach the return line from the cylinder head. Make sure to counter with a wrench when doing this in order to prevent damage to the oil container.
Page 580: Installing Oil Container
einordnung Installing oil container 1. Tightening fastening screws Tighten the two oil container −fastening screws− at the side holders. Tightening torque: 23 Nm (17 ftlb.) Installing oil container...
Page 581 einordnung 2. Tightening inlet line a. Fit a new O−ring on the inlet line between the oil container and engine and insert the line. b. Tighten the two hexagon socket head bolts. Tightening torque: 9.7 Nm (7 ftlb.) 3. Tightening positive crankcase ventilation and oil container fastening c.
Page 582 einordnung 5. Tightening oil return line and vent line g. Tighten oil return line on the oil container. Make sure to counter with a wrench at the oil container when doing this. h. Push on vent hose again and fit the −spring band clamp−...
Page 583: 38 17 Draining And Filling In Coolant
19 38 17 Draining and filling in coolant Caution Draining coolant Filling in coolant Bleeding the cooling system CAUTION Risk of damage! The drain cocks of the front radiator and side radiators must be opened only manually . Never open them with tools.
Page 584: Draining Coolant
• The engine cooling system is factory−filled with a lifetime engine coolant. This engine coolant must not be mixed or replaced with other coolants. Use only original Porsche coolant when changing or topping up the engine coolant. top of page...
Page 585 • The following message appears on the screen: Start function with [F8] 5. Press the F8 key and follow the further instructions of the Porsche System Tester 2 . 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841 Bleeding the cooling system...
Page 586: 40 19 Removing And Installing Coolant Expansion Tank
19 40 19 Removing and installing coolant expansion tank Removal Installation top of page Removal 1. Unscrew the fastening screw M6 x 34 (a/f 13) on the rear side of the air cleaner housing. 2. Disconnect the hot film mass air flow meter line of the air cleaner housing: •...
Page 587 einordnung 3. Tilt the air cleaner housing upwards to the right by 90° and then turn the air cleaner housing and remove from the engine compartment. 4. Unscrew the hose clamp (a/f 7) between the air cleaner housing and the cowl.
Page 588 einordnung 10. Completely remove fuel filter with holder. To to this, bend the retaining clip upward as shown −arrow− and at the same time remove the filter with holder. 11. Remove holder for fuel return line on the intake pipe (hexagon−head bolt M 6). 12.
Page 589 einordnung Unscrew upper hexagon−head bolt, lift intake pipe out of the shaft bolt and remove rearwards. Remove and dispose of seal. 15. Disconnect coolant hose with commercially available hose clip. 16. Unscrew spring band clamp or hose clamp on the coolant expansion tank. 17.
Page 590: Installation
einordnung Installation 1. Push coolant expansion tank into the guide rails and fasten. 2. Attach connector from the sensor for the coolant−level indicator. 3. Fasten the coolant hose with a new hose clamp 999.512.552.00 . Observe the installation position of the screw−type hose clamp.
Page 591 einordnung Fasten separation point. • 5. Position the fuel filter with holder on the coolant expansion tank and press it down at the rear. The holder must engage audibly. 6. Install fuel hoses. 7. Install rear pressure pipe. 8. Fit air cleaner assembly. 9.
Page 592: 50 19 Removing And Installing Coolant Pump (Engine Installed)
19 50 19 Removing and installing coolant pump (engine installed) Tools Removal Installation top of page Tools Item Designation of the special tool Explanation Retaining device 9624/1 Commercially available; refer to Workshop Equipment Manual, Chapter 2.4, Nos. 72 and 73 top of page Removal 1.
Page 593 einordnung 6. Remove lateral shields. 7. Loosen fastening nuts. 8. Loosen fastening nuts on the turbocharger. Remove the shield. 9. Detach restraining straps. Undo the two restraining straps on the rear muffler. Loosen the two −hexagon socket screws− for this purpose. CAUTION Falling rear muffler! The rear muffler is loose after the restraining straps are removed.
Page 594 einordnung 12. Undo fastening screw M 6 x 34 on the air cleaner housing. 13. Undo hose clamp between the air cleaner housing and intake manifold. 14. Tilt the complete air cleaner housing 90° upward and then remove from the engine compartment. 15.
Page 595 einordnung 2− ). • Pull off vacuum hose to the control valve. 17. Disconnect oxygen sensor plug on the rear closing panel. 18. Disconnect oxygen sensor plug. 19. Undo the three fastening screws of the belt pulley on the hydraulic system pump by approx. 1/2 turn. 20.
Page 596 einordnung • When swiveling, make sure not to damage the bellows on the lower joint! 23. Undo stabilizer of the cross member and swivel downwards or disengage. 24. Support the engine−transmission unit: In order to do this, fasten special tool (retaining device) 9624/1 on the take−up points of the stabilizer •...
Page 597: Installation
einordnung 27. Immediately secure the bracket with a shorter auxiliary screw (M10 x 55). 28. Loosen and remove belt guard on the coolant pump. 29. Loosen hose clamp and pull coolant filler hose off the coolant pump. 30. Undo fastening screws of the coolant pump. 31.
Page 598 einordnung 5. Remove auxiliary screw again. 6. Fasten engine carrier onto the bracket. Tightening torque: 65 Nm (48 ftlb.). 7. Fasten engine carrier onto the engine mounts (a/f 18). Tightening torque: 85 Nm (63 ftlb.). 8. Remove special tool (retaining device) 9624/1 . 9.
Page 599 einordnung 11. Push the heat shields over the studs of the exhaust turbocharger. Fit new hexagon nuts. Tightening torque: 30 Nm (22 ftlb.). 12. Tighten restraining straps on the rear muffler. Tightening torque: 15 Nm (11 ftlb.). 13. Fit heat shields, bumper and rear spoiler. 14.
Page 600 22. Connect battery. 23. Enter radio code. Note • The cooling system is bled in connection with the Porsche System Tester 2. • Select special functions. Menu point. 24. Bleed the cooling system => Draining and filling in coolant. 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841...
Page 601: 62 19 Removing And Installing Coolant Hose At Front Left (Y−Type Coolant Distributor)
19 62 19 Removing and installing coolant hose at front left (Y−type coolant distributor) Tools Removal Installation top of page Tools Item Designation Special tool Explanation Spring−band Commercially available; refer to Workshop For opening and closing clamp pliers Equipment Manual, Chapter 2.4, No. 72 or 73 spring−band clamps top of page Removal...
Page 602 einordnung 7. Drain coolant. To do this, unclip the −locking spring− on the flange for the coolant hose and pull the coolant hose off. Approx. 5 litres of coolant will pour out. Collect the coolant. 8. Pull the pipe holder off the support after first lifting the holding straps somewhat with a small screwdriver. Then pull the coolant line with the holder off the support.
Page 603: Installation
einordnung top of page Installation 1. Put the two hose clamps back onto the connections which lead to the radiators. Fit the hose clamp above the lower flange. Note • In order to facilitate fitting, wet the inside of the coolant hose with water in the fitting area and push the hose onto the coolant pipes.
Page 604 einordnung 9. Wet the O−ring with plenty of water in order to facilitate fitting the coolant hose. Push on the coolant hose. Press the coolant hose firmly onto the connection neck. The locking clip of the hose fitting must audibly engage. Then re−check the correct fitting by tilting and pulling on the coolant hose.
Page 605 15. Mount front wheel. Tighten the wheel bolts. Tightening torque 130 Nm (96 ftlb.). 16. Fill in coolant and bleed the cooling system in connection with the Porsche System Tester 2. To do this, select menu item Special function , => Draining and filling in coolant.
Page 606: 02 01 Checking Fuel Pressure
20 02 01 Checking fuel pressure Caution WARNING Observe the general safety instructions when working on the fuel system and when handling petrol and other fuels => Precautionary measures when working on fuel system ! Attach or mount a warning notice on the vehicle in a clearly visible position −see Figure− ! Ensure good ventilation in the work area (e.g., open window, switch on exhauster)! Secure vehicle with warning sign! Item...
Page 607 The battery voltage may not fall below 12 volts during the fuel pressure check! 1. Check the charge state of the battery, e.g. using a voltmeter or the Porsche System Tester PST 2. The battery voltage must not fall below 12 volts during the check.
Page 608 einordnung 8. Switch off ignition, pull off System Tester connecting lead in the vehicle and switch off System Tester. Checking while engine is idling: 9. To check the engine while it is idling, connect the pressure gauge as described above and start the engine. Switch off the engine after reading the fuel pressure.
Page 609: 10 19 Removing And Installing Fuel Tank
20 10 19 Removing and installing fuel tank Caution Removing fuel tank Installing fuel tank WARNING Observe the general safety instructions when working on the fuel system and when handling petrol and other fuels => Precautionary measures when working on fuel system ! Attach or mount a warning notice on the vehicle in a clearly visible position −see Figure−...
Page 610 einordnung No. Designation Qty. Removal Installation Union nut VW / Audi socket Replace and secure with a spot of hot−melt wrench 3217 adhesive; tightening torque 70 Nm (52 ftlb.) Fuel level sensor Sealing ring Replace Tank closure Grease sealing ring with Vaseline Hexagon−head bolt Tightening torque 10 Nm (7.5 ftlb.) M6 x 12...
Page 611: Removing Fuel Tank
einordnung 11 Combination screw Tightening torque: 23 Nm (17 ftlb.) M8 x 40 12 Restraining strap Loosen before Engage in front subframe (right and left) removal of front−axle 13 Combination screw Tightening torque: 23 Nm (17 ftlb.) M8 x 40 14 Restraining strap (transverse) 15 Bottom guard...
Page 612 einordnung • Remove fuel level sensor. 5. Empty the fuel tank. The fuel must be sucked out through the hole for the fuel level sensor. To do this, remove the closure cap in the luggage compartment (unscrew four hexagon nuts a/f 10) and disconnect all cable plugs and fuel lines from the fuel level sensor.
Page 613 einordnung 10. Unclip seal of the filler neck in the right front wheel well −1− . Disconnect plug connections for the vent lines at the filler neck −2− . Press release buttons and simultaneously pull the lines apart. Disconnect ground strap −4− on the plug. Disconnect vent line to fuel tank −3− behind the spring strut.
Page 614 einordnung M10 x 1.5 a/f 15 (on the underside of the suspension subframe) −5− and press off the steering gear ’ 48 90 19 Removing and installing steering gear . 14. Support suspension subframe with a transmission jack. Pull off the cable plug on the sensor of the headlight beam adjustment −right arrow−...
Page 615 einordnung wheel well by undoing the spring−band clamps. If necessary, collect the draining coolant. Pull off vent line to the side. Note • Observe the installation position of both connector tubes to the radiators in relation to the plastic holders. 19.
Page 616: Installing Fuel Tank
einordnung Installing fuel tank Note • Fix connecting cable and fuel lines, using adhesive tape if necessary, to the body aperture for the fuel level sensor • Observe line routing between fuel tank and body (e.g. chafing, pinching) 1. Lift the fuel tank with the help of a second person and carefully insert from below (avoiding damage to the hole for the fuel level sensor).
Page 617 einordnung 5. Insert vent line into distributor hose in the left front wheel well −2− and into coolant hose in the right front wheel well and fit the spring−band clamps. 6. Clip vent line into the two holders−arrows− on the coolant pipes. 7.
Page 618 einordnung 9. Carefully lift suspension subframe and fix with the six hexagon−head bolts −Items 2, 6 and 7− . Screw suspension subframe into place to the prescribed tightening torque. Tightening torque M14 x 1.5 : 160 Nm (118 ftlb.) (−Item 2− ) Tightening torque of corner plate to side member M10 x 1.5 : 65 Nm (48 ftlb.) (−Item 6−...
Page 619 einordnung Note • The lug on the toothed steering gear pin must engage in the clamping slot of the universal joint −arrows− . 12. Push universal joint of the steering shaft onto the toothed steering gear pin. The lug must engage in the clamping slot of the universal joint.
Page 620: Tightening Torques For Front Axle And Fuel Tank
einordnung 16. Tighten hexagon−head bolt M6 x 12 of the filler neck −arrow− . Coat seat of the cap seal with Vaseline. Tightening torque 10 Nm (7.5 ftlb.) 17. Fill and bleed cooling system ’ 19 38 17 Filling and bleeding the cooling system . 18.
Page 621 einordnung Wheel to wheel hub M14 x 1.5 996410, 996411, 996420, 996421, 996450, 996451, 996430, 996431, 996610, 996611 Tightening torques for front axle and fuel tank...
Page 622: 15 01 Calibrating Fuel Level Sensor System
5. −Make sure that the two recesses on the left and right−hand sides of the tank are emptied completely.− 6. Reinstall the fuel level sensor and, with "ignition off", fill the tank with −28 litres− of fuel. 7. Perform tank calibration with the Porsche System Tester 2: • Select vehicle type (911 Carrera) Select control modules •...
Page 623: 39 19 Removing And Installing Fuel Return Line
20 39 19 Removing and installing fuel return line Removal Installation top of page Removal 1. Remove engine−transmission unit ’ 10, 10 removing and installing engine 2. Remove coolant expansion tank. Undo the hexagon nut. • • Disconnect electrical plug connection from the sensor for coolant−level indicator. •...
Page 624: Installation
einordnung 3. Open line holder. 4. Disconnect line plug connection on the vehicle floor. In order to do this, press button and at the same pull the wires apart. Collect residual fuel. Protect the open lines against dirt. 5. Guide the fuel return line out of the line holder and remove.
Page 625 einordnung 3. Close line holders. 4. Push coolant expansion tank into the guide rails and fasten. 5. Attach connector from the sensor for the coolant−level indicator. 6. Install engine again ’ 10 removing and installing engine. 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841 Installation...
Page 626: 60 55 Replacing Fuel Filter
20 60 55 Replacing fuel filter Removing fuel filter top of page Removing fuel filter 1. Disconnect plug on the hot film mass air flow meter. To do this, push the plug downwards and press the grooved surface at the sides. Pull the plug up and off at the same time. 20 60 55 Replacing fuel filter...
Page 627 einordnung 2. Pull off the connecting hose between the left turbocharger and the intake pipe. To do this, unclip the retaining clip using a screwdriver and pull out the hose. Refit the retaining clips immediately. 3. Unscrew the fastening screw M6 x 34 at the rear of the air cleaner housing. 4.
Page 628 einordnung 7. Pull off the ground cable from the fuel filter. 8. Undo fuel pressure line. Make sure to counter with a wrench when doing this. Collect emerging fuel. 9. Disconnect the plug connection and collect the residual fuel. Protect open lines against dirt. 10.
Page 629 einordnung 12. Push the new fuel filter into the restraining strap and tighten again. Position the filter in such a way that the mark −arrows− on the filter is aligned with the outer edge of the holder in installation position. 13.
Page 630 einordnung Clip in hot film mass air flow sensor cable. To do this, insert the cable into the omega clip on the left air cleaner housing side and then close the clip. 18. Place the air cleaner housing in the engine compartment as shown and move into installation position.
Page 631: 66 01 Checking Quantity Delivered By Fuel Pump
Insert receptacle in open end 9507 2.2.2 of the hose −B− Receptacle Original Porsche spare parts; part number To connect to the 996.106.255.00 rapid−action coupling of the fuel return line Note 20 66 01 Checking quantity delivered by fuel pump...
Page 632 The battery voltage may not fall below 12 volts during the fuel pressure check! 1. Check the charge state of the battery, e.g. using a voltmeter or the Porsche System Tester PST 2. The battery voltage must not fall below 12 volts during the check.
Page 633 (must engage audibly) by pulling the line apart! 10. Install underside panels ’ 911 Carrera (996), 51 90 19 Removing and installing underside panels. 11. Switch off ignition, switch off Porsche System Tester and disconnect. 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841...
Page 634: 68 19 Removing And Installing Fuel Cooler
20 68 19 Removing and installing fuel cooler Removing fuel cooler Installing fuel cooler top of page Removing fuel cooler Note • It is necessary to remove the refrigerant by suction before removing the fuel cooler. • The safety regulations must be observed during all work on the refrigerant system! (See: 87−1 Safety regulations when handling refrigerant R134a) 1.
Page 635: Installing Fuel Cooler
einordnung 4. Undoing fuel lines. Counter union nut with a/f 17 and with a/f 14. 5. Collect residual fuel. Undo holding clamp and remove fuel cooler. top of page Installing fuel cooler 1. Fit new seals on to refrigerant lines and fasten on to fuel cooler. 2.
Page 636: 10 19 Removing And Installing Air Guide For Charge Air Cooling
21 10 19 Removing and installing air guide for charge air cooling Removing air guide for charge air cooling Installing air guide for charge air cooling top of page Removing air guide for charge air cooling Preliminary work: Disassemble the accessories of the rear spoiler (includes rear end, lower central heat shield and bumper) ’...
Page 637 einordnung Open hose clamp at bottom of charge air cooler and pull off the flange. 3. Remove charge air cooler. To do this, disconnect both hose connections on the charge air cooler. Then unscrew the seven fastening screws on the charge air cooler (two at rear) two at heat shield and three in wheel housing.
Page 638: Installing Air Guide For Charge Air Cooling
einordnung Installing air guide for charge air cooling 1. Reinstall air guide. Replace all seals on the air guide. Insert the front end of the air guide into the body. Press the back end upwards into the wing. 2. Retighten air guide. Replace the four fastening clips of the intake pipe and tighten the air duct with the −four fastening screws−...
Page 639 einordnung 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841 Installing air guide for charge air cooling...
Page 640: 30 19 Removing And Installing Turbocharger
21 30 19 Removing and installing turbocharger Removing turbocharger Installing turbocharger top of page Removing turbocharger Preliminary work: Disassemble the accessories of the rear spoiler (includes rear end, lower central heat shield and bumper) ’ 635519 Removing and installing rear spoiler . CAUTION Danger of burns! Parts of the exhaust system can be extremely hot.
Page 641 einordnung 6. Remove heat shield. Unscrew the heat shield covering the catalytic converter and the turbocharger. Undo the two fastening nuts on the vehicle for this purpose. WARNING Danger of fire! The heat shield should not be bent or deformed. Bent or deformed heat shields must be replaced.
Page 642: Installing Turbocharger
einordnung 10. Undo pressure pipe from turbocharger. Undo the hose clamp and remove the pressure hose from the exhaust turbocharger for this purpose. 11. Unscrew the four fastening nuts on the turbocharger flange to the catalytic converter. 12. Unscrew exhaust manifold. Unscrew the nine fastening screws for this purpose. Remove turbocharger with exhaust manifold.
Page 643 einordnung 2. Tighten exhaust manifold on the cylinder head. Position exhaust manifold with new seals (cylinder head and on the catalytic converter) on the cylinder head and insert in the exhaust catalytic converter at the same time. Position the nine fastening screws on the cylinder head by hand and tighten in two stages. First stage 25 Nm (18 ftlb.).
Page 644 einordnung 5. Screw on the turbocharger support. Do not forget the washer beneath the new hexagon nut when doing this. Tighten the hexagon nut to 23 Nm (17 ftlb.). Then position the hexagon nut of the vent line by hand and tighten to 20 Nm (15 ftlb.).
Page 645 einordnung 10. Tighten the two sheetmetal nuts on the heat shield. 11. Reconnect the two hose connections. Make sure that the clips are properly inserted when doing this. Press in the hose support until it is heard to engage. 12. Carry out oil level and tightness test. Note •...
Page 646: 43 19 Removing And Installing The Charge Air Cooler
21 43 19 Removing and installing the charge air cooler Removing the charge air cooler. Installing the charge air cooler top of page Removing the charge air cooler. Preliminary work: The accesories rear end bumper (Serv. No.: 635519) and the wheel housing liner (Serv.:536919) must be removed.
Page 647: Installing The Charge Air Cooler
einordnung 6. Remove charge air cooler. top of page Installing the charge air cooler 1. Re−install the shield of the exhaust system. Tighten the two fastening nuts on the side member for this purpose. 2. Install charge air cooler. To do so, place the charge air cooler back in the vehicle. 3.
Page 648: 67 05 Checking And Adjusting The Bypass Flap Control Boxes On The Turbocharger
21 67 05 Checking and adjusting the bypass flap control boxes on the turbocharger Check and adjust (cylinder bank 1 − 3) Check and adjust (cylinder bank 4 − 6) Item Designation of the special tool Explanation Dial gauge holder VW 387 Tester 9160/1 Pressure gauge 9103/2 Use boost pressure gauge from 944 Turbo...
Page 649: Adjusting
einordnung Fasten special tooldial gauge holder VW 387 onto the underneath of the camshaft housing (cylinder bank 1−3). Flanges with thread M 8 have been provided or this procedure. 3. Align tracer pin with push rod, set the dial gauge with pre−tension to 0.
Page 650 einordnung 1. Fasten special tool dial gauge holder VW 387 onto the underneath of the right camshaft housing. 2. Make tracer pin (shop−made). The tracer pin must be bent accordingly in the area of the deflector plate. 3. Carry out checking and adjusting, using the same method used on cylinder bank 1−3. 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841 Check and adjust (cylinder bank 4 −...
Page 651: 67 19 Removing And Installing Bypass Flap Control Box On The Turbocharger − Engine Installed
21 67 19 Removing and installing bypass flap control box on the turbocharger − Engine installed Removing bypass flap control box on the turbocharger Installing bypass flap control box on the turbocharger top of page Removing bypass flap control box on the turbocharger CAUTION •...
Page 652: Installing Bypass Flap Control Box On The Turbocharger
einordnung 4. Undo and unscrew the two holder screws of the control box. 5. Remove control box. top of page Installing bypass flap control box on the turbocharger 1. Push the push rod of the control box into the bypass flap release.
Page 653 einordnung 6. Fit the safety bracket again, and check for correct seating. 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841 Installing bypass flap control box on the turbocharger...
Page 654: 75 20 Removing And Installing Oil Container For Exhaust Turbocharger − Engine Installed
21 75 20 Removing and installing oil container for exhaust turbocharger − Engine installed Removing oil container for exhaust turbocharger Installing oil container for exhaust turbocharger top of page Removing oil container for exhaust turbocharger WARNING • Danger of scalding from draining oil! •...
Page 655 einordnung 3. Unscrew the M6 screw on the heat shield −arrow− . 4. Undo both union nuts of the oil lines −arrows− a/f 17 and pull the lines out of the oil container by removing the M6 screw −arrow− from the oil line holder. Oil line holder 5.
Page 656: Installing Oil Container For Exhaust Turbocharger
einordnung Note • Always replace the oil sealing ring −arrow− and the sealing ring for the oil drain plug! top of page Installing oil container for exhaust turbocharger 1. Place the lower union nut of the oil line −lower arrow− in position on the oil container. 2.
Page 657 einordnung 4. Tighten the M6 screw −arrow− of the line holder. Tightening torque 10 Nm (7.5 ftlb.) 5. Fit the heat shield using the M6 screw −arrow− . Tightening torque 10 Nm (7.5 ftlb.) 6. Insert the drain plug −arrow− and the sealing ring. Tightening torque 30 Nm (22 ftlb.) 7.
Page 658: 80 19 Removing And Installing Oil Pump For Turbocharger
21 80 19 Removing and installing oil pump for turbocharger Tools Removal Installation top of page Tools Item Designation of the special tool Explanation Retaining device 9624/1 Commercially available; refer to Workshop Equipment Manual, Chapter 2.4, Nos. 72 and 73 top of page Removal 21 80 19 Removing and installing oil pump for turbocharger...
Page 659 einordnung No. Designation Qty. Removal Installation Pan−head screw M6 When tightening, simultaneously check operating x 16 smoothness of the oil pump. Oil−pump cover Check for signs of scoring O−ring 68 x 2 Replace; ensure correct position Oil pump gear 1 Grease with Optipit Oil pump gear 2 Grease with Optipit...
Page 660 einordnung 6. Remove lateral shields. 7. Loosen fastening nuts. 8. Loosen fastening nuts on the turbocharger. Remove the shield. 9. Detach restraining straps. Undo the two restraining straps on the rear muffler. Loosen the two −hexagon socket screws− for this purpose. CAUTION Falling rear muffler! The rear muffler is loose after the restraining straps are removed.
Page 661 einordnung 13. Undo hose clamp between the air cleaner housing and intake manifold. 14. Tilt the complete air cleaner housing 90° upward and then remove from the engine compartment. 15. Pull of the connecting hoses between the charge air coolers and the pressure pipe. Unclip the locking clips using a screwdriver and pull off the hose.
Page 662 einordnung 20. Relieve drive belt. To do this turn the tensioning roller clockwise, hold and simultaneously remove the drive belt. 21. Remove pulley from the hydraulic pump. 22. Remove generator. 23. Disconnect the hydraulic lines with plug−in coupling on the expansion tank. Note •...
Page 663 einordnung 26. Unscrew three M8 screws and one M6 screw between the hydraulic pump and the console. Pull the expansion tank with hydraulic pump out of the bracket and suspend on the side. 27. Detach the air conditioning compressor and remove the bracket. To do this, disconnect the electrical plug connection, remove the compressor and set it down with the hoses connected.
Page 664 einordnung 32. Pull off the right and left coolant hoses. Lever off the locking clip for this purpose. 33. Refit the locking clip on the coolant neck. 34. Remove bracket for generator. Undo hexagon−head bolts. 35. Loosen coolant neck. 36. Undo coolant hoses over the coolant pump. Removal...
Page 665 einordnung Note • Tip for easier assembly! • The coolant hoses are easier to remove when the complete bracket is removed later. 37. Loosen the stabilizer at top and swivel it downward. Note • When swivelling, make sure not to damage the bellows on the lower joint! 38.
Page 666 einordnung 41. Secure the bracket with a shorter auxiliary screw (M10 x 55). 42. Detach the oil supply line from the bracket (right−hand side). 43. Detach the oil supply lines from the bracket (left−hand side). 44. Remove auxiliary screw again. 45.
Page 667: Installation
einordnung 47. Check oil pump cover and contact surface of the oil pump gears in the bracket for signs of seizing or excessive wear. The entire bracket must be replaced if necessary. The bracket, oil pump gear and oil pump cover are matched. top of page Installation 1.
Page 668 einordnung 6. Position bracket on the crankcase and simultaneously use a screwdriver to connect the oil pump drive shaft and the intermediate shaft. Do not use excessive force; gently press in place by hand. 7. Provisionally fasten the bracket using an auxiliary screw. The auxiliary screw can be removed again once the oil lines and coolant hoses have been fastened.
Page 669 einordnung 10. Fit oil lines for the left−hand side. Use new O−rings. 11. Fit coolant lines over the coolant pump. Use water or coolant to facilitate fitting. Note • If incorrectly positioned, the generator bracket would make contact and cause leaks. 12.
Page 670 einordnung 15. Remove special tool (retaining device) 9624/1 . 16. Fasten stabilizer. 17. Install rear mufflers with new seals. The seals between the exhaust turbochargers and the rear muffler must be replaced. Move the rear muffler into installation position and push the two tensioning straps over the holder on the engine carrier.
Page 671 29. Fit drive belt (service No.: 13 78 19). 30. Install air cleaner assembly. 31. Bleed the cooling system. Use the Porsche System Tester 2 for this purpose. Select the "Special functions" menu 32. Bleed the steering system. (Group 48) 33.
Page 672: 90 19 Removing And Installing Pressure Sensor
21 90 19 Removing and installing pressure sensor Removal Installation top of page Removal 1. Undo hexagon−head bolt and pull pressure sensor out of the pressure pipe. 2. Press the button on the plug and pull off the plug at the same time.
Page 673: 00 33 Completing The Vacuum Connections
24 00 33 Completing the vacuum connections 24 00 33 Completing the vacuum connections...
Page 674 einordnung 1 Recirculating air valves 2 T−piece 3 Recirculating air valve hose 4 Air hose 5 Recirculating air valve hose 6 Pipe 5 x 1 x 250 7 Curved hose 8 Pipe 5 x 1 x 245 9 Four−way branch piece 10 Pipe 5 x 1 x 250 11 Three−way branch piece 12 Pipe 4 x 1...
Page 675 einordnung 16 Fuel pressure regulator 17 Electric switch−over valve for secondary air 18 Pipe 4 x 1 x 350 19 Pipe 4 x 1 x 500 20 Pipe 4 x 1 x 500 21 Curved protective hose 22 Check valve Note •...
Page 676: 25 19 Removing And Installing Air Cleaner
24 25 19 Removing and installing air cleaner Removing air cleaner Installing air cleaner top of page Removing air cleaner 1. Disconnect plug on the hot film mass air flow meter. To do this, push the plug downwards and press the grooved surface at the sides.
Page 677 einordnung 3. Unscrew the fastening screw M6 x 34 at the rear of the air cleaner housing. 4. Undo hose clamp. Undo the hose clamp −arrow− between the air cleaner housing and the intake pipe. 5. Tilt air cleaner housing outwards. To do this, tilt the housing upwards and to the right by 90° and then turn the housing to the left by approx.
Page 678: Installing Air Cleaner
einordnung Installing air cleaner 1. Insert filter element. Insert the filter element into the cleaned air cleaner housing. Retighten the two air cleaner housing halves with the new captive screws. 2. Clip in hot film mass air flow sensor cable. To do this, insert the cable into the omega clip on the left air cleaner housing side and then close the clip.
Page 679 einordnung 4. Tighten the fastening screw M6x34 to 10 Nm (7.5 ftlb.). 5. Tighten the hose clamp on the connecting hose. Reconnect the plug on the hot film mass air flow sensor. The plug must engage audibly! 6. Attach the connecting hose between the left turbocharger and the intake distributor. The hose must engage audibly! 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841 Installing air cleaner...
Page 680: 42 19 Removing And Installing Throttle Body − Engine Installed
24 42 19 Removing and installing throttle body − Engine installed Removing throttle body Installing throttle body top of page Removing throttle body 1. Remove air cleaner housing => Removing and installing air cleaner. 2. Pull off the pressure hoses between the charge air coolers and the Y−shaped pressure pipe. To do this, unclip the retaining clips using a screwdriver and pull out the hose.
Page 681: Installing Throttle Body
einordnung 7. Disconnect the connector at the throttle potentiometer −top arrow− and unscrew the four M6 screws −arrows− . 8. Remove the throttle body. top of page Installing throttle body Note • Always replace the seal between the intake distributor and the throttle body! 1.
Page 682 einordnung 5. Connect hose to the Y−shaped pipe and fasten with the spring band clamp −arrow− . 6. Install the pressure hoses between the charge air coolers and the Y−shaped pressure pipe; the pressure hoses must engage audibly. 7. Install air cleaner housing => Removing and installing air cleaner. 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841 Installing throttle body...
Page 683: 46 01 Testing The Intake Distributor (Leak Test)
24 46 01 Testing the intake distributor (leak test) Tools Leak test top of page Tools Item Designation of the special Explanation tool Plug 9264/6 Rubber sleeve belongs to the scope of delivery of special tool 9264/6 top of page Leak test 1.
Page 684 einordnung 2. Undo rear hose clamp between the air cleaner housing and intake manifold. 3. Tilt the complete air cleaner housing 90 ° to the left and remove to the rear. 4. Push rubber sleeve of special tool 9264/6 onto the plug. 5.
Page 685: 46 20 Removing And Installing Intake Distributor Engine Removed
24 46 20 Removing and installing intake distributor Engine removed Note Removing intake distributor Installing intake distributor Note • Pay attention to the routing of the vacuum hoses! => Completing the vacuum connections • Pay attention to the storage of the individual parts! => Disassembling and assembling intake distributor top of page Removing intake distributor...
Page 686 einordnung 5. Pull the three vacuum hoses −arrows− off the intake distributor. 6. Undo the holder of the fuel return line. Unscrew the M6 screw −arrow− for this purpose. 7. Connect the connector of the overrun air valve −arrow− and pull off the two vacuum hoses −arrow− . 8.
Page 687: Installing Intake Distributor
einordnung Remove the activated carbon filter lead. To do so, disconnect the plug connection on the bleeder valve −arrow− and disconnect the coupling on the pressure pipe. 10. Undo the six upper screw−type hose clamps on the rubber sleeves of the intake distributors. 11.
Page 688 einordnung 4. Install the activated carbon filter lead. To do so, connect the plug connection on the bleeder valve −arrow− and the coupling on the pressure pipe. 5. Install the overrun air valve module. 6. Connect the connector of the overrun air valve module −top arrow− and push on the two vacuum hoses −bottom arrow−...
Page 689 einordnung 8. Connect the three vacuum hoses −arrows− on the intake distributor. 9. Clip the vacuum line −arrow− on to the strain relief strut. 10. Connect the three hoses to the upper box of the distributor pipe and fasten the hose clamps −arrows− . 11.
Page 690: 46 37 Disassembling And Assembling Intake Distributor
24 46 37 Disassembling and assembling intake distributor Disassembling the intake distributor Vacuum lines top of page Disassembling the intake distributor 24 46 37 Disassembling and assembling intake distributor...
Page 691 einordnung 1 Left intake distributor 2 Right intake distributor 3 Closure cap with strut 4 Hose clamp 70 to 90 5 Rubber sleeve Ø 80 with two hose clamps 80 to 100 6 Throttle with E−gas actuator 7 Fastening screws M6 x 50 8 Hexagon−head bolt M6 x 12 9 Hexagon−head bolts M6 x 12 10 Hexagon−head bolts M6 x 18...
Page 692: Vacuum Lines
einordnung 2. In each case, undo the two hose clamps on the left and right of the distributor pipe and push the rubber sleeves as far as possible on to the distributor pipe. Then remove the distributor pipe. 3. Open the two hose clamps on the closure caps with strut and remove the strut.
Page 693 einordnung 6 Pipe 5 x 1 x 250 7 Curved hose 8 Pipe 5 x 1 x 245 9 Four−way branch piece 10 Pipe 5 x 1 x 250 11 Three−way branch piece 12 Pipe 4 x 1 13 Distributor pipe 14 Vacuum accumulator 15 Combination valve for secondary air 16 Fuel pressure regulator...
Page 694: 69 19 Precautionary Measures When Handling Oxygen Sensors
24 69 19 Precautionary measures when handling oxygen sensors Caution CAUTION Oxygen sensor can be damaged if handled improperly. Do not remove the plastic cap on the thread until just prior to fitting the oxygen sensor. The thread • grease must under no circumstances come into contact with the connector. •...
Page 695: 73 19 Removing And Installing Oxygen Sensors Behind Catalytic Converter
24 73 19 Removing and installing oxygen sensors behind catalytic converter Removing oxygen sensors behind the catalytic converter Installing oxygen sensors behind the catalytic converter For tools, refer to Service No. 24 69 19 : Removing and installing oxygen sensors in front of the catalytic converter.
Page 696: Oxygen Sensor, Left Side
einordnung Oxygen sensor, left side : 1. Remove air cleaner housing => Removing and installing air cleaner 2. Separate the oval plug connection for the oxygen sensor behind the catalytic converter in the left engine compartment −2− . 3. Unclip the oxygen sensor wire behind the catalytic converter from the wire retainer and the sheetmetal clips.
Page 697: Installing Oxygen Sensors Behind The Catalytic Converter
einordnung Installing oxygen sensors behind the catalytic converter Install the oxygen sensors in reverse order. Note • Always expose oxygen sensor wire so that the wire can turn when screwing in the sensor. 1. Position the oxygen sensor by hand and screw in as far as possible.
Page 698: 01 05 Exhaust System Leak Test
26 01 05 Exhaust system leak test Caution Tools Leak test CAUTION • The permissible maximum pressure for performing the leak test is 1 bar ! Note • The leak test must not be performed on a hot exhaust system as the rubber seals are only functional at temperatures below 200 °...
Page 699: Leak Test
einordnung Plug 9710/1 for 911 Gr. 2.2; Workshop Equipment Manual ; order replacement seals from the Turbo (996) manufacturer (specification on the bottom of the plug) Leak detection spray e.g. test spray TPS674, Messrs. TEGA, Würzburg top of page Leak test 1.
Page 700: 33 19 Removing And Installing Rear Mufflers
26 33 19 Removing and installing rear mufflers Removing rear mufflers Installing rear mufflers top of page Removing rear mufflers Preliminary work: Remove rear spoiler, rear bumper and centre heat shield (Serv. No.: 635519). 26 33 19 Removing and installing rear mufflers...
Page 701 einordnung 1. Unscrew rear muffler from the turbocharger. Unscrew the −four fastening nuts− on the left and right for this purpose. 2. Disconnect oxygen sensors. Disconnect and disengage the four plugs at the rear of the closing panel for this purpose. 3.
Page 702: Installing Rear Mufflers
einordnung top of page Installing rear mufflers 1. Install rear mufflers with new seals. The seals between the exhaust turbochargers and the rear muffler must be replaced. Move the rear muffler into installation position and push the two tensioning straps over the holder on the engine carrier. Then slightly tighten the two hexagon socket head bolts.
Page 703 einordnung 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841 Installing rear mufflers...
Page 704: 65 19 Removing And Installing Secondary Air Pump
26 65 19 Removing and installing secondary air pump Removal Installation top of page Removal 1. Pull off right connecting hose between charge air cooler and pressure pipe: Unclip the locking clips using a screwdriver and pull off the hose. •...
Page 705: Installation
einordnung 3. Undo lower fastening screw M6 x 10. 4. Disconnect the electrical plug connection. Undo air hose and pull off. 5. Lift the secondary air pump out of the engine compartment. top of page Installation 1. Install secondary air pump. Install plug connection and air hose. 2.
Page 706: 22 19 Removing And Installing Three−Phase Generator
27 22 19 Removing and installing three−phase generator Note Removing the three−phase generator Installing the three−phase generator Undoing and tightening the belt pulley Tool for holding the free−wheel pulley Note • When the engine is being cleaned with high−pressure cleaning equipment, make sure that the high pressure blast is not directed directly onto the three−phase generator (risk of bearing damage).
Page 707: Installing The Three−Phase Generator
einordnung top of page Installing the three−phase generator 1. Fasten B+ lead and install three−phase generator. 2. The B+ lead must be fastened onto the long wiring arrangement −(arrow)− of the three−phase generator (see Figure). 3. Install deflection roller and fit drive belt.
Page 708 einordnung • Only for vehicles with manual transmission! 1. Use an a/f 17 multiple−tooth adapter to hold the free−wheel pulley. 2. A/f 17 multiple−tooth adapter: see Workshop Equipment Manual, chapter on commercially available tools, No. 32−1. 3. Counter with a double ring wrench when tightening with the a/f 17 multiple−tooth adapter.
Page 709: 27 19 Removing And Installing Bracket For Generator
27 27 19 Removing and installing bracket for generator Removing bracket for generator Installing bracket for generator top of page Removing bracket for generator Removal CAUTION 27 27 19 Removing and installing bracket for generator...
Page 710 einordnung Risk of short circuit with battery connected The battery must be disconnected before any work is carried out on the engine. • 1. Drain coolant. Open cap of coolant expansion tank. Unscrew coolant drain plugs on left and right and drain the coolant.
Page 711 einordnung 7. Separate the B+ disconnection point −arrow− under the cover for this purpose. Unscrew the left fastening screw. Unscrew the right fastening screw by approx. 1 cm. Then drive it in with gentle taps of a hammer until the screw head makes contact with the generator again. Now unscrew fastening screw completely. Lift the generator upwards out of the engine compartment.
Page 712: Installing Bracket For Generator
einordnung 13. Pull off the hose clamp −arrow− on the coolant connecting hose. Take bracket for the generator out of the engine compartment upward and to the right. 14. Separate bracket for the generator. The bracket can be disassembled in the event of leaks. Unscrew the three screws −arrows−...
Page 713 einordnung 2. Push on the coolant connecting hose between the oil/coolant heat exchanger and the bracket again and tighten the hose clamp −arrow− . 3. Fit coolant outlet neck of cylinder bank 4 to 6. Insert the neck with the connecting sleeve into the bracket for the generator for this purpose.
Page 714 einordnung Install generator. Return the generator to its mounting position. Connect plug connection and connect the B+ line. Tightening torque for M8 hexagon nut: 15 Nm (11 ftlb.) Tightening torque for M10 hexagon−head bolt: 46 Nm (34 ftlb.) 8. Install holder for oil filter bracket. To do this, push in the holder in downward direction.
Page 715: 60 19 Removing And Installing Starter (Manual Transmission)
27 60 19 Removing and installing starter (manual transmission) Removing the starter Installing the starter top of page Removing the starter 1. Disconnect the battery and cover terminal or battery. 2. Pull back protective cap on the solenoid switch and undo terminal 30 lead (M8 nut) and terminal 50 (M6 nut).
Page 716: 39 19 Removing And Installing Hall Sender − Engine Installed
28 39 19 Removing and installing hall sender − Engine installed Caution Removing hall sender Installing hall sender Tightening torques WARNING • Danger of burns! Parts of the exhaust system can be extremely hot. • Do not begin work until the exhaust system has cooled down or wear suitable protective gloves! Danger of fire! The heat shield should not be bent or deformed.
Page 717: Installing Hall Sender
einordnung Sheetmetal nuts on heat shield 3. Remove the shields above the plug coils. Unscrew the two hexagon−head bolts for this purpose. 4. Disconnect plug connection on hall sender by pressing the cable connector up using a long screwdriver, if necessary.
Page 718: Tightening Torques
einordnung 2. Clip in cable plug for hall sender using both hands. 3. Fit the shields above the plug coils. Screw in the two hexagon−head bolts for this purpose. Tightening torque: 10 Nm (7.5 ftlb.) WARNING Danger of fire! The heat shield should not be bent or deformed. Bent or deformed heat shields must be replaced! 4.
Page 719: 70 55 Replacing The Spark Plugs
28 70 55 Replacing the spark plugs Removing spark plugs Installing spark plugs top of page Removing spark plugs Item Designation Special tool Explanation Spark plug Workshop Equipment Manual, Chapter 2.4, No. 1 and extension wrench no. 15 Note Only this spark plug wrench has been tested and approved. •...
Page 720: Installing Spark Plugs
einordnung 4. Remove shields. Remove the shields located above the exhaust system. 5. Remove shield. Remove the shields above the plug coils. Unscrew the two hexagon−head bolts for this purpose. 6. Undo hexagon socket head bolts −arrows− . 7. Pull off the plug coils and detach them to the side with connected cables.
Page 721 einordnung 3. Push on the plug coils again. 4. Tighten hexagon socket heat bolts −arrows− to 10 Nm (7.5 ftlb.). 5. Fit shields. Reinstall the shields above the plug coils and tighten to 10 Nm (7.5 ftlb.). 6. Reinstall the shields above the exhaust system.
Page 722: 72 20 Removing And Installing Knock Sensor Engine Removed
28 72 20 Removing and installing knock sensor Engine removed Removing and installing knock sensor, cylinder bank 1−3 Removing knock sensor, cylinder bank 4 − 6 Installing knock sensor, cylinder bank 4 − 6 top of page Removing and installing knock sensor, cylinder bank 1−3 Removal 1.
Page 723: Removing Knock Sensor, Cylinder Bank 4 − 6
einordnung Removing knock sensor, cylinder bank 4 − 6 1. Remove the oil container ’ 175219 Removing and installing oil container 2. Undo the crankcase ventilation tube. Unscrew the union nut −arrow− for this purpose. 3. Remove crankcase ventilation tube. Unscrew the two M6 screws −arrows− for this purpose.
Page 724: Installing Knock Sensor, Cylinder Bank 4 − 6
einordnung Installing knock sensor, cylinder bank 4 − 6 1. Clean contact surface for the sensor on the engine block. Note • In order to guarantee the proper function of the knock sensor, always use the correct tightening torque! 2. Position the knock sensor, then screw in and tighten the M8 hexagon−head bolt −upper arrow− with the correct tightening torque.
Page 725 einordnung 5. Replace the flange seal; then place the two M6 screws −arrows− in position and tighten. Tightening torque for hexagon−head bolts 10 Nm (7.5 ftlb.) 6. Tighten the union nut −arrow− with the correct tightening torque. Tightening torque 30 Nm (22 ftlb.) 7.
Page 726: 01 01 Checking Clutch Booster Circuit
30 01 01 Checking clutch booster circuit Caution 1. Checking accumulator 2. Checking valve (pressure−regulating valve) CAUTION Danger of material damage if the wrong fluid is used for the clutch hydraulic system! Danger of damage to property if too much Pentosin CHF 11 S is filled or if Pentosin comes into contact with the coolant hoses when topping up or filling in! •...
Page 727: Checking The Valve (Pressure−Regulating Valve) In The Clutch Save Cylinder
einordnung • Checking the valve in the clutch save cylinder (2.1) is a direct measurement, while the valve in the upper part of expansion tank cannot be directly tested (2.2)! • If there is no hydraulic clutch boost after a hold time of 24 hours, at least one of the two valves is definately damaged! •...
Page 728 einordnung If the valve in the clutch save cylinder is functioning correctly according to the test in 2.1, the upper part of the tank −A− must be replaced. Note • Before removing the upper part of the tank, slowly remove the Pentosin through the filler neck by suction! When replacing the part, ensure thorough cleanliness! •...
Page 729: 01 07 Bleeding Clutch Operation
30 01 07 Bleeding clutch operation Disposal of Pentosin The actuating hydraulic system is bled via pumps on the pedal. Note • On right−hand drive vehicles, the supply tank is located in the area of the brake fluid reservoir/control module for automatic headlight beam adjustment (ALWR)! 1.
Page 730: Disposal Of Pentosin
einordnung • If a bleeding device filled with Pentosin is available, clutch bleeding can proceed in the same manner as for previous systems! • To do this, the bleeding device is connected to the clutch reservoir at the front! • The clutch high−pressure hydraulic system does not need to be bled in a special manner! •...
Page 731: 27 19 Removing And Installing Clutch Pressure Hose − Engine Installed
30 27 19 Removing and installing clutch pressure hose − Engine installed Caution Removing clutch pressure hose Installing clutch pressure hose WARNING Danger of injury if the clutch pressure hose is undone or disconnected without pressure reduction beforehand! Reduce the pressure in the clutch system by actuating the clutch pedal at least 25 times! Note •...
Page 732: Installing Clutch Pressure Hose
einordnung 3. Disconnect the clutch pressure hose −1− from the slave cylinder with an open ring or open−ended wrench a/f 14 and remove the hose. Note • Dispose of the old hose complete with the union nut and the holder! top of page Installing clutch pressure hose Note...
Page 733 einordnung 3. Then pull out the assembly mandrel and press the connecting piece of the pressure hose into the plug−in coupling. Note • If the pressure hose has been replaced, use a new holder and a new plug−in coupling! • Instructions for the plug−in coupling are enclosed in the packaging! 4.
Page 734: 30 19 Removing And Installing Clutch Slave Cylinder
30 30 19 Removing and installing clutch slave cylinder Removal Tightening torques Installation top of page Removal 1. Raise vehicle on lifting platform. Disconnect battery. 2. Actuate the clutch pedal at least 25 times with the engine switched off so that the system is depressurised. 30 30 19 Removing and installing clutch slave cylinder...
Page 735 einordnung 3. Undo the screws −arrows− and remove the front cross member. 4. Remove clips from the coolant lines. 5. Remove bracket for the coolant lines. 6. Remove the ventilation connection piece from the clutch housing (3 screws). Note • This makes the area from the pressure line to the clutch slave cylinder more accessible! 7.
Page 736: Tightening Torques
einordnung 10. Remove the bracket for the slave cylinder (on transmission −arrow− and disconnect the slave cylinder). Only undo the slave cylinder fastening screws (2 screws) −arrows− slightly (do not yet unscrew completely). 11. Disconnect (unscrew) lead −1− on slave cylinder. Pull off return line −2− . To do so, press on the red ring evenly (never on one side) −2a−...
Page 737: Installation
einordnung Cross member at front to side section M10 x 1.5 65 (48) Drive shaft to transmission 81 (60) top of page Installation Note • Before installing the slave cylinder, it is sensible to remove the starter! This guarantees a better test and the unequivocal centring of the tappet push rod of the slave cylinder in the release lever! The slave cylinder can also be held in its installation position from this side! •...
Page 738 einordnung 14. Install the starter ’ 276019 Removing and installing starter. 15. Install the front cross member. 16. Connect the battery and carry out the necessary subsequent work ’ 0 Entire Vehicle − General, 0 Power supply (work instructions after connecting the battery). CAUTION Danger of material damage if the wrong fluid is used for the clutch hydraulic system! Danger of damage to property if too much Pentosin CHF 11 S is filled or if Pentosin comes into contact with...
Page 739: 31 19 Removing And Installing The Accumulator
30 31 19 Removing and installing the accumulator Removal Installation top of page Removal 1. Raise vehicle on lifting platform. 2. Actuate the clutch pedal at least 25 times with the engine switched off so that the system is depressurised. 30 31 19 Removing and installing the accumulator...
Page 740: Installation
einordnung 3. Undo the screws −arrows− and remove the front cross member. 4. Remove clips from the coolant lines. 5. Remove bracket for the coolant lines. Note • Take care when handling Pentosin! Wear protective glasses, gloves and protective clothing! •...
Page 741 einordnung • Multiple steering operations (manoeuvring) and/or actuating the clutch with the engine switched off change the fluid level in the engine−compartment reservoir! Fluid level rises. In this case, the engine must be run for approx. 20 seconds immediately prior to the fluid level check! •...
Page 742: 45 19 Removing And Installing Release Bearing (Clutch Removed)
30 45 19 Removing and installing release bearing (clutch removed) Removing release bearing Installing release bearing No. Designation Qty. Removal Installation Snap ring Remove using pointed−nose pliers, Ensure correct seating simultaneously push down pressure plate using a press. Thrust plate Engage lug (twist lock) in the opening of a diaphragm spring tongue...
Page 743: Removing Release Bearing
einordnung Release bearing Spring Mount in correct position washer Spacer Fit 2 spacer washers washer Thrust plate Check for wear, replace if necessary top of page Removing release bearing 1. The release bearing is removed under a shop press. For this purpose, lay the release bearing down on the bottom and press down on the pressure plate from above with a pressure piece (e.g.
Page 744 einordnung Note • The guide sleeve of the release bearing is slotted. The slot is irregular. 1. Fit spacer washers and spring washers on the new release bearing. When doing so, ensure that the parts are fitted in the correct order and the spring washer is seated properly. 2.
Page 745: 50 19 Removing And Installing Clutch
30 50 19 Removing and installing clutch Tools Removing clutch Installing clutch Tightening torques top of page Tools Item Designation of the special tool Explanation Toothed segment P201b Centring mandrel 9102 top of page Removing clutch 1. Remove transmission ’ 34 35 27 Removing and refitting the transmission.
Page 746: Installing Clutch
einordnung 2. Position the toothed segment P201b −A− on the stud and undo the pan−head screws in several stages and in diametrically opposite sequence, to avoid deforming the thrust plate. top of page Installing clutch 1. Fit drive plate with centring mandrel, special tools centring mandrel 9102 in the guide bearing (needle bush).
Page 747: 50 37 Disassembling And Assembling Clutch
30 50 37 Disassembling and assembling clutch No. Designation Qty. Removal Fitting Pan−head In order to avoid deformation of the In order to avoid deformation of the screw M8 thrust plate housing, loosen screws in thrust plate housing, loosen screws in several stages and in diametrically several stages and in diametrically opposite sequence.
Page 748: 56 01 Checking Clutch Drive Plate For Wear
30 56 01 Checking clutch drive plate for wear 1. Remove clutch ’ 30 50 19 Removing and installing clutch. 2. With a depth gauge, measure the distance between the lining surface and the rivet head (dimension x). Note • Only measure on the flanged side of the rivet head.
Page 749: 24 00 Minor Maintenance − Usa
03 24 00 Minor maintenance − USA Caution WARNING Damage is possible if the wrong maintenance schedules are used for reimported vehicles! • These maintenance schedules are invalid for RoW (rest of world) vehicles and for vehicles reimported from the USA •...
Page 750 einordnung => Checking and changing the brake fluid Drive shafts: visual inspection of the boots for leaks and damage => Axle joints/drive shafts Tyres and spare wheel (collapsible wheel): check condition and tyre pressure => Tyres and spare wheel&colon; checking condition and tyre pressure Check the door locks, lid locks and safety hooks of the front lid to ensure that they are secure and functioning properly =>...
Page 751: 24 00 Minor Maintenance − As Of My 2003
03 24 00 Minor maintenance − as of MY 2003 Note Note Not valid for USA. • The engine oil and oil filter must be changed every 10,000 km (6,000 mls) on vehicles which are • operated in countries where the fuel has a high sulphur content (country coding M 150 in the control module).
Page 752 einordnung Check the door locks, lid locks and safety hooks of the front lid to ensure that they are secure and functioning properly => Checking lid and doors Vehicle lighting: check function; all headlights: check adjustment; horn: check operation => Checking the function of the vehicle's lights Windscreen washer, headlight washer: check fluid level and nozzle settings, pay attention to antifreeze protection in the winter months =>...
Page 753: 24 00 Minor Maintenance − Usa − As Of My 2003
03 24 00 Minor maintenance − USA − as of MY 2003 Caution WARNING Damage is possible if the wrong maintenance schedules are used for reimported vehicles! • These maintenance schedules are invalid for RoW (rest of world) vehicles and for vehicles reimported from the USA •...
Page 754 einordnung Particle filter: replace filter element => Particle filter&colon; replacing the filter element Brake hoses and lines: visual inspection for damage, routing and corrosion => Visual inspection&colon; brake lines/brake pads/brake discs. Check brake fluid level => Checking and changing the brake fluid Drive shafts: visual inspection of the boots for leaks and damage =>...
Page 755: 24 00 Minor Maintenance − As Of My 2004
03 24 00 Minor maintenance − as of MY 2004 Note Note Not valid for USA. • The engine oil and oil filter must be changed every 10,000 km (6,000 mls) on vehicles which are • operated in countries where the fuel has a high sulphur content (country coding M 150 in the control module).
Page 756 einordnung Windscreen washer, headlight washer: check fluid level and nozzle settings, pay attention to antifreeze protection in the winter months => Windscreen wiper/washer system, headlight washer All other electrical equipment as well as warning and indicator lights: check operation => Checking the function of electrical equipment, as well as the indicator and warning lights Test drive: Remote control, front seats, foot and parking brakes (also actuation travel), engine, clutch, steering, transmission, ParkAssist, automatic speed control, PSM switch, heating, air−conditioning...
Page 757: 24 00 Minor Maintenance − Usa − As Of My 2004
03 24 00 Minor maintenance − USA − as of MY 2004 Caution WARNING Damage is possible if the wrong maintenance schedules are used for reimported vehicles! • These maintenance schedules are invalid for RoW (rest of world) vehicles and for vehicles reimported from the USA •...
Page 758 einordnung Drive shafts: visual inspection of the boots for leaks and damage => Axle joints/drive shafts Tyres and spare wheel (collapsible wheel): check condition and tyre pressure => Tyres and spare wheel&colon; checking condition and tyre pressure Check the door locks, lid locks and safety hooks of the front lid to ensure that they are secure and functioning properly =>...
Page 759: 47 19 Removing And Installing Torque−Converter Sealing Ring
32 47 19 Removing and installing torque−converter sealing ring Tools Removing the torque−converter sealing ring Installing the torque−converter sealing ring top of page Tools Item Designation of the special tool Explanation Lever VW 681 Pressure piece 9670 top of page Removing the torque−converter sealing ring Removing converter ’...
Page 760: Installing The Torque−Converter Sealing Ring
einordnung 1. Lever out the sealing ring using the lever VW 681 . top of page Installing the torque−converter sealing ring 1. Thinly coat sealing lip of sealing ring with Vaseline and drive sealing ring home as far as the mounting face with pressure piece 9670 .
Page 761: 50 19 Removing And Installing Torque Converter
32 50 19 Removing and installing torque converter Tools Removing the torque converter Installing the torque converter top of page Tools Item Designation of the special tool Explanation Locating pin 9595/1 long top of page Removing the torque converter 1. Remove engine−transmission unit (’ 100119 ) and remove the transmission ( => Removing and refitting the transmission).
Page 762: Installing The Torque Converter
einordnung top of page Installing the torque converter Note • Check converter hub for traces of scoring. In the event of damage or faults, the converter must be replaced. 1. Carefully push converter onto transmission shaft as far as the first stop. Then press converter by hand into the converter bell housing and turn it until the recess in the converter hub engages in the driver of the impeller and the converter perceptibly slides inward.
Page 763: 26 00 Major Maintenance − Usa
03 26 00 Major maintenance − USA Caution WARNING Damage is possible if the wrong maintenance schedules are used for reimported vehicles! • These maintenance schedules are invalid for RoW (rest of world) vehicles and for vehicles reimported from the USA •...
Page 764 einordnung Brake hoses and lines: visual inspection for damage, routing and corrosion => Visual inspection&colon; brake lines/brake pads/brake discs. Check brake fluid level => Checking and changing the brake fluid Clutch: play or pedal end position is to be checked => Clutch&colon; checking the play and pedal end position Throttle actuation: check smooth operation, check the full throttle position with the Tester Steering gear: visually inspect the bellows for damage =>...
Page 765: 26 00 Major Maintenance − As Of My 2003
03 26 00 Major maintenance − as of MY 2003 Note Note Not valid for USA. • The engine oil and oil filter must be changed every 10,000 km (6,000 mls) on vehicles which are • operated in countries where the fuel has a high sulphur content (country coding M 150 in the control module).
Page 766 einordnung Clutch: play or pedal end position is to be checked => Clutch&colon; checking the play and pedal end position Steering gear: visually inspect the bellows for damage => Steering gear&colon; fluid level and bellows Checking the tie rod end play and dust bellows => Axle joints/drive shafts Axle joints: check play, visual inspection of dust bellows for damage =>...
Page 767: 26 00 Major Maintenance − Usa − As Of My 2003
03 26 00 Major maintenance − USA − as of MY 2003 Caution WARNING Damage is possible if the wrong maintenance schedules are used for reimported vehicles! • These maintenance schedules are invalid for RoW (rest of world) vehicles and for vehicles reimported from the USA •...
Page 768 einordnung Brake system: visual inspection of the brake pads and brake discs for wear => Visual inspection&colon; brake lines/brake pads/brake discs Brake hoses and lines: visual inspection for damage, routing and corrosion => Visual inspection&colon; brake lines/brake pads/brake discs. Check brake fluid level =>...
Page 769: 26 00 Major Maintenance − As Of My 2004
03 26 00 Major maintenance − as of MY 2004 Note Note Not valid for USA. • The engine oil and oil filter must be changed every 10,000 km (6,000 mls) on vehicles which are • operated in countries where the fuel has a high sulphur content (country coding M 150 in the control module).
Page 770 einordnung Brake system: visual inspection of the brake pads and brake discs for wear => Visual inspection&colon; brake lines/brake pads/brake discs Brake hoses and lines: visual inspection for damage, routing and corrosion => Visual inspection&colon; brake lines/brake pads/brake discs. Check brake fluid level =>...
Page 771: 26 00 Major Maintenance − Usa − As Of My 2004
03 26 00 Major maintenance − USA − as of MY 2004 Caution WARNING Damage is possible if the wrong maintenance schedules are used for reimported vehicles! • These maintenance schedules are invalid for RoW (rest of world) vehicles and for vehicles reimported from the USA •...
Page 772 einordnung Fuel system: visual inspection for damage, routing and secure fit of line connections Power steering: check fluid level => Steering gear&colon; fluid level and bellows Parking brake: check the free play of the parking brake lever => Parking brake&colon; checking the free play of the parking brake lever Brake system: visual inspection of the brake pads and brake discs for wear =>...
Page 773: 01 55 Changing Transmission Oil
Changing transmission oil Note • Top up only with transmission oil approved by Porsche. See Parts Catalogue! Filling capacity: 3.8 litres Change quantity: 3.0 litres 1. Place oil collection pan under the transmission. 2. Unscrew the oil filler screw and drain plug and drain the oil with the vehicle horizontal.
Page 774: 08 19 Removing And Installing Shift Console
34 08 19 Removing and installing shift console Tools Removing and installing shift console Removing shift console Installing shift console Tightening torques top of page Tools Item Designation of the special tool Explanation Locking bridge 9619 top of page Removing and installing shift console 34 08 19 Removing and installing shift console...
Page 775: Removing Shift Console
einordnung A Shift console B Selector cable (blue) C Shift cable (black) D Shift console cover top of page Removing shift console 1. Remove centre console.’ 68 17 19 Removing and installing centre console. 2. Move shift lever to neutral position and fix with special tool (locking bridge) 9619 .
Page 776: Installing Shift Console
einordnung 4. Disengage selector cable −A− and shift cable −B− on shift console. To do this, slide the locking sleeve −F− forward as far as it will go and turn it clockwise to removal position. A Selector cable (blue) B Shift cable (black) C Adjuster open D Adjuster closed E Support bracket sleeve...
Page 777: Tightening Torques
einordnung 2. Insert the support brackets −E− in the correct position in the shift console. It must be possible to hear and feel the support brackets engage. A Selector cable (blue) B Shift cable (black) C Adjuster open D Adjuster closed E Support bracket sleeve 3.
Page 778: 12 19 Removing And Installing Shift And Selector Cables
34 12 19 Removing and installing shift and selector cables Tools Removing and installing shift and selector cables Tightening torques top of page Tools Item Designation of the special Explanation tool Removal tool Commercially available (refer to Workshop Equipment Manual, Chapter 2.4, No.
Page 779: Removing Shift And Selector Cables
einordnung A Selector cable (blue) B Shift cable (black) C Rubber sleeve Removing shift and selector cables Note • The shift and selector cables have a common rubber sleeve and can only be replaced together. The shift and selector cables must not be excessively bent. 1.
Page 780 einordnung Overview of shift console A Selector cable (blue) B Shift cable (black) C Adjuster open E Adjuster closed E Support bracket sleeve F Locking sleeve 4. Disengage selector cable −A− and shift cable −B− on shift console. To do this, slide the locking sleeve −F−...
Page 781: Installing Shift And Selector Cables
einordnung through the body opening. 12. Press the shift and selector cables downward through the body opening. To do this, carefully press the support bracket sleeves through the body opening and pull the B+ wire out of the slotted rubber sleeve.
Page 782: Tightening Torques
einordnung 11. Insert the support brackets −E− in the shift console. It must be possible to hear and feel the support brackets engage. A Selector cable (blue) B Shift cable (black) C Adjuster open E Adjuster closed E Support bracket sleeve 12.
Page 783: 35 27 Removing And Refitting The Transmission
34 35 27 Removing and refitting the transmission Tools Removing transmission Refitting transmission Tightening torques top of page Tools Item Designation of the special Explanation tool Gripper Commercially available ’ Workshop Equipment Manual Chapter 2.4, No. 50 top of page Removing transmission 1.
Page 784 einordnung 3. Undo pressure pipe from slave cylinder. 4. Unscrew fastening screws for slave cylinder. 5. Hang slave cylinder on the engine without tension. 6. Remove left air flange and unscrew hexagon−head bolt for support. 7. Remove bearing cover with commercially available pliers (’ Workshop Equipment Manual Chapter 2.4, No.
Page 785: Refitting Transmission
einordnung Refitting transmission Refitting occurs in reverse order, observing the following points: Note • Grease teeth of the drive shaft with a very thin coat of Olista Longtime 3P (only as protection against corrosion). 1. Insert release lever into the release bearing and fix in installation position with suitable adhesive tape. 2.
Page 786: Tightening Torques
einordnung 1 Hexagon−head bolt 2 Holder 3 Bearing cover 4 Needle−roller bearing with assembly bore 5 Sealing ring 6 Clutch control shaft 7 Release lever 5. Remove adhesive tape through the assembly opening in the release fork. 6. Fit needle−roller bearing, bearing cover and support for clutch control shaft. top of page Tightening torques Location...
Page 787: 49 19 Removing And Installing Closure Cap For Selector Force Mechanism
34 49 19 Removing and installing closure cap for selector force mechanism Tools Removing and installing closure cap for selector force mechanism Tightening torques top of page Tools Item Designation of the special tool Explanation Press−out mandrel P 375 top of page Removing and installing closure cap for selector force mechanism 34 49 19 Removing and installing closure cap for selector force mechanism...
Page 788: Removing Closure Cap For Selector Force Mechanism
einordnung A Closure cap Removing closure cap for selector force mechanism 1. Remove engine−transmission unit.’ 10 01 19 Removing and installing engine. 2. Shift transmission to neutral, unscrew fastening screw −A− and remove snap ring −B− . A Fastening screw B Snap ring C Closure cap 3.
Page 789: Installing Closure Cap For Selector Force Mechanism
einordnung Installing closure cap for selector force mechanism 1. Insert closure cap and snap ring into the housing bore. 2. Use special tool (press−out mandrel) P 375 to push the snap ring and closure cap down until the snap ring engages in its groove.
Page 790: 50 00 Annual Maintenance − Usa
03 50 00 Annual maintenance − USA Caution WARNING Damage is possible if the wrong maintenance schedules are used for reimported vehicles! • These maintenance schedules are invalid for RoW (rest of world) vehicles and for vehicles reimported from the USA •...
Page 791 einordnung Drive shafts: visual inspection of the boots for leaks and damage => Axle joints/drive shafts Tyres and spare wheel (collapsible wheel): check condition and tyre pressure => Tyres and spare wheel&colon; checking condition and tyre pressure Vehicle lighting: check function; all headlights: check adjustment; horn: check operation =>...
Page 792: 50 00 Annual Maintenance − As Of My 2004
03 50 00 Annual maintenance − as of MY 2004 Note Note There is no annual maintenance for vehicles as of model year 2004. • 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841 03 50 00 Annual maintenance − as of MY 2004...
Page 793: 50 00 Annual Maintenance − Usa − As Of My 2004
03 50 00 Annual maintenance − USA − as of MY 2004 The maintenance schedules for the US market have been added to the Technical Manual for the sake of completeness. Note There is no annual maintenance for vehicles as of model year 2004. •...
Page 794: 02 35 Checking And Topping Up The Atf
Tools Item Special tool designation Remarks Connection hose 9507/1 top of page Checking and topping up the ATF Note • Top up only with ATF approved by Porsche. See Parts Catalogue! 37 02 35 Checking and topping up the ATF...
Page 795 • The vehicle must stand horizontally. 1. Place oil collection pan under the transmission. 2. Connect the Porsche System Tester 2 and call up the ATF temperature. Note • The ATF temperature must not be higher than 40 °C at the start of the test.
Page 796: Tightening Torques
einordnung continue with step 10. Note • The control screw must be closed no later than when an ATF temperature of 45 °C is reached. 5. If no ATF escapes from the control bore even though approx. 40 °C has been reached, the ATF must be topped up.
Page 797: 02 55 Replacing Atf Fluid
Replacing ATF fluid Note • Top up only with ATF approved by Porsche. See Parts Catalogue! Filling capacity: approx. 9.0 litres Change quantity: approx. 4.5 litres 1. Place oil collection pan under the transmission. 37 02 55 Replacing ATF fluid...
Page 798 einordnung 2. Unscrew drain plug −A− and drain ATF. Note • Without ATF, the engine must not be started and the vehicle must not be towed. 3. Replace sealing ring for drain plug and screw in plug. Tightening torque: 22 Nm (16 ftlb.) 4.
Page 799: Tightening Torques
7. Connect the Porsche System Tester 2 and call up the ATF temperature. 8. Move selector lever to position "P" and allow engine to idle. 9. With engine running, top up ATF again until excess ATF emerges from the bore of the ATF control screw −B−...
Page 800: 08 19 Removing And Installing Selector Support
37 08 19 Removing and installing selector support Removing and installing selector support Tightening torques top of page Removing and installing selector support Removing selector support 1. Remove selector knob ’ 37 04 19 Removing and installing selector knob. 2. Remove centre console ’ 68 17 19 Removing and installing centre console.
Page 801: Installing Selector Support
einordnung 8. Disconnect electrical plug connections −A− and remove the selector support. Installing selector support Note • Install in reverse order to removal. 1. Insert selector support and connect electrical plug connections. 2. Tighten fastening nuts. Tightening torque: 10 Nm (7.5 ftlb.) 3.
Page 802: Tightening Torques
einordnung 6. Engage the selector lever cable into the open adjuster and close the adjuster (see enlarged view). The locking sleeve on the adjuster must move to the end position automatically. 7. Engage cable nipple in the keylock lever. 8. Insert adjuster on the keylock cable into the support bracket. Make sure the two retaining clips engage properly.
Page 803: 15 19 Removing And Installing Selector Lever Cable
37 15 19 Removing and installing selector lever cable Tools Removing and installing selector lever cable Tightening torques top of page Tools Item Designation of the special Explanation tool Removal tool Commercially available (refer to Workshop Equipment Manual, Chapter 2.4, No. 21) top of page Removing and installing selector lever cable Removing selector support...
Page 804 einordnung 3. Disengage selector lever cable −A− on the selector support. To do this, slide the locking sleeve −B− forward as far as it will go and turn it clockwise to removal position (see enlarged view 1). 4. Carefully disengage support bracket sleeve −C− upward out of the selector support. Unlock the support bracket sleeves by pressing in both plastic clips (see enlarged view 2).
Page 805 einordnung 9. Remove transmission lever −A− from the transmission housing. To do this remove retaining clamp −D− from the pivot point. Undo the transmission lever holder screws −C− and remove the transmission lever holder −B− . 10. Remove support bracket sleeve −A− on selector lever cable from support bracket −B− . To do this, press retaining clip −C−...
Page 806: Installing Selector Support
einordnung 12. Bend up the tabs −A− in the vehicle interior at the body opening and press the rubber sleeve outward through the body opening. 13. Pull B+ cable out of the slotted sleeve and pull the selector lever cable out through the body opening. Installing selector support Note •...
Page 807: Tightening Torques
einordnung 11. Check function of parking brake and adjust if necessary.’ 46 83 16 Adjusting parking brake shoes. 12. Insert support bracket sleeve on the selector lever cable in the support bracket on the selector support. Make sure the two plastic clips engage properly. (See enlarged view) 13.
Page 808 einordnung 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651 Tightening torques...
Page 809: 35 27 Removing And Refitting The Transmission
37 35 27 Removing and refitting the transmission Note Tools Removing transmission Refitting transmission Tightening torques Note When installing a new or replacement transmission, the adaptation values must be reset with the PST • 2. The shifting quality may deteriorate slightly during the adaptation phase of the transmission control module.
Page 810: Removing Transmission
einordnung Removing transmission 1. Remove engine−transmission unit ’ 100119 . 2. Remove starter ’ 276019 . 3. Disengage B+ wire on bracket. 4. Pull off vacuum line for flat−seat valve on branch piece. 5. Disconnect coolant supply hose on pipe. 6.
Page 811: Refitting Transmission
einordnung • Turn the crankshaft 120° further in each case for the remaining four fastening screws. 10. Unscrew the remaining four fastening screws. 11. Remove crash support. 12. Unscrew the two upper fastening screws of the converter bell housing and suspend the transmission from the workshop crane with special tool holder 9674 .
Page 812: Tightening Torques
einordnung 2. Check installation dimension of the converter. Installation dimension approx. 15 mm 3. Hold converter in installation position with special tool locating pin 9595/1 and push transmission in until the toothed ring on the flywheel touches the centering pin. 4.
Page 813: 58 19 Removing And Installing Atf Filter
37 58 19 Removing and installing ATF filter Tools Removing ATF filter Installing ATF filter Tightening torques top of page Tools Item Special tool designation Remarks Connection hose 9507/1 top of page Removing ATF filter 1. Remove underbody panels, rear and centre. 2.
Page 814: Installing Atf Filter
einordnung 3. Disengage cable at the retaining clips of the ATF pan. 4. Place oil collection pan under the transmission. 5. Unscrew drain plug −A− and drain ATF. Note • Without ATF, the engine must not be started and the vehicle must not be towed. 6.
Page 815: Tightening Torques
einordnung Tightening torques Location Thread Tightening torque Nm (ftlb.) Drain plug to ATF pan M 10 22 (16) ATF pan to transmission 8 (6) Transmission cross member to body M 10 65 (48) 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651 Tightening torques...
Page 816: 77 19 Removing And Installing Electrohydraulic Control Unit
38 77 19 Removing and installing electrohydraulic control unit Tools Removing the electrohydraulic control unit Installing the electrohydraulic control unit Tightening torques top of page Tools Item Special tool designation Remarks Assembly aid 9663 Ratchet 1/4 inch Commercially available Extension 1/4 inch Commercially available top of page Removing the electrohydraulic control unit...
Page 817 einordnung Note • Do not let engine run with the ATF pan removed or without ATF filling. 1. Remove rear underside panel. 2. Remove cross member. 3. Disengage the coolant lines at the fastening points. 4. Disengage cable at the retaining clips of the ATF pan. Removing the electrohydraulic control unit...
Page 818 einordnung 5. Disengage the coolant hoses in the area of the flanged shaft. 6. Pull vacuum pipe off the switch−over valve. 7. Undo the left drive flange on the transmission side. 8. Remove the holders for the coolant hoses. 9. Unlock the plug connection by turning it to the left and pull out the plug. 10.
Page 819: Installing The Electrohydraulic Control Unit
einordnung 12. Unscrew drain plug −A− and drain ATF. 13. Remove ATF pan (loosen screws crosswise). 14. Remove ATF filter. 15. Place selector lever in position − P − and unscrew the fastening screws for the control unit. top of page Installing the electrohydraulic control unit Install in reverse order, observing the following points: 1.
Page 820 einordnung 3. Replace gasket for ATF pan. 4. Insert the plug connection with new sealing rings in the correct position and tighten the fastening screw. Tightening torque: 2.5 Nm (2 ftlb.). 5. Screw in ATF drain plug. Tightening torque: 22 Nm (16 ftlb.). 6.
Page 821: Tightening Torques
einordnung top of page Tightening torques Location Thread Tightening torque Nm (ftlb.) Cross member to carrier side section 65 (48) Plug connection to socket 2.5 (2.0) Drain plug to ATF pan 22 (16) Control screw to ATF pan 22 (16) ATF pan to transmission 8 (6) Control unit to transmission...
Page 822: 77 37 Disassembling And Assembling Electrohydraulic Control Unit
38 77 37 Disassembling and assembling electrohydraulic control unit Tools Overview Disconnecting hydraulic and electrical control unit Removing solenoid and control valve Installing solenoid and control valve Reassembling the hydraulic and electrical control unit top of page Tools Item Special tool Remarks designation −...
Page 823 einordnung No. Designation Qty. Removal Installation Cover Cover Screw (6x80) Tighten to 8 Nm (6 ftlb.) Screw (6x55) Tighten to 8 Nm (6 ftlb.) Leaf spring Mount in correct position Solenoid valve, 2−3 gearshift Pull out with gripper Control solenoid valve, converter jumper As No.
Page 824: Disconnecting Hydraulic And Electrical Control Unit
einordnung 13 Hydraulic control unit top of page Disconnecting hydraulic and electrical control unit 1. Remove electrical control unit − 12 in overview −. To do so, bend back the retaining lug at the strengthening rib on the oil temperature sensor. top of page Removing solenoid and control valve 1.
Page 825 einordnung 1. Place the control unit carefully in position. The guide pin must engage in the guide bore of the hydraulic control unit. 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651 Reassembling the hydraulic and electrical control unit...
Page 826: 41 19 Removing And Installing The Front Drive Shaft
40 41 19 Removing and installing the front drive shaft Tools Removal Installation top of page Tools Item Designation of the special tool Explanation Torx screwdriver 9546 To counter the ball joints (track rod and joint mount) during assembly and disassembly.
Page 827 einordnung • Remove diagonal brace to facilitate assembly (2 M12 screws)! 1. Remove front wheel and underside panel. 2. Undo the pan−head screws of the drive shaft on the transmission flange. Note The CV joint can come apart if the dust bellows holder −arrow− is removed or damaged. The joint •...
Page 828: Installation
einordnung 9. Do not damage the boots of the ball joints. Push a transport protective cap onto the joint if necessary. top of page Installation Install in reverse order. Note • Before installing, give the parts a visual check! • Replace fastening nuts! •...
Page 829: 85 19 Removing And Installing Front Spring Strut
40 85 19 Removing and installing front spring strut Removal Installation Item Designation of the special tool Explanation Torx screwdriver 9546 To counter the ball joints (track rod and joint mount) during assembly and disassembly. Ball joint extractor (track rod Commercially available;...
Page 830: Installation
einordnung Note • Use press−out tool 9560 −C− to press off the control arm −1− ! Use a commercially available track rod extractor to press off the track rod −2− ! • • When loosening the fastening nut, counter with Torx screwdriver! 6.
Page 831 einordnung Note • The installation side "RE" (right) or "LI" (left) −arrow− is stamped on the spring strut mount! Note the installed position of the spring strut mount! • • The arrow markings must point in the direction of travel! 3.
Page 832: 58 19 Removing And Installing Rear−Wheel Bearing
42 58 19 Removing and installing rear−wheel bearing Tools Notes on removal and installation top of page Tools Designation of the special Item tool Explanation Press−out For pressing out the rear−wheel hub mandrel P 297 a Separator Commercially available, see Workshop Equipment Manual, Chapter 2.4, No. 111. (12−115 mm As a support when pressing out the rear−wheel hub and the wheel bearing inner Ø)
Page 833: Notes On Removal And Installation
einordnung No. Designation Qty. Removal Installation Wheel hub Press out with pressure piece P Press in under a hydraulic press. To do 297 a under a hydraulic press. For this, place the wheel hub on the wheel this purpose, use the separator and centring device and press it on the corresponding shims for support.
Page 834: Removal
einordnung Removal 1. Remove brake disc, parking brake shoes, brake disc cover and speed sensor. 2. Press the rear−wheel hub out using press−out mandrel P 297 a . Use the separator as a support. If there is not enough space for the wheel hub between the press, appropriate shims will additionally be necessary. 3.
Page 835: Installation
einordnung 5. Press inner wheel bearing race off the wheel hub. Use the press−out mandrel P 297 a in connection with the separator. Installation 1. Before installation, clean the bore in the wheel bearing housing and remove any surface irregularities with a polishing cloth.
Page 836: 71 19 Removing And Installing Rear Spring Strut
42 71 19 Removing and installing rear spring strut Removal Installation top of page Removal 1. Lift the vehicle. 2. Remove the rear wheel. 3. Mark the installed position of the spring strut mount (position of the three collar nuts, −arrows− ). 4.
Page 837 einordnung • When new parts are installed that affect vehicle height, suspension alignment must be carried out! Before tightening the fastening nuts, adjust spring strut mount in accordance with the applied marking • (position of the three fastening nuts)! Insert spring strut into vehicle. Tightening torque 46 Nm (34 ftlb.). 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651 Installation...
Page 838: 05 19 Removing And Installing The Wheel − Turbo And Gt2
44 05 19 Removing and installing the wheel − Turbo and GT2 Wheel mounting − Turbo and GT2 Removing/installing the wheel on vehicle − Turbo and GT2 top of page Wheel mounting − Turbo and GT2 • The wheels of the Turbo and GT2 are mounted with series wheel bolts −A− M14 x 1.5 (length 45 mm) dimension −X−...
Page 839 The assembly aids (2 assembly pins) are located in the luggage compartment! 1. In the case of vehicles with PCCB (Porsche Ceramic Composite Brake), screw the 2 assembly aids (assembly pins), instead of 2 wheel bolts, into the wheel hub before wheel removal/installation. During removal, first remove the 3 remaining wheel bolts and remove the wheel carefully, without touching the brake discs.
Page 840 einordnung A Spherical cap ring (permanently connected with the wheel bolt) X Spherical cap bearing surface facing the wheel (do not grease) Note • Rework on wheel bolts is impermissible! 5. Always replace damaged wheel bolts. This damage includes mechanical damage to the thread, the spherical cap and damage resulting from seizure of the bolt head bearing surface and spherical cap ring.
Page 841: 35 19 Removing And Installing Valve (Steel Valve) (Turbo Ll Wheel)
The steel valve must always be replaced when changing a tyre! CAUTION Loss of tyre pressure if the installation position of the components is not observed and the original Porsche SP parts are not used when installing the steel valve.
Page 842: Removal
einordnung • The valve cap −1− is provided with a seal (air−tight seal). Do not confuse with a commercially available valve cap! The shaft of the fastening nut −2− must point towards the valve foot, because otherwise the valve will not be secure! •...
Page 843 einordnung 2. Place O−ring −4− carefully on to the valve from the outside. Mount disc −3− in the correct position −arrow− . The O−ring then lies in the disc depression. 3. Install the fastening nut −2− with the shaft facing towards the valve foot. Tighten the fastening nut −2−...
Page 844: 11 19 Removing And Installing Front Speed Sensors
10 Nm (7.5 ftlb.). 3. If the speed sensor has been removed or replaced due to an ABS fault or Traction Contol fault, or because of accident repairs, a functional check should be carried out with the Porsche System Tester 2 via the Actual Values menu, Speed submenu.
Page 845: 15 19 Removing And Installing Rear Speed Sensors
10 Nm (7.5 ftlb.). 3. If the speed sensor has been removed or replaced due to an ABS fault or Traction Contol fault, or because of accident repairs, a functional check should be carried out with the Porsche System Tester 2 via the Actual Values menu, Speed submenu.
Page 846 einordnung 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841 Installation...
Page 847: 30 19 Removing And Installing Hydraulic Unit
45 30 19 Removing and installing hydraulic unit Replacing the hydraulic unit Removal Installation top of page Replacing the hydraulic unit When replacing the hydraulic unit −D− , observe the following points! • 3 hydraulic unit variants have been installed in the 911 Turbo (996) since the production launch. First version 996.355.955.51, modified version 996.355.955.57 and new/current version 996.355.955.58.
Page 848: Removal
einordnung New/current version: Rate−of−turn sensor with part No. 996.606.145.00. top of page Removal Note • For the removal and installation of the hydraulic unit −D− , the booster pump −A− of the brake master cylinder −B− and the brake booster −C− remains fitted (installed). 1.
Page 849: Installation
einordnung 3. To remove the hydraulic unit −D− , carry out the following removal procedure: Undo the brake lines on the hydraulic unit. Remove the lines between the brake master cylinder intermediate piston circuit and the hydraulic unit. Close the brake lines and the brake line connections with suitable plugs. Pull off pressure sensor plug.
Page 850 • First bleed brakes as usual! Do not carry out booster pump activation with the Porsche System Tester 2 until after this has been • done (after conventional bleeding) as otherwise damage to the booster pump can occur! •...
Page 851: 59 19 Removing And Installing Rate−Of−Turn Sensor
Removal Installation Two versions of the rate−of−turn sensor have been installed for the PSM (Porsche Stability Management) system in the 911 Turbo (996) since series intoduction of this vehicle. The first version −A− with part number 996.606.147.00 and the new/current version −B− with part number 996.606.145.00.
Page 852: Removal
einordnung • First version of the rate−of−turn sensor with part number 996.606.147.00. will no longer be available after existing supplies are used up. • The new/current rate−of−turn sensor 996.606.145.00 (introduction shortly before the end of model year 2000) can be retrofitted instead of the first version 996.606.147.00. In case of first−time installation, various parts must be replaced in the surrounding area and some parts are omitted.
Page 853: Installation
Installation 1. Install in reverse order. 2. After installing the rate−of−turn sensor, read out the PSM fault memory with the Porsche System Tester 2 and erase. Carry out a static test. Then start the engine. The PSM−related lights in the instrument cluster must go out when the engine is running.
Page 854: 59 31 Conversion Of Rate−Of−Turn Sensor
Removal Fitting Two versions of the rate−of−turn sensor have been installed for the PSM (Porsche Stability Management) system in the 911 Turbo (996) since the production launch of this vehicle. The first version −A− with part number 996.606.147.00 and the new/current version −B− with part number 996.606.145.00.
Page 855: Overview Of Rate−Of−Turn Sensor Conversion
einordnung First version: Rate−of−turn sensor with part No. 996.606.147.00 After supplies of the old sensor have been used up, install the new rate−of−turn sensor with part number 996.606.145.00! New/current version: Rate−of−turn sensor with part No. 996.606.145.00. Introduced in production shortly prior to the end of model year 2000. The new/current rate−of−turn sensor can be retrofitted.
Page 856 einordnung Front centre console support Holder Rate−of−turn sensor Bow over rate−of−turn sensor Cable guide Plug (Item X = adapter plug that is installed between the new rate−of−turn sensor and the existing plug). The table below for the 911 Turbo (996) provides an overview of the part allocation for replacement of a rate−of−turn sensor 996.606.147.00 (first version).
Page 857: Removal
einordnung Note • The adapter plug is necessary because the plug and the connector assignment have changed as well! top of page Removal CAUTION Danger of damage! The negative terminal of the battery must be disconnected before the airbag control unit is removed! •...
Page 858 einordnung 5. Remove cable guide for the rate−of−turn sensor and remove the front centre console support −arrows− . 6. On Tiptronic vehicles, disengage (loosen) the keylock cable −5− on the selector lever: To do this Press the retaining clip −4− together and carefully pull the adjuster −3− upward out of the support bracket.
Page 859: Fitting
einordnung Note • Socket wrench insert 9259 is required for removal and installation of the airbag triggering unit. 9. Undo the fastening screws −arrows− on both sides and remove the holder −2− . To do this, guide the electrical wiring and, if necessary, the keylock cable through the holder opening. top of page Fitting CAUTION...
Page 860 einordnung 3. On Tiptronic vehicles, engage (fasten) the keylock cable on the selector lever. To do this, engage the cable nipple −1− on the keylock lever −2− . Press housing for adjuster −3− into the support bracket until the retaining clip −4− engages. Note •...
Page 861 Read out and erase the fault memories of the airbag, PCM and PSM control modules with the Porsche System Tester 2. Additionally perform the static test in the PSM system. Then start the engine. The PSM−related lights in the instrument cluster must go out when the engine is running.
Page 862: 60 19 Removing And Installing Steering Angle Sensor
Notes on replacing the steering angle sensor − vehicles prior to '03 model Installation • A steering angle sensor −C− is attached to the steering column/steering shaft for PSM (Porsche Stability Management) in the 911 Turbo. • Cover −D− remains fitted during removal and installation of the steering angle sensor.
Page 863 einordnung 3. Remove air duct. 4. Turn front wheels to a straight−ahead position. Fix the front wheels and the steering wheel in this position. 5. Undo hexagon−head bolt on universal joint −A− . Detach universal joint −A− from the upper steering shaft and push into the lower steering shaft (−direction arrow−...
Page 864: Notes On Replacing The Steering Angle Sensor − Vehicles Prior To '03 Model
einordnung top of page Notes on replacing the steering angle sensor − vehicles prior to '03 model A new steering angle sensor −C2− is installed as of the 2003 model (3−programme). This internally modified steering angle sensor, −C2− , differs (externally) from the previous steering angle sensor, −C1− , in having a larger plug connection that is also located in a different position.
Page 865: Component Overview
einordnung • The main difference between the old cable guide, −B1− , and the new cable guide, −B2− , (implemented as standard as of the 2003 model) is the cable deflector at the end of the cable. There are interruptions (openings) in the cable slot (ribs) of new cable guide −B2− for routing the lead (there is no open circuit in the ribs in the old cable guide −B1−...
Page 866: Installation
einordnung Designation New Replaced component component Steering 996.606.119.00 996.606.109.02 angle sensor (C2 = new sensor) Cable guide 996.610.123.01 996.610.123.00 (B2 = new cable guide) Adapter lead 996.622.906.00 Additional lead −E− (connection between the old lead and the new steering angle sensor) Pin assignment of adapter lead −E−...
Page 867 The steering angle sensor has no defined zero position when new. The position for "straight ahead" direction of travel must be programmed. This is done by calibrating with the Porsche System Tester, when the wheels are in a straight−ahead position, on the measuring station.
Page 868 einordnung Push steering angle sensor −C− across the hub adapter that has already been fitted. The driver of steering angle sensor −2− is facing the steering column. External locking tab −4− in the hub adapter must engage completely in the driver engagement. In order for locking tab −4− to be visible in the opening of cover −D−...
Page 869 The steering angle sensor has no defined zero position when new. The position for "straight ahead" direction of travel must be programmed. • Calibrate steering angle sensor using the Porsche System Tester with the wheels in a straight−ahead position on the measuring station. 5. Calibrating steering angle sensor => Steering angle sensor.
Page 870: 64 19 Remove And Install Booster Pump For Psm
45 64 19 Remove and install booster pump for PSM Removal Installation top of page Removal Note The booster pump −1− is removed with the holder −1a− . • 1. Switch off ignition. 2. Remove cover −A− from the hydraulic unit. 3.
Page 871: Installation
First bleed brakes as usual! • Do not carry out booster pump activation with the Porsche System Tester 2 until after this has been done (after conventional bleeding) as otherwise damage to the booster pump can occur! To bleed at front on right with running booster pump, the bleeding device should remain connected •...
Page 872: 11 15 Adjusting The Brake Pushrod
46 11 15 Adjusting the brake pushrod The brake pedal has no stop. Since, when the brake pushrod is correctly set, the brake pedal has no support possibility in its original position, the permanently set free play in the brake unit is guaranteed. As a result a pushrod play of approx.
Page 873: 36 20 Removing And Installing The Front Disc Brake Pads
WARNING Danger of accident if brake pads with the wrong brake pad quality are installed! Use only the type−specific brake pads in the Porsche Spare Parts Catalogue! • The pad backing plates (rear side of the brake pads) must not be greased!
Page 874: Installation
einordnung brake pad plates. Note • Replace warning contacts if the core of the wire is worn or worn through! The warning contact can continue to be used if there are only scrape marks on the plastic part of the •...
Page 875: Bedding In The Brake Pads
einordnung 5. Fit new expanding spring, new retaining pin and new retainer (safety bracket) −arrow− . These parts are available as a repair set and must be renewed each time the pads are changed. 6. Insert the warning contact wire and warning contacts.
Page 876: 38 20 Removing And Installing The Rear Disc Brake Pads
WARNING Danger of accident if brake pads with the wrong brake pad quality are installed! Use only the type−specific brake pads in the Porsche Spare Parts Catalogue! • The pad backing plates (rear side of the brake pads) must not be greased.
Page 877: Installation
einordnung Note • Replace warning contacts if the core of the wire is worn or worn through. • The warning contact can continue to be used if there are only scrape marks on the plastic part of the warning contact. 4.
Page 878: Bedding In The Brake Pads
einordnung 5. Fit new expanding spring, new retaining pin and new retainer (safety bracket) −arrow− . These parts are available as a repair set and must be renewed each time the pads are changed. 6. Insert the warning contact wire and warning contacts.
Page 879: 50 04 Measuring Front Brake Discs
46 50 04 Measuring front brake discs Measuring the front brake disc lateral runout top of page Measuring the front brake disc lateral runout Includes: Measuring the brake disc thickness tolerance • Measuring prerequisite: No tilt play at the wheel. Note •...
Page 880: Measuring The Brake Disc Thickness Tolerance
einordnung • Lateral runout of the removed brake disc: max. 0.03 mm! Wheel hub lateral runout: max. 0.03 mm! • • The permissible lateral runout of the installed brake disc is max. 0.06 mm! • Do not damage the brake hoses or brake lines during removal/installation of the brake caliper! 5.
Page 881: Removing And Installing The Front Brake Disc
Removing and installing the front brake disc Removal Installation top of page Removal Note • In order to gain better access for assembly work, it is beneficial to turn the wheels fully either to the right or the left! 1. Remove front wheel. Press the electrical lead for the speed sensor/wear indicator out of the holder. 2.
Page 882 einordnung 4. Fit the brake disc. L Left brake disc 5. Fit the brake caliper. Replace the brake caliper fastening screws after each removal. Tightening torque of the fastening screws = 85 Nm (63 ftlb.). 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651 Installation...
Page 883: 53 04 Measuring Rear Brake Discs
46 53 04 Measuring rear brake discs Measuring the rear brake disc lateral runout top of page Measuring the rear brake disc lateral runout Includes: Measuring the brake disc thickness tolerance • Measuring prerequisite: No tilt play at the wheel. Note •...
Page 884: Measuring The Brake Disc Thickness Tolerance
einordnung • Lateral runout of the removed brake disc: max. 0.03 mm! Wheel hub lateral runout: max. 0.03 mm! • • The permissible lateral runout of the installed brake disc is max. 0.06 mm! • Do not damage the brake hoses or brake lines during removal/installation of the brake caliper! 5.
Page 885: 53 19 Removing And Installing The Rear Brake Disc
46 53 19 Removing and installing the rear brake disc Removal Installation top of page Removal 1. Remove the rear wheel. Open the plug connection on the wheel carrier and pull out the plug for the brake pad wear indicator. 2.
Page 886 einordnung • Spare part on right−hand side − third group number is even (SP No. Right brake disc: 996.352.406.00). 3. Adjust the parking brake shoes and parking brake cables. 4. Fit the brake caliper. Replace the brake caliper fastening screws after each removal. Tightening torque of the fastening screws = 85 Nm (63 ftlb.).
Page 887: 83 16 Adjusting The Parking Brake Shoes
46 83 16 Adjusting the parking brake shoes Note Check the free play of the parking brake lever Adjusting the parking brake Note Includes: Adjust the parking brake shoes and parking brake cables. • top of page Check the free play of the parking brake lever The parkiing brake must be adjusted if the parking brake lever can be pulled up by more than 4 teeth with medium force application without a braking effect being apparent.
Page 888 einordnung 3. Undo the adjustment nuts −arrow− on the turnbuckle until the cables are without pretension. 4. With a screwdriver −Figure− , turn the adjustment device through a wheel bolt threaded hole so that the brake disc can no longer be moved. 5.
Page 889: 83 19 Removing And Installing The Parking Brake Shoes
46 83 19 Removing and installing the parking brake shoes Removal Installation top of page Removal 1. Remove the rear wheel. Open the plug connection on the wheel carrier and pull out the plug for the brake pad wear indicator. 2.
Page 890 einordnung 2. Install the actuating lever (spreading lever) No. −12− , brake shoes, return springs, compression springs and adjustment device. The spreading lever (No 12.) is a 1−part assembly that cannot be disassembled. This assembly consists of parts No. −6− , No. −7− and No. −8− . Note •...
Page 891 einordnung • Spare part on right−hand side − third group number is even (SP No. Right brake disc: 996.352.406.00). 6. Adjust the parking brake shoes and parking brake cables. Fit the brake caliper. Tightening torque of the fastening screws: 85 Nm (63 ftlb.). Ensure that the brake hose and brake line are in perfect position. Note •...
Page 892: 01 07 Bleeding Brakes (Vehicle With Psm)
1st step: Bleed brakes as usual 2nd step: Bleeding at front on right with running booster pump top of page PSM (Porsche Stability Management) is standard in the 911 Turbo (996). Note Observe brake−fluid quality! Use only new DOT4 brake fluid! •...
Page 893: 2Nd Step: Bleeding At Front On Right With Running Booster Pump
einordnung 2. Connect a bleeding device to the brake fluid reservoir. Switch on the bleeding device. Bleeding pressure approximately 2.0 bar. Note • Bleed the outer bleeder valve first! 3. Continue bleeding at the brake calipers in the sequence: Sequence: Rear right / rear left / front left / front right.
Page 894 • Do not carry out booster pump activation with the Porsche System Tester 2 until after this has been done (after conventional bleeding) as otherwise damage to the booster pump can occur! • To bleed at front on right with running booster pump the bleeding device remains connected (switched on)! Bleeding pressure approximately 2.0 bar!
Page 895: 08 55 Changing Brake Fluid
47 08 55 Changing brake fluid Note Procedure for changing brake fluid Note • Observe brake−fluid quality! Use only new DOT4 brake fluid! • The brake−fluid change interval using Super DOT4 brake fluid is two years! • This brake fluid is available under the following part numbers: Quantity supplied 1 litre = 000.043.203.66! Quantity supplied 30 litre = 000.043.203.67! top of page Procedure for changing brake fluid...
Page 896 einordnung 7. Switch off and disconnect the bleeding device. Correct the brake fluid level if necessary. 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841 Procedure for changing brake fluid...
Page 897: 15 19 Removing And Installing Brake Master Cylinder
47 15 19 Removing and installing brake master cylinder Removal Installation top of page Removal Note • The booster pump −1− remains fitted (installed) during removal and installation of the brake master cylinder. 1. Remove cover −A− from the hydraulic unit/brake unit.
Page 898: Installation
• First bleed brakes as usual! • Do not carry out booster pump activation with the Porsche System Tester 2 until after this has been done (after conventional bleeding) as otherwise damage to the booster pump can occur! • To bleed at front on right with running booster pump the bleeding device remains connected (switched on)! Bleeding pressure approximately 2.0 bar!
Page 899 einordnung 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841 Installation...
Page 900: 70 19 Removing And Installing Brake Booster
47 70 19 Removing and installing brake booster Removal Installation top of page Removal Note To remove and install brake booster −C− , the brake master cylinder−B− , the hydraulic unit −D− and • the booster pump −A− in vehicles with PSM (GT2 without PSM) must be removed. •...
Page 901 einordnung brake master cylinder. The brake master cylinder must be disconnected from the brake booster if both parts should continue • to be used! −A− = Brake master cylinder fastening nuts • • −B− = Brake booster fastening screws (Torx) 5.
Page 902: Installation
einordnung 8. Separate the 2 push rods from each other (loosen). For this purpose, remove the fastening nut (fastening nut, standard as of April 2001)−arrow− . To make the retainer or the fastening nut accessible, adjust the bellows positioned above the body. 9.
Page 903 einordnung Basic setting of the push rod −dimension X− is 138 mm (set in new brake boosters)! If necessary, correct during the relevant work! 2. Insert brake booster with bellows −B− and tightened clamps −6− . Note • Do not trap wiring harness! 3.
Page 904 einordnung • Adjusting the brake pushrod length changes the position of the brake pedal. Perform a fine adjustment of the brake pushrod if the correct position of the brake pedal is not given! • • After the brake pushrod is adjusted, check the brake light switch adjustment! 5.
Page 905 12. Carry out the following tests: Check the system (brake lines and connections) for leaks. Read out and erase the fault memory of the ABS or PSM control module with the Porsche System Tester 2 (PST 2). Additionally, perform the static test in the system.
Page 906 einordnung 13. Install covers −A / B− . 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841 Installation...
Page 907: 10 19 Removing And Installing Steering Wheel
48 10 19 Removing and installing steering wheel Removal Installation top of page Removal Note • Replace fastening screws of the airbag unit whenever they have been loosened! The airbag unit must always be set down so that the cushioned side faces upwards! If removed for an extended period, the airbag unit must be kept in a locked place! Observe the safety regulations! •...
Page 908: Installation
einordnung Installation WARNING Malfunctions of the driver's airbag unit possible! Do not trap the cable of the contact unit. Ensure correct routing! 1. Refit the steering wheel with the wheels in the straight−ahead position or after disassembly with the marking so that the upper spokes of the steering wheel are horizontal. 2.
Page 909: 90 19 Removing And Installing Steering Gear
48 90 19 Removing and installing steering gear Removal Installation top of page Removal 1. Remove underside panel. Note Fix the steering wheel with the wheels in straight−ahead position or remove the steering wheel with • the wheels in straight−ahead position! If this is not done, the airbag contact unit will have to be put in centre position after installation of the stearing gear! 2.
Page 910: Installation
einordnung • For this purpose, loosen the hexagon socket head bolt −(arrow)− and remove the retainer plate. • Plug lines or use collecting container. Cover lines if necessary (danger of soiling). 6. Loosen the two steering−gear fastening screws (on the underside of the cross member).
Page 911: Notes For Sliding Piece And Airbag Contact Unit
einordnung • Observe note on steering−gear centre position in the section describing front track adjustment in Repair Group 44! Note When topping up or filling in Pentosin, make sure that it does not come into contact with the coolant • hoses! Observe the specifications in order to avoid overfilling and thus overflowing! •...
Page 912 einordnung 4. Turn contact unit two revolutions back from the end stop and then continue turning as far as the centre position mark. The exact centre position is indicated by the two No. −1− arrows. Center position mark arrows No. −1− Drivers that engage in the steering wheel Locking (securing against turning), which becomes effective after removal of the steering wheel 5.
Page 913: 55 19 Removing And Installing The Wing
50 55 19 Removing and installing the wing 50 55 19 Removing and installing the wing...
Page 914 einordnung Note • Before removing the wing, the following parts must be removed: • ’ 440519 Removing and installing wheel • => Removing and installing wheel housing liners, front => Removing and installing filler flap • • ’ 941419 Removing and installing headlight mount •...
Page 915 einordnung No. Designation Qty. Removal Installation Plastic Press out pin in the centre body−bound rivet of the rivet head. 5.0 x 11.5 Rubber sleeve Pull off. Press in. Guide ring Press lug −A− and disengage. Tank lock Sleeve Press lugs of the sleeve −B−...
Page 916 einordnung 22 Sheetmetal screw B 4.2 x 18 23 Servo motor 996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841 50 55 19 Removing and installing the wing...
Page 917: 56 19 Removing And Installing Wheel Housing Liners, Front
50 56 19 Removing and installing wheel housing liners, front 50 56 19 Removing and installing wheel housing liners, front...
Page 918 einordnung Designation Qty. Removal Installation Front left wheel housing liner, front Front left wheel housing liner, rear Sheetmetal nut Adjust to centre of hole. B4.8 12 Expanding rivet St 6.3 Check, replace if necessary. Combination screw B4.8 x 16 Plastic nut T5 Check, replace if necessary.
Page 919: 69 19 Removing And Installing Wheel Housing Liners, Rear
53 69 19 Removing and installing wheel housing liners, rear 53 69 19 Removing and installing wheel housing liners, rear...
Page 920 einordnung No. Designation Qty. Removal Installation Rear left wheel housing liner, front 1 Pull out downwards. Rear left wheel housing liner, rear Pull out downwards. Sheetmetal screw −3− Undo Plastic nut T5. Undo. Inspect and replace if necessary. Sheetmetal nut 996420, 996421, 996450, 996451, 996840, 996841 53 69 19 Removing and installing wheel housing liners, rear...
Page 921: 10 37 Disassembling And Assembling Release For Front Lid
55 10 37 Disassembling and assembling release for front lid Disassembling release for front cover Assembling release for front cover Removing and installing support for cap release top of page Disassembling release for front cover 55 10 37 Disassembling and assembling release for front lid...
Page 922 einordnung No. Procedure Instructions Releasing hexagon socket head Remove plastic plugs −3− and undo the hexagon socket head bolts −2− bolts −2− from the sill by approx. 4 − 5 threads. Removing sill −1− Lift sill −1− upwards out of the bottom support with a plastic spatula and press out.
Page 923: Assembling Release For Front Cover
einordnung Assembling release for front cover No. Procedure Instructions Installing actuating switch for Clip locking tabs of the actuating switch for the front lid −7− front lid −7− into the fastening ribs of the sill. Joining plug connections −5, 6− Push plug connections −5, 6−...
Page 924: Removing And Installing Support For Cap Release
einordnung Removing and installing support for cap release Shown on the Boxster Note • In order to remove the support for the cap release, the front seat must be removed.’ 720119 Removing and installing front seat No. Designation Qty. Removal Installation Fastening screw Unscrew.
Page 925 einordnung 996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841 Removing and installing support for cap release...
Page 926: 17 19 Removing And Installing Front Lower Part Of Lid Lock
55 17 19 Removing and installing front lower part of lid lock Removing and installing bowden cable for lock actuation 55 17 19 Removing and installing front lower part of lid lock...
Page 927 einordnung Designation Qty. Removal Installation Electrical plug Turn in −direction of arrow A− and Position electrical plug connection extend. connection on the lock lock side panel and turn in −direction of arrow B− Electrical plug At −arrow C− , press and disconnect. Plug in the electrical connection plug connection.
Page 928: Removing And Installing Bowden Cable For Lock Actuation
einordnung Bowden cable Disengage nipple of the bowden cable Press in bowden cable −6− and press the cover out of the cover −6− and engage lower part of the lock. the nipple in the lower part of the lock. Bowden cable Press bowden cable −7−...
Page 929 einordnung No. Designation Qty. Removal Installation Hexagon−head Back off by 2 turns. Tightening torque:−10 Nm (7.5 bolt ftlb.)− Cover panel Lift out of the lower part of the lid Position on lower part of lid lock. lock. Electrical plug Disconnect. Connect.
Page 930 einordnung Servo motor for Extend bowden cable −5−2− out of Insert bowden cable −5−2− into the lid opener the stamp of the servo motor. stamp of the servo motor. 996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841 Removing and installing bowden cable for lock actuation...
Page 931: 22 19 Removing And Installing Front Lid
55 22 19 Removing and installing front lid 55 22 19 Removing and installing front lid...
Page 932 einordnung No. Designation Qty. Removal Installation Combination Tightening torque: −10 Nm (7.5 ftlb.)− screw M6 x 14 Undo combination screws −1− Position lid −2− on the left and right hinges from the hinge and remove lid and adjust according to the lid contour to the −2−...
Page 933: 22 37 Disassembling And Assembling Front Lid
55 22 37 Disassembling and assembling front lid 55 22 37 Disassembling and assembling front lid...
Page 934 einordnung Designation Qty. Removal Installation Adjust lid −1− to the hinges in accordance with the contours of the wings and the front spoiler. Rubber buffer Unscrew rubber pads Screw in rubber pads −2− . −2− . Self−adhesive label tyre pressure Combination Tightening torque: −10 Nm (7.5 ftlb.)−...
Page 935 einordnung Unscrew tapping nut −6− of lid badge. Badge on lid Remove base −8− of lid Insert base −8− and lid badge −7− into the badge −7− . lid and fasten with tapping nut −6− . Base 996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841 55 22 37 Disassembling and assembling front lid...
Page 936: 25 19 Removing And Installing Front Lid Hinge
55 25 19 Removing and installing front lid hinge 55 25 19 Removing and installing front lid hinge...
Page 937 einordnung Designation Qty. Removal Installation Clip Press out with a narrow Press in. screwdriver. Pneumatic spring 4 Combination Undo fastening screws −3− Position hinge −4− on the body and screw from the hinge −4− . screw in place with the fastening M6 x 14 screws −3−...
Page 938: 37 19 Removing And Installing Filler Flap
55 37 19 Removing and installing filler flap 55 37 19 Removing and installing filler flap...
Page 939 einordnung Designation Qty. Removal Installation Filler flap Insert a narrow screwdriver from above in front of Position filler flap the clip −arrow− , press the fastening lug backwards on the wing and hold, and carefully pull off the filler flap cut−out and press upwards.
Page 940 einordnung 996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841 55 37 19 Removing and installing filler flap...
Page 941: 57 37 Disassembling And Assembling Release For Rear Lid
55 57 37 Disassembling and assembling release for rear lid Disassembling release for rear lid Assembling release for rear lid top of page Disassembling release for rear lid 55 57 37 Disassembling and assembling release for rear lid...
Page 942 einordnung No. Procedure Instructions Undoing hexagon socket head Remove plastic plugs −3− and undo the hexagon socket head bolts −2− bolts −2− from the sill by approx. 4 − 5 threads. Removing sill −1− Lift sill −1− upwards out of the bottom support with a plastic spatula and press out.
Page 943: Assembling Release For Rear Lid
einordnung Assembling release for rear lid No. Procedure Instructions Installing actuating switch for Clip locking tabs of the actuating switch for the rear lid −7− rear lid −7− into the fastening ribs of the sill. Joining plug connections −5, 6− Push plug connections −5, 6−...
Page 944 einordnung 996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841 Assembling release for rear lid...
Page 945: 86 19 Removing And Installing Lower Part Of Lid Lock
55 86 19 Removing and installing lower part of lid lock 55 86 19 Removing and installing lower part of lid lock...
Page 946 einordnung Designation Qty. Removal Installation Undo fastening Tightening screws −1− torque: −10 Nm (7.5 ftlb.)− Lower part of lid Undo fastening screws −1− from the servo motor lock unit −3− . Servo motor unit Retaining clip Press out. Press in. Emergency release cable Electrical plug...
Page 947 einordnung −7− . 996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841 55 86 19 Removing and installing lower part of lid lock...
Page 948: 90 19 Removing And Installing Rear Lid
55 90 19 Removing and installing rear lid 55 90 19 Removing and installing rear lid...
Page 949 einordnung No. Designation Qty. Removal Installation Electrical plug Press the lug of the electrical Connect electrical plug connection −1− . connection plug connection −1− and separate. Hexagon−head Undo. Tightening torque: −10 Nm (7.5 ftlb.)− bolt M6 x 16 Rear lid Adjust lid −3−...
Page 950: 90 37 Disassembling And Assembling Rear Lid
55 90 37 Disassembling and assembling rear lid Disassembling rear lid Assembling rear lid Replacing the model logo top of page Disassembling rear lid 55 90 37 Disassembling and assembling rear lid...
Page 951 einordnung DANGER Danger of injury/damage during assembly work on the hydraulic system! • The hydraulic system is under approx. 30 bar pressure when extended Do not smoke during work, avoid open flames. Danger of fire! • • Do not swallow hydraulic oil, avoid contact with skin/eyes. •...
Page 952 einordnung No. Procedure Instructions Remove spoiler ’ 665819 Removing and installing rear spoiler Remove rear lid => Removing and installing rear lid Remove additional brake Disengage cover −A− at the sides, unlock lock −B− . Remove brake light −3− light and disconnect plug connection −C− . Pull off rubber cover −4−...
Page 953: Assembling Rear Lid
einordnung Remove fan with fan housing Disconnect plug connections for fan and engine compartment −11− lighting on the fan housing. Unscrew fastening screws −10− and remove fan with fan housing −11− . Undo mount −13− Unscrew fastening screws −12− . Remove pump unit −17−...
Page 954 einordnung No. Procedure Instructions Install additional Insert additional brake light holder −19− . Screw in fastening screws −18− brake light holder and tighten to −10 Nm (7.5 ftlb.)− . Insert plug connection of the brake light −19− under the additional brake light holder −19− . Install pump unit Put on pump unit with extension elements.
Page 955 einordnung Remove air guide Unscrew fastening screws −8− and remove air guide −9− . −9− Procedure Instructions Install upper part of lock −8− Position upper part of lock −8− and fasten with fastening screws −7− . Install adjusting element Engage collar −6− . Screw in rubber pads −5− . Install rubber cover −4−...
Page 956: Replacing The Model Logo
einordnung fastening screws. the extension elements. Tighten fastening screws −arrows− to −10 Nm (7.5 ftlb.)− . Stick on model logo => Replacing the model logo top of page Replacing the model logo 1. Position logo with the dimensions −X = 332 mm− and −Y = 20 mm− on the rear lid and affix. 996420, 996421, 996450, 996451 Replacing the model logo...
Page 957: 91 19 Removing And Installing Lid Hinge
55 91 19 Removing and installing lid hinge 55 91 19 Removing and installing lid hinge...
Page 958 einordnung No. Designation Qty. Removal Installation Pneumatic spring Press in lugs at the sides. Press together until the lugs engage at the right cable sides. sleeve Fuse Press out with a narrow Press in. screwdriver. Pneumatic spring left/right Stop clip left/right Combination Tightening torque: −10 Nm (7.5 ftlb.)−...
Page 959 einordnung Lid hinge, left Undo combination screws Adjust to the left side section in accordance −5− . with lid contour. 996420, 996421, 996450, 996451, 996840, 996841 55 91 19 Removing and installing lid hinge...
Page 960: 11 37 Disassembling And Assembling Door Handle
57 11 37 Disassembling and assembling door handle 57 11 37 Disassembling and assembling door handle...
Page 961 einordnung CAUTION There is a danger of injury if fingers or hands are trapped by the door window when the comfort function is triggered: lower and raise door window! • When carrying out assembly work in the area of the connection piece, the bottom part of the door handle and the door lock, the fuse No.
Page 962 einordnung Base Unclip. Clip in. Microswitch Unclip. Clip in. Circlip Press out. Press in. Actuating shaft 1 Pull pin −7− out of the handle Position actuating shaft on the handle −No. −13− and remove actuating 13− . Insert pin −7− and secure pin with the shaft.
Page 963: 37 19 Removing And Installing Inner Door Release (Bowden Cable) For Door Lock
57 37 19 Removing and installing inner door release (bowden cable) for door lock 57 37 19 Removing and installing inner door release (bowden cable) for door lock...
Page 964 einordnung CAUTION Damage to the bowden cable when removing door trim panel! Damage by bending the bowden cable at the hook! • Pull the hook out of the end piece only after installation in the inner door release! No. Designation Qty. Removal Installation Door trim ’...
Page 965 einordnung Lock side: handle −2− . −Inset X− Unclip bowden cable from the door lock −C− . Swivel bowden Lock side: cable by 90° −A− and pull it out of the −Inset Y− Insert the bowden cable in actuating lever −B− . the actuating lever −B−...
Page 966: 45 19 Removing And Installing Door Handle
57 45 19 Removing and installing door handle Removing and installing orientation lighting (LED light−emitting diodes) 57 45 19 Removing and installing door handle...
Page 967 einordnung No. Designation Qty. Removal Installation Door trim ’ 705919 Removing and installing panel door trim panel Return spring Unclip from the door handle −5− and Clip into the door handle −5− and the −2− the door trim panel −1− . door trim panel −1−...
Page 968: Removing And Installing Orientation Lighting (Led Light−Emitting Diodes)
einordnung top of page Removing and installing orientation lighting (LED light−emitting diodes) Removing orientation lighting (LED light−emitting diodes) No. Procedure Instructions Remove light−emitting Pull light−emitting diode housing −2− to the rear out of the locks on diode housing −2− the cover −3− . Pull cover at front out of the door handle. Remove light−emitting Raise the lug −arrow−...
Page 969: Installing Orientation Lighting (Led Light−Emitting Diodes)
einordnung Pull LED unit out into the Pull LED unit out of the door handle to the rear. door handle Installing orientation lighting (LED light−emitting diodes) No. Procedure Instructions Insert LED unit into the Insert LED unit into the door handle from the rear. door handle Install light−emitting Insert the light−emitting diode housing −1−...
Page 970 einordnung door handle from the front until there is no more play on the lock of the light−emitting diode housing. 996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841 Installing orientation lighting (LED light−emitting diodes)
Page 971: 14 15 Re−Teaching The Lifting/Sliding Roof Drive
60 14 15 Re−teaching the lifting/sliding roof drive It is necessary to re−teach the lifting/sliding roof in the event of emergency operation or replacement of parts on the lifting/sliding roof (seals, sliding−roof drive) or if the entire system is replaced. The data of limit positions and characteristics are stored and are retained even if the battery is disconnected.
Page 972: 14 19 Removing And Installing Lifting/Sliding Roof Drive
60 14 19 Removing and installing lifting/sliding roof drive Removing lifting/sliding roof drive Installing lifting/sliding roof drive Emergency operation on lifting/sliding roof drive top of page Removing lifting/sliding roof drive 1. Using a small screwdriver, carefully unclip both cover lenses at the openings provided. Undo fastening screws with a crosshead screwdriver −arrow A−...
Page 973: Installing Lifting/Sliding Roof Drive
einordnung Installing lifting/sliding roof drive Note • Do not press on or touch the transmission/reception diodes with your fingers! • The cover lenses must not be soiled or smudged with grease. 1. Engage electrical plug connection and carefully lay the wire (do not pinch). Note •...
Page 974: Emergency Operation On Lifting/Sliding Roof Drive
einordnung Emergency operation on lifting/sliding roof drive The lifting/sliding roof drive can also be operated manually if the electric drive should fail. Check fuse D 3 before emergency operation. An angle screwdriver (a/f 4 hexagon socket) is clipped in behind the cover. The drive axle can be turned with the angle screwdriver −see figure−...
Page 975: 28 19 Removing And Installing Frame For Sliding Roof
60 28 19 Removing and installing frame for sliding roof Removing frame for sliding roof Installing frame for sliding roof top of page Removing frame for sliding roof 60 28 19 Removing and installing frame for sliding roof...
Page 976 einordnung Note Due to additional body structure reinforcements in the roof, the connection points for the sliding roof • frame have changed in vehicles produced as from production date 01.01.2001. In these vehicles, the holders at the side of the sliding roof frame have been omitted. The new sliding roof frame can also be used in vehicles with a production date before 01.01.2001, if the separately available holders are prefitted at the side of the frame.
Page 977: Installing Frame For Sliding Roof
einordnung No. Procedure Instructions Removing sliding roof panel => Removing and installing sliding roof panel Removing roof lining ’ 708419 Removing and installing roof lining Pull off water drain hoses Disconnect water drain hoses at the front and rear from the water drain brackets of the frame for the sliding roof.
Page 978 einordnung No. Procedure Instructions Prefit side holder −1− on Position side holder for sliding roof frame and fasten with fastening the sliding roof frame screws −D− . Only tighten screws slightly, so that the holder can still (only vehicles without be shifted.
Page 979: Tightening Torques
einordnung Screw in the fastening Position the fastening screw of the sliding roof frame at the side and screws −B− at the side tighten by hand. (vehicles with roof frame reinforcement in the body structure) Screw in the front Position the fastening screws on the sliding roof frame at the front and fastening screws −A−...
Page 980: 28 37 Disassembling And Assembling Frame For Sliding Roof
60 28 37 Disassembling and assembling frame for sliding roof Disassembling frame for sliding roof Assembling frame for sliding roof top of page Disassembling frame for sliding roof 60 28 37 Disassembling and assembling frame for sliding roof...
Page 981 einordnung The following accessories must be removed for the work operation "Disassembling and assembling frame for sliding roof"! ’ 708419 Removing and installing roof lining ’ 602819 Removing and installing frame for sliding roof Note • The following parts must be transferred from the sliding roof frame to be replaced to the new sliding roof frame: Lifting/sliding roof drive, draught deflector, frame clips No.
Page 982: Assembling Frame For Sliding Roof
einordnung ’ 601419 Removing and installing lifting/sliding roof drive top of page Assembling frame for sliding roof No. Procedure Instructions Fitting frame clips Press the frame clips −A− in until the left and right tabs engage. Fitting lifting/sliding Position lifting/sliding roof drive into the teeth of the frame. Screw in roof drive with the Torx T25 fastening screws and tighten.
Page 983 einordnung Fitting draught Press the draught deflector in on the left and right and insert it into the deflector guides at the sides. Fold up the draught deflector. 996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841 Assembling frame for sliding roof...
Page 984: 40 19 Removing And Installing Sliding Roof Panel
60 40 19 Removing and installing sliding roof panel Additional instructions for removing the inner panels Additional instructions for fitting the inner panels 60 40 19 Removing and installing sliding roof panel...
Page 985 einordnung CAUTION Damage to rear water drainage channel or to the sliding roof mechanism when the sliding roof panel is removed and when moving the trim of the sliding/tilting roof (Item 4) • The sliding roof frame must not be moved to the "Open" position when the sliding roof panel has been removed.
Page 986 einordnung Sliding/tilting roof trim Push trim of sliding/tilting roof back evenly on the left and right as far as it will go. Close sliding roof panel Move the sliding roof panel to zero position (closed). Remove sliding roof panel Unscrew fastening screws T25 from the sliding roof panel and remove the panel from the sliding roof frame.
Page 987: Additional Instructions For Removing The Inner Panels
einordnung Adjust sliding roof Adjust the sliding roof panel in line with the roof contour: lower at the panel front −dimension A− by up to −1.0 mm and higher at the rear −dimension B− by up to +1.0 mm. Tighten fastening screws Torx T25. Tightening torque −6 Nm (4.5 ftlb.)−...
Page 988: Additional Instructions For Fitting The Inner Panels
einordnung Position the sliding/tilting roof trim −dimension A− approx. 80 mm in front of the roof edge cut−out. Disengage left and right inner side panels. Pull out the connector springs −B− on the gate and pull the sliding/tilting roof trim upwards. Push the sides of the inner panels out of the sliding roof frame inwards (centre of the vehicle).
Page 989 einordnung Position the sliding/tilting roof trim −dimension A− approx. 80 mm in front of the roof edge cut−out. Engage the left and right−hand inner side panels in the sliding/tilting roof trim. Repeat the procedure for installing the sliding roof panel. 996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841 Additional instructions for fitting the inner panels...
Page 990: 10 19 Removing And Installing Front Bumper
63 10 19 Removing and installing front bumper Removing and installing front bumper top of page Removing and installing front bumper 63 10 19 Removing and installing front bumper...
Page 991 einordnung Note: No. Designation Qty. Removal Installation Collar nut Retaining strip, Undo collar nut −1− and Fix retaining strip on the transverse lock centre remove centre retaining panel and fasten with the collar nuts −1− . strip Tightening torque:−10 Nm (7.5 ftlb.)− Left and right Undo the collar nut −1−...
Page 992 einordnung Spacer sleeve 5.2 x 14 Sheetmetal nut St Inspect and replace if necessary. Protective foil left, Inspect and replace if necessary. transparent foil on right Hexagon−head bolt Tightening torque:−85 Nm (63 ftlb.)− M12 x 1.5 x 100 Bumper mount Undo hexagon−head bolt Attach the bumper mount to the impact −8−...
Page 993: 15 19 Removing And Installing Front Spoiler
63 15 19 Removing and installing front spoiler Removing front spoiler Installing front spoiler top of page Removing front spoiler 63 15 19 Removing and installing front spoiler...
Page 994 einordnung Note Before removing the front spoiler the ’ 505619 Removing and installing wheel housing liner must be • removed! No. Procedure Instructions Remove cover. Turn hexagon cap nut −2− by 45° and remove. Undo sheetmetal screws −4− from the front part −1− . Remove direction Press in spring clip of direction indicator light −arrow A−...
Page 995: Installing Front Spoiler
einordnung Press out temperature Press temperature sensor −9− out of the inlet grille. sensor. Undo front spoiler on Undo fastening screws −10− of the front spoiler on the underbody. the underbody. Remove front spoiler −1− to the front. top of page Installing front spoiler No.
Page 996 einordnung Fit front spoiler on the Position front spoiler on the underbody and screw in place with the underbody. fastening screws −10− . Fit front spoiler at the Affix front spoiler to the retaining strip and fasten it with the sheetmetal sides.
Page 997: 15 37 Disassembling And Assembling Front Spoiler
63 15 37 Disassembling and assembling front spoiler Disassembling front spoiler Assembling front spoiler 63 15 37 Disassembling and assembling front spoiler...
Page 998: Disassembling Front Spoiler
einordnung top of page Disassembling front spoiler No. Procedure Instructions Remove covering cap −2− . Gently press out covering cap −2− with a screwdriver. Cut through the securing cord of the covering cap −2− and the front end −1− . Pull off protective film −3−...
Page 999: Removing Front Spoiler
einordnung −7− on all sides using a screwdriver. Install USA version grille frame Carefully disengage the lugs of the grille frame −7A− on all −7A− and impact horn −12A− on sides using a screwdriver. the left and right. Remove hexagon−head bolt −10A− and the hexagon socket head bolts −8A−...
Page 1000: Assembling Front Spoiler
einordnung • The spoiler trim can be removed without removing the front spoiler! No. Procedure Instructions Undo fastening screws Undo fastening screws −3− from the front spoiler −1− at the sides. −3− . Remove sheetmetal Pull sheetmetal frame −2− out of the lower rib of the front spoiler −1− . frame −2−...

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