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Porsche 911 CARRERA - 2001, Technical Manual

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Summary of Contents for 911 CARRERA - 2001

Page 1: ...TechnicalManual 9 1 1 7 I z 9 9 6 TechnicalInformation Contents Group1 Engine Part 1 up to Repair Group 13 WKD483 721 TITEL CHP www WorkshopManuals co uk...

Page 2: ...em withoutfail It is notpossiblefor PorscheAGto give a detailedevaluationof all dangersituationsfor the personscarrying outthe work It is there fore imperativethatallpersonscarryingoutrepairandmainten...

Page 3: ...IJ Note Containsadvisoryinformationwhichmakestheworkprocedureeas ier Dueto the continuousdevelopmentand improvementof our vehi cles there maybe discrepanciesbetweenthe actualtechnicalsta tus of the ve...

Page 4: ...911 Carrera 996 Foreword Table of Contents 1 Foreword Foreword Foreword Use 1 page 2 page t Table of Contents Printedin Germany 44 2001 masterVlt2 www WorkshopManuals co uk...

Page 5: ...oreword Overview Supple ment Edition Topic Article number Basicedition 0 44 WKD483721 05 1997 OS 2000 11 2000 i Foreword WKD483721 44 Supplement Overview Printed in Germany 44 2001 masterVlt2 www Work...

Page 6: ...up15 2 Fuel exhaust engineelectronics 3 Transmission manualtransmission 3 Transmission automatictransmission 4 Runninggear 5 Body 6 Bodyequipment exterior 7 Bodyequipment interior 8 9 Air conditioning...

Page 7: ...n repairs Ascan be seenfrom the breakdown the publishedTechnicallnfor mationis in the front part of eachfolder numbered accordingto the Groups TheTable of Contentsassignedto eachGroupwill be periodica...

Page 8: ...ote Thesupplementoverviewsheetis replacedwiththerelevant supplementin thecorrespondingfolderandmustnolongerbe maintainedby hand 2 The page numbering in the new and the replaced chap ters are no longer...

Page 9: ...d valvedrive Engine Lubrication Engine Cooling Group 2 2 20 21 24 25 26 27 28 Fuel exhaust engine electronics Fuel supply control Exhaustsystem turbocharging Fuelsystem electronicinjection Fuel system...

Page 10: ...control Exteriorequipment Interiorequipment Passenger protection Group 7 Body equipment interior Linings insulation Seatframes Seatupholsteries covers 7 70 72 74 Group 8 8 80 85 87 88 Air conditioning...

Page 11: ...13 7 13 9 13 19 13 23 13 33 13 39 13 41 13 69 13 79 13 201 13 209 13 213 13 220 Engine Crankshaft pistons Removing and installing drive belt Removing and installing deflection rollers for drive belt...

Page 12: ...ining crankcase halves M6 13 10 0 M9 x 160 M9 x 95 22 16 22 16 Additional bolts crankcase bearing housing Oil suction pipe to crankcase M6 10 7 5 Air oil separatorto crankcase 10 7 5 M6 Oil panto cran...

Page 13: ...ghtening M16 x 15 50 37 1 x 900 turn Double mass flywheelto crankshaft Initialtightening Finaltightening MI0 x 1 x 50 12 9 25 19 1 x 900 turn Thrustplate to double mass flywheel M8 23 17 Drive plate o...

Page 14: ...Ia x 145 10 9 MIa x 145 8 8 65 48 46 34 Belt deflection roller 2 to bracket for hydraulic pump M8x 55 23 17 M16x 1 5 Belt pulleyto generator 65 t 5 48 t 3 5 Beltpulleyto hydraulicpump M8 x 12 23 17 8...

Page 15: ...derhead M6 10 7 5 Cylinder head cover to cylinderhead M6 13 10 0 30 22 3 2 0 first fitting 25 19 5 3 5 re fitting Sparkplugs M14 x 1 25 Camshaft drive pinion and drive plate to camshaft M6 x 15 10 9 1...

Page 16: ...ttemperature M14x 1 5 25 t 5 19 t 3 5 Oil pressure switch M14x 1 5 25 t 5 19 t 3 5 Starter MID 45 33 MID Generator 45 33 Igniti ncoil to cylinder head cover M6 10 7 5 Power steering pump hydraulic pum...

Page 17: ...a 996 X51 M96 01 M96 01 S Engin type Numb rof cylinders 6 6 Bore 96 96 mm 78 Strok 78 mm cm3 3 387 Displ cement 3 387 11 3 11 3 1 Compressionratio Max ngine power kW HP 221 300 235 320 6 800 6 600 at...

Page 18: ...911 Carrera 996 Engine Differences 22_99 www WorkshopManuals co uk...

Page 19: ...exhaust camshafts Item Valve discs valve springs valve guides valve seats Item 4 Valves valve caps Item 5 Dual chamber suction pump at cylinder bank 4 6 Item 6 Oil suction pipe 1 3 4 I engine perform...

Page 20: ...Engine 911 Carrera 996 Differences 12 I l 10 9 7 8 608_98 8 1 3 4 I engine performance kit X51 Printed in Germany 21 1999 1 10 9961_7 www WorkshopManuals co uk...

Page 21: ...ition box Item 8 Gasket for exhaust manifolds Item 9 Exhaust manifolds Item 10 Suction line on A C compressor Item 11 Intake pipes Item 12 Intake distributors 1 3 4 I engine performance kit X51 Printe...

Page 22: ...troke Camshafts of cylinder bank 1 3 Identificationon the camshaft lL i 996 00 991 003 4 L KIT IN 1 3 996 00 3 4 L KIT IN 1 3 Inletcamshaft Exhaust camshaft 605_98 Camshafts of cylinder bank 4 6 Ident...

Page 23: ...art 6 Valvedisc at bottom 7 Valveguides 8 Cylinderhead 9 Valveseats Thevalveseats are additionallyprovidedwith a seat surface of 60 21_99 further to Item 3 Valve guides Thevalveguideswere shortenedin...

Page 24: ...ther to Item 4 Valves Version 2 Introducedin December 98 Inletand exhaustvalveslengthenedby 1 5 mm Valvecapswere omitted after introductionof the valves version2 Thevalve capswill remainin stock as re...

Page 25: ...242 or 243 592_98 Item 6 Oil suction pipe Theoil suctionpipe is fitted betweenthe dual chamber suctionpump andthe cylinderheadcover The rear M6 x 40 fastening screw is fitted with Loctite 242 or 243 5...

Page 26: ...The shieldwasmodified accordinglyin the area of the oil suctionpipe 604_98 Item 7 Oil pan with partition box The partitionbox was redesignedand consists of metal aluminiumsheetmetal Thestandardparts c...

Page 27: ...haustducts 594_98 Item 9 Exhaust manifolds The exhaustmanifoldswere also adaptedto the larger exhaustducts 71 60O_98 Item 10 Suction line on the AjC compressor The suctionlinewas modifiedfor space rea...

Page 28: ...tours of the inletducts on the cylinderhead 598_98 Intake distributors The right andthe left intake distributorshavebeen modifiedand are nowcastings Thefigure shows the completelyassembledintakesystem...

Page 29: ...rkshopjack or use adapter of transmissionhol dingplate specialtool 9163 for the 928 model B Retainerplate Adapter 9592 1 c Included in9592 1 scopeofdelivery Cl Included in 9592 1 scope of delivery Sup...

Page 30: ...u Bender seeWorkshopEquipmentManual Usedto checkwhetherthe plug in couplingsare seatedproperly Suitablefor pressureand return lines nominaldiameter6 and nominaldia meter 10 9623 B Testing tool for plu...

Page 31: ...sion 11 Detachandremoveright hand coolant hose 202 97 12 Detachandremoveleft hand coolant hose 281 97 10 5 1001 19 Removing and installing engine vehicle with Tiptronic transmission Printed in Germany...

Page 32: ...ock in the direction indicatedby the arrow and pull off the reservoir Immediatelysealthe lower reservoirwith a suitableplug 30 mm y Bayonettlock open 264 97 b Disconnectbattery positive at B disconnec...

Page 33: ...forethe vehicleis raised the side covers of the undersidepanel mustbe removedin the rear area of the jacking points 363_97 6 Remove sideretaining brackets heatshield 278_97 4 Raisevehicle at the presc...

Page 34: ...ethe coolanthoses After drainingthe coolant fit a newsealing ring on the drainplug Tighteningtorque 10 5 Nm 7 5 3 5 ftJb 249_97 471_96 10 Disconnectoxygensensorplug connections 9 Remove aircleanerasse...

Page 35: ...off the drive pulleys 248 97 e Lift the compressorout set it downwith the hosesconnectedand secure it againstbeing dropped 263 97 229 97 d Undofrontcompressor fastening screws 2ea Undorearfasteningscr...

Page 36: ...g return line The plug incouplingsare openedby unscrewing Returnline large diameter pressure line small diamter CollectPentosinresidues 15 Undo engine wiring harnesses round con nectors with bayonet l...

Page 37: ...nectvacuumlinefor the brake boo ster Pressthe black unlockingring arrow and simultaneously pull the line off 203 97 10 9 10 01 19 Removing and installing engine vehicle with Tiptronic transmission Pri...

Page 38: ...cross members 262 97 336 97 18 Undothe fuel supplyline and fuel return line in the engine compartment left It is very im portantto counter whenperformingthis step Collectresidualfuel 20 Undogroundstr...

Page 39: ...w 22 Disengage Tiptronicpluganddisconnect plugconnection 260 97 266 97 23 DisengageTiptronic selector lever cable a Unclipright handacceleratorcable mount sleeveand disengagethe accelerator cable 186...

Page 40: ...r bayonet lock in the direction indicated bythe arrow and pull it off a DisengageTiptronic selector lever cablefrom the mount Pull off coolantline l I Q v I 1 1 207 97 224 97 24 Remove coolanthoses 33...

Page 41: ...r with the support plate 27 Placepre fittedretainerplate on the crank case It is recommendedthat the retainerplate be fitted to the crankcasefirst Onlythen should the workshopcar jack be fitted Placec...

Page 42: ...lly and in steps Havea second personob servethe engine transmission clearanceat the sametime I Note Important If the vehicle is placed on its wheels or moved in the workshop the rear cross member shou...

Page 43: ...holder C on one side and simultaneously pullto disengage 367 97 B c Closeholder C Screwthreaded part A with fit ted holder C into plug ncouplingBand tighten Counterwhentightening Tighteningtorque of...

Page 44: ...ness b Use special tool 9263 to check whether the plug in coupling was engaged properly Insert special tool 9263 into the groove ar row and apply slight pressure on the special tool to check whether t...

Page 45: ...or powersteeringsystem Note The round connectors are marked Left connector white mark Rightconnector blue mark a Remove plug 6 Fitair conditioningcompressor Beforeinstallation check whetherthe spacer...

Page 46: ...ing SeeGroup48 Page48 4 264 97 9 Fitroundconnector onTiptronic transmission C Pushreservoir downwardand turn adjusting ring clockise until the marks line up a Turnadjustingring counter clockwiseto its...

Page 47: ...9 Page 19 1 225 97 10 Engageaccelerator cable and close accelera tor cable mountsleeve 378 97 a Turn rotary sleevein the directionindicatedby the arrow closed and line up the marks on the accelerator...

Page 48: ...body MIDx 1 5 65 48 Diagonalbrace to cross member M12 x 1 5 100 74 Diagonalbrace to carrier side section collar nut M10x 1 5 23 17 Stabilizerto carrier side section M8 23 17 Stabilizerto stabilisor m...

Page 49: ...suspension 1001 37 Disassembling and assembling engine Designationof cylinders 3 2 1 J 6 5 4 355 97 FIRING ORDER 1 6 2 4 3 5 10 21 10 01 37 Disassembling and assembling engine Printed in Germany 1997...

Page 50: ...ation on engine Cylinderarrangement Enginetype and enginenumber 380 97 339 97 Identification ofthedimensional groups cylin der piston 8 340 97 8 10 01 37 996101 Disassembling and assembling engine Pri...

Page 51: ...ith Wv 313 clam ping block and 3054 assemblystand B 9590 c 9538 1 Partsfor fasteningengine to engineholder Toothed segment Securewith hexagon head bolt M12 x 50 Note Do not usetoothed segmentto undo t...

Page 52: ...Item Designation A 9607 9609 B 9610 c 9593 D Mountingdevice for bearinghousing Insertiondevicefor crankcasesealingring flywheelside Insertiondevicefor crankcasesealingring pulleyside Holderfor pulley...

Page 53: ...cial tool Explanation E Socketwrench insert for screwingthe pulley screws with the engine installed 9594 F Spacer sleeves for holdingthe bearinghousing 9613 10 01 37 Disassembling and assembling engin...

Page 54: ...bearing housingin the crankcasehalf cylinders1 3 As the bearinghousingis heavy it shouldbe re movedand installedusinga workshopcrane 482 96 Disassemblingand assemblingbearing housing crankshaftand con...

Page 55: ...911 Carrera 996 Engine Crankcase suspension 382 97 10 27 10 01 37 Disassembling and assembling engine Printed in Germany 1997 996101 www WorkshopManuals co uk...

Page 56: ...roller for drive belt Item 4 Removing and installing oil pump with coolant guide housing Item 5 Removing and installing air oil separator Item 6 Removing and installing camshafts Item 7 Disassembling...

Page 57: ...nd assemblingintakedistributor Removingand installingdrive belt Removingand installingdeflectionrollers andtensioningroller for drive belt 10 01 37 Disassembling and assembling engine Printed in Germa...

Page 58: ...J d 9J a AJ 5 jl7 If 0 J I J 0 i I R 10 I Le i 5 374 97 Item 4 Item 5 Removing and installing oil pump with coolant guide housing Removing and installing air oil separator Disassembling and assemblin...

Page 59: ...z W 2 P 4 8 7 Removingand installingcamshafts Disassemblingand assemblingcylinderhead Disassemblingand assemblingcrankcasehalves 8 10 01 37 Disassembling and assembling engine Printed in Germany 1997...

Page 60: ...Item 11 Removingand installingpistons Disassemblingand assemblingintermediateshafton bearinghousing Disassemblingand assemblingbearinghousingwith crankshaft Disassembling and assembling engine Printed...

Page 61: ...in plug on the oil pan and drain off the engineoil Usea hexagonsocket wrench insertfor 8 mm hexagonsockethead bolts I I 607_97 2 Detachthrust plate Note In order to avoiddeformationof the thrust plate...

Page 62: ...neously removethe belt from the drive pulleys 444_98 229 97 9 Removegeneratorfrom bracket To do this undoupper right handfastening screwon generator 1 byapprox 3 turns A gentle tap on the fastening sc...

Page 63: ...teering system To do this remove the fluid in the upper supplytank until below the joint 12 Removefluid in lower supplytank 13 Undooil separatoron the crankshaft f 151_98 11 Turn bayonetlock in the di...

Page 64: ...linefrom the supply tank push the red unlocking ring forward arrows and simultaneously pullout the line Usetwo plastic spatulas to pressthe unlockingring 15 Pull out oil dipstick and undo guide for d...

Page 65: ...tect the line againstdirt and scratches with a cap IA 0 t I l 0 545_98 23 Removeoil waterhe ventline Undofour t bolts aff 5 mm 24 Remove vacuum tank 25 Removeknock sensors 1 544_98 22 Detachhydraulicp...

Page 66: ...tioncoils 29 Remove exhaust manifold 155_98 30 Turn crankshaftclockwiseuntilthe bore 1 aT top dead centre in the belt pulley is alignedwith the fixing bore on the crankcase Positionor fix with fixing...

Page 67: ...tallation Unscrewhexagonsocket headbolts and replacewith M8 x 25 hexagon head bolts Adjustinsertiondepth Insertiondepthfor inlet camshaft15 mm insertion depthfor outlet camshaft 17mm 32 If the positio...

Page 68: ...elside 38 Unscrewhexagon head bolts M6 x 20 2 ea Removeclosure cap from tensioningelement VarioCam 63o_97 39 Removecylinderhead cover Loosen hexagon head bolts from the outsideto the inside Detachthe...

Page 69: ...ry UI hi I n a F J 663_97 44 Remove driveplateandsprocket wheel 246_97 48 Remove valvetappets 49 Detachguidefor valvetappets Undo the parrheadscrews 15 ea from the outsideto the inside and remove the...

Page 70: ...d screwsfrom outside to insideand removethe cylinderhead Removeand dispose of cylinderhead gasket The oil baffle is fitted only on cylinder head 1 3 f r I I r I 1 493_97 51 Unscrewfour pan headscrews...

Page 71: ...t of specialtool 9595 Viewfrom the belt pulleyside 624_97 56 Unscrew chain tensioner of cylinder bank 4 6 Identification Ohne without 0 tI 155_98 55 Check camshaftadjustmentat cylinder bank 4 6 The gr...

Page 72: ...bolt M16 x 1 5 x 60 with specialtool 9594 socketwrench insert and holdwith special tool 9593 retainingdevice at the sametime I I JJ 8 252_97 59 Turnprimary chaintensioner out of the crankcase cylinder...

Page 73: ...ngrail of cylinder bank 1 3 flywheelside i W A 4 Viewfrom the belt pulleyside Viewfrom the belt pulleyside 72_98 71_98 0 i Viewfrom the belt pulleyside Viewfrom the flywheelside 073_98 469_97 10 45 10...

Page 74: ...d leverthe oil pan off at the leveragebar usinga plastic coatedmountinglever 66 Turn crankcaseby 180 Undofastening screwsbetweencrankcasehalf of cylinder bank 1 3 and bearinghousing 594_97 538_98 65 R...

Page 75: ...ed Do not tilt crankshafthalf Lift the crankcase halfup and off Two peoplerequiredto remove crankcasehalf IIIQII __Q I 57_98 I 608_97 495_96 68 T rncrankcase900 further Crankcasehalf oi cylinder bank...

Page 76: ...x 20 Nm 15 ftlb Use Torx screwdriver insert T50 or T55 71 Removepistonswith connectingrods on cylinderbank1 3 Markpistons Unscrew connecting rod bolts Removetwelve dged socketwrench insert aft 14 mm a...

Page 77: ...connectingrod and connecting rodbearing cap again immediatelyafter removal The connecting rodbearing caps mustalways remain allocated to the respectiveconnecting rods and must never be interchanged 7...

Page 78: ...ing a workshop crane or enginelifter Do not damagesealing surfaceswhenlifting out 77 Removecrankcasehalfcylinderbank1 3 from the engineholder Note The bearinghousingand assemblyfixture specialtool 960...

Page 79: ...96 Engine Crankcase suspension 10 10 37 Disassembling and assembling crankcase halves 420 96 10 1037 Disassembling and assembling crankcase halves Printed in Germany 19 1998 9961051 10 51 www Workshop...

Page 80: ...fastened Tightening torque 22 Nm 16 ftlb Tightening torque 80 Nm 59 ftlb 1 Screwplug for assembly bore of the piston pin M27x 2 6 Alwaysreplace Sealing ringA27x 32 1 7 25 8 Hexagon head bolts for scre...

Page 81: ...instructions Separating crankcase halves Note Loctite 5900 sealantis usedto sealthe crankcasehalves This makesit somewhatmore difficultto separatethe crankcasehalves The sealantcan be recognised by i...

Page 82: ...018 Assembly instructions Sealing of crankcase halves g Only DreiBondsiliconetype 1209 and Loctite 5900 shouldbe usedfor surface sealing After applicationof surface seals siliconebead screwtogether wi...

Page 83: ...le 515_1_97 3 Carefully setthecrankcase halfinplaceso thatthesealing beadis notdamaged 4 Fastencrankcase Alwaysuse micro encapsulated hexagon head bolts Tighteningtorque 13 Nm 7 5 ftlb Observe tighten...

Page 84: ...nstructions Tightening sequence for crankcase halves Tighteningtorque for micro encapsulated hexagon head bolts 13 Nm 10 0 ftlb 443_ 10 10 37 Disassembling and assembling crankcase halves 9961053 Prin...

Page 85: ...in 12 x 22 3 15 Dowelsleeve 2 16 Dowelsleeve 1 17 Cap 1 18 1 For disassembly fastento engineholder specialtool 9589 For assembly fasten to engine holder special tool 9689 Crankcase half I cylinder ban...

Page 86: ...one bead screwtogether within five minutes 1 At the processing nozzle cut off the first meteringstep 2 Applya uniformbead approximately1 5 mm wide to the cleanedsealingsurface of the crankcasehalf cyl...

Page 87: ...Assemblyinstructions Tightening sequence for crankcase halves Tightening torque for hexagon head bolts 13 Nm 10 0 ftlb 443g 96 10 37 10 10 37 Disassembling and assembling crankcase halves Printed in G...

Page 88: ...ar as it will go using inser tion tool 9609 11 240 97 Fitting crankshaft sealing ring pulley side Insertsealingring as far as it will go using inser tion tool 9610 210 97 Disassembling and assembling...

Page 89: ...Specialtool 9111 3 9111 1 Explanation 1 2 3 9111 5 To compensatefor the engine retainerplate in the necessary horizontalposition Engine retainerplate Adapter for engine retainer plate Spacer 4 Support...

Page 90: ...ngineand movethe mountingplate of the lifting platform into the highestposition 279_97 3 Removethe centre and rear undersidepanels 6 Unscrewcap from coolantexpansiontank 4 Removerear spoiler 7 Undocoo...

Page 91: ...colouredpen Slackenbelt byturningthe tensioningpulley wrenchsize 24 mm clockwise holdstill and simultaneously take the belt off the drive pulleys 058_99 9 Disconnectoxygensensor plug connections on t...

Page 92: ...of the fastening bracket and set down on the right handside r VI c c 061_99 c Disconnectelectricalplug connection Lift out compressorand set it downwith the hoses connected 059_99 18 Undoenginewiring...

Page 93: ...e engine compartment left It is very importantto counterwhen performingthis step Collectresidualfuel 336_97 Note Drill an accessbore of approx 30 mm 3on the side membersfor better accessto the outer f...

Page 94: ...21 27 Removecoolanthoses i Lc4 l f 25o_97 24 Undoground strap betweenengineand body Undothe strap on the body cylinderhead near cylinder6 I 176_99 28 Undoclutch slavecylinderand hangto one side with t...

Page 95: ...horizontal position Spacer specialtool 9111 5 fitted I 301_97 0 178_99 122_97 31 Separateenginecarrier from the engine mounts wrenchsize 18 81_99 32 Lowerthe engine transmission unit carefully and in...

Page 96: ...tention 362_97 2 Fitair conditioning compressor Liberallygrease and fit the thread of the rear fastening screwand spacer sleeve 1 Fitenginewiring harness The roun plugs are colour codedon the inside I...

Page 97: ...lerator cablemountsleeve 82_99 6 Fit coolant hoseswith newQ rings Attachthe safetybrackets onto the coolant supports before engagingthe coolanthoses 378_97 87_99 7 Move coolant hosesinto installationp...

Page 98: ...indicated bythe arrow closed and line up the marks on the accelerator mountsleeveand rotary sleeve 266_97 9 Fillin coolantand bleed cooling system SeeGroup 19 Page 19 1 8 8 Removing and installing eng...

Page 99: ...74 Crossmember at front to carrier side section 65 48 MIDx 1 5 65 48 Diagonal brace to body MID x 1 5 100 74 Diagonalbrace to cross member M12 x 1 5 Diagonalbrace to carrier side section collar nut 2...

Page 100: ...rrera 996 Engine 10 01 37 Disassembling and assembling engine GT3 l q 1 I o v dJ ir 130_99 10 69 1001 37 Disassembling and assembling engine GT3 Printed in Germany 32 1999 9961069 www WorkshopManuals...

Page 101: ...lanation Special tool 9589 No Designation Assemblyholder 1 For holdingthe engineon the assemblysupport For blockingthe crankshaft 9538 1 Toothed segment Disassembling and assembling engine GT3 Printed...

Page 102: ...Special tool 9653 No A Designation Holdingwrench Explanation For turning the camshaft adjuster B Torxsocketwrench Torque anglewrench gradoscope 9330 715 20 or 716 20 c 10 71 1001 37 Disassembling and...

Page 103: ...ntof the camshafts Withthistool the camshaftscan be fixed in the correct position Special tool 9661 and9661 1 A Designation Adjustmentdevice 9401 In order to remove play from the timing chain B Auxili...

Page 104: ...iningstrap over the piston rings 9659 B Restrainingstrap Forthe piston assemblyof pistons from cylinders2 and 5 c Piston ring restraining strap Referto WorkshopEquipment Manual Chapter2 4 No 57 9660 9...

Page 105: ...psin 9500 5 9500 4 9500 5 9500 3 H Plunger Assemblytool Assemblyaid for circlip For assembly of piston pin circlip For pre assembly of circlips in 9500 5 Part No 999 917 788 00 K Greasefor O rings Dis...

Page 106: ...rrera 996 Engine Disassembling engine GT3 Overview 3 2 J j z r 1 c I I c Y 0 t j v I 296_99 10 75 1001 37 Disassembling and assembling engine GT3 Printed in Germany 32 1999 9961069 www WorkshopManuals...

Page 107: ...Removingexhaustsystem 3 Removing clutch 305021 4 Removing intakedistributor 24 26 37 5 Removingbracketfor oil cooler 17 67 21 Removingbracketfor generator 27 27 19 Removinghousingfor coolant 19 55 21...

Page 108: ...911 Carrera 996 Engine Disassembling engine GT3 Overview 3 I v 1 299_99 10 77 1001 37 Disassembling and assembling engine GT3 Printed in Germany 32 1999 9961069 www WorkshopManuals co uk...

Page 109: ...hafts Repair number 150321 8 9 Removing cylinder head 157021 102021 10 Removingcylinders 131019 1 Removing pistons 101037 12 Removing crankcase 152037 3 Removing intermediate shaft and oil pump Removi...

Page 110: ...911 Carrera 996 Engine Assembling engine GT3 Overview 297_99 10 79 1001 37 Disassembling and assembling engine GT3 Printed in Germany 32 1999 9961069 www WorkshopManuals co uk...

Page 111: ...4837 3 Installingintermediateshaft and oil pump 152037 4 Installing crankcase 101037 5 131037 131037 157023 150323 Installingpistons 6 7 8 Installingcylinders Installingcylinderhead Installingcamshaft...

Page 112: ...911 Carrera 996 Engine Assembling engine GT3 Overview I 298_99 10 81 1001 37 Disassembling and assembling engine GT3 Printed in Germany 32 1999 9961069 www WorkshopManuals co uk...

Page 113: ...talling bracket for generator 272719 176723 11 Installingbracketfor oil cooler 12 13 Installingintakedistributor Installingclutch 24 26 37 30 50 23 2601 23 175219 14 Installingexhaustsystem 15 Install...

Page 114: ...using M6 10 7 5 ftlb Screwed socket crankcase M 22xl 5 70 52 ftlb Rearmufflerholder M8 23 17 ftlb Generator M 10 65 48 ftlb M 16xl 5 31 23ftlb Guide tensioningrail on crankcase Shortguide rail on cams...

Page 115: ...then 1300 turn Oildrain plug on the oil container M20xl 5 60 44 ftlb M 20xl 5 Oil drain plug crankcase 60 44 ftlb Oilextractionpump M6 13 9 5 ftlb Oil extractionpump cover M6 10 7 5 ftlb Oilcontainerf...

Page 116: ...11 0 ftJb Deflectionroller on unit support M 10 46 34ftlb Plug crankcase M 18xl 5 45 33 ftlb Plug reliefvalve M 18xl 5 60 44 ftlb Plug excesspressure valve M 18xl 5 60 44 ftlb Heatexchanger M6 10 7 5f...

Page 117: ...ationdamper Retainingdevice 9662 For bracingthe tensionrod bolts whentightening c 0 SurfacesealOreiBondSilicon Type 1209 Retainerplate 209a Screwthe crankshaftto the retainer platewith internalserrati...

Page 118: ...efor flywheel P 238b H Commercially available Part No 000 043 300 12 Snapring pliers Special grease for con rod bolts titanium Holderfor cylinder P 140 For stabilisingthe retainingdevice 9662 whenbrac...

Page 119: ...ring P 16d Assemblysleevesfor tension 9511 rod bolt seal Explanation Item A B 9517 1 9517 c 0 Assemblyaid Pressurepiecefor sealingring flywheelside 9285 1 E Forcingscrewfor vibration damper 10 203 10...

Page 120: ...ion Item Designation Engineholder Special tool P201 A Fastento the right half of the crankcase cyl 4 6 P 201b B Toothedsegmentand mountingelements 10 1037 Disassembling and assembling crankcase GT3 99...

Page 121: ...ankcase suspension Disassembling and assembling crankcase Left crankcase half cylinder bank 1 3 10100001 10 10 37 Disassembling and assembling crankcase GT3 Printed in Germany 32 1999 99610201 10 205...

Page 122: ...ealingring A22 x 27 1 10 1 Screwplug for oil pressure reliefvalveMI8 x 24 11 Tighteningtorque 60 Nm 44 ftlb Alwaysreplace Sealingring Ala x 24 1 12 1 13 Compression spring 1 14 Pistonfor excesspressur...

Page 123: ...tightenwith doublehexagonwrench insertwhile bracingwith retainingdevice special tool 9662 27 Washer 11 28 a ring 8 x 2 11 29 Straightpin A8 0 x 14 30 Straightpin 31 Oversizeplug 8 5 x 8 0 32 Oversize...

Page 124: ...Carrera 996 Disassembling and assembling crankcase Right crankcase half cylinder bank 4 6 24 I J 25 9 10100002 10 10 37 Disassembling and assembling crankcase GT3 99610201 Printed in Germany 32 1999 1...

Page 125: ...ace 10 Fasteningnut M8 Washer 8 4 12 Hexagon head bolt M8 x 45 13 Fasteningnut M8 14 Fasteningnut M8 1 15 Washer 16 Hexagon head bolt M8 x 55 1 17 Hexagon head bolt M8 x 45 18 Lockinghook 19 Tension r...

Page 126: ...ud 1 Projection length22 mm 31 Stud BM8 x 22 3 Projectionlength49 mm Stud 8M8 x 48 2 32 Projection length 107 mm Stud BM10 x 105 1 33 1 34 Stud 8MB x 52 35 Stud 8M8 x 28 1 36 Stud 8M8 x 32 Stud BM10 x...

Page 127: ...ort specialtool P 201 2 Loosenthe vibrationdamper belt pulley with the help of a second person bracingwith holdingwrench specialtool 9548 232_99 231_99 3 Forcevibrationdamper belt pulley off with the...

Page 128: ...Note Thetensionrod bolts in thrust blocks2 3 4 and 5 arrows can only be removedafter removingthe crankcasehalf cyl 1 3 7 Loosentensionrod bolts from the outsideto the inside 3 u v 1 11 I l i 101CXKM 7...

Page 129: ...2 3 4 and 5 243_99 11 Lift crankshaftoutwith connectingrodsfrom the crankcasehalfcyl 4 6 12 Unscrewfasteningnuts of oil pumpand lift out oil pumpwith intermediateshaft 285_99 10 213 10 10 37 Disassemb...

Page 130: ...k thematching numbers ofthe crank casehalves 424_99 425_99 3 Checkallocationof crankcase crankshaft gearwheeland intermediateshaftgearwheel 423_99 4 Inserta newthrust bearingshell halfand a newbearing...

Page 131: ...426_99 6 Greaseboth sides of sealingring and insert it into the crankcasehalf 4 6 426_99 10 Insertbearingshellsof the crankshafts Insertcrankshaftwith bearing8 and mounted connectingrodsinto crankcase...

Page 132: ...sleevefrom specialtool 9511 over the threadedarea and pushthem on to the tapered section towardsthe head of the bolts 328_99 12 Preparetensionrod bolts for installation Note On 4 tensionrod bolts of t...

Page 133: ...3 Placeconicalsleeveon end of the thread PushO ring dry overthe conicalsleeve Removeconicalsleeveand pushthe O ring with the cylindersleeveasfar asthe cham fer in the thrustblock Removecylinder sleev...

Page 134: ...sertsealingrings in the oil pump 2 pieces and in the crankcasehalf cyl 4 6 with grease 385_99 15 Insertbearing halvesof the crankshaftbear ing and of the intermediateshaft ofcyl 1 3 10 10 37 Disassemb...

Page 135: ...de f I 7f L d hi T I iiJi i 101 j J IIJ G1 V v I I 1 4 I I b I v lo l O c I c L IIf olllh o 5 II I r 0 tS I Q 0 Q 336_99 17 Insertthe crankcasehalf carefullyover the preas sembledtensionrod bolts of t...

Page 136: ...owto the stop 240_99 239_99 239_99 19 Pushthe conicalsleeveof specialtool 9511 with an oileda ring to the end of the thread 10 220 10 10 37 Disassembling and assembling crankcase GT3 99610201 Printed...

Page 137: ...3_99 24 Proceedin the same waywith both studson the right crankcasehalf areaof bearing1 25 Mounthexagonnut MID x 1 25 andwasher AID 5 on stud with roundedside pointing towardsthe hexagonnut IL 7 I r 2...

Page 138: ...ningdevice9662 a secondpersonshould bracethe bolts withoutfail so that the a rings are not damaged Use socket M14from the companySnapon 237_99 402_99 27 Tightentensionrod bolts or studswith 50 Nm 37ft...

Page 139: ..._99 29 Mountthe remainingcrankcasebolt self lockinghexagonnuts M8 with washers Tighteningtorque 23 Nm 17 ftlb Note In the case of connectingrod cyl 1 and 4 attach damageprotectionto the rod hoseor rub...

Page 140: ...position Degreasefasteningbolt wetthe threadwith Loctite 242 andmount Tightenthe hexagon head bolt braced atthe sametime by a secondpersonwith holding wrench specialtool 9548 Ensurethat the holdingwr...

Page 141: ...eplacesealingrings Removeand replacethe three sealingrings two in the cylinder one on the bushing 255_99 2 Takecylinderfrom crankcase Carefullypullthe cylinder out of crankcase Makesure that the pisto...

Page 142: ...www WorkshopManuals co uk...

Page 143: ...Engine Crankshaft pistons 911 Carrera 996 Removingand installing drive belt 2 c I 7 3 0 4 381 97 Removing and installing drive belt 13 78 19 13 2 www WorkshopManuals co uk...

Page 144: ...e drivepulleys Visuallycheck state of belt and replace if necessary 3 Removingthe drivebelt Installing drive belt Instructions No Procedure Fiting and tensioning the drive belt 4 Fitdrive belt by hand...

Page 145: ...efore undoing 2 Deflection roller 1 with spacer pin 1 Whenfitting a curved cover plate observe the installationposition Theinscriptionmust face the bolt head 3 Coverplate Tighteningtorque 23 Nm 17 ftl...

Page 146: ...tightening wrenchsize15 2 Hexagon head bolt 1 This is not not requiredfor micro encapsulated removaland installationof the tensioningroller Thehexagon head bolt can be removed onlyafter the belttensio...

Page 147: ...movingand installing belt tensioner Engine installed Tools 342 97 Explanation Designation Specialtool Item Commercially available e g Snap on orderNo A177A Supplier saddress refer to Workshop Equipmen...

Page 148: ...Removingbelt tensioner 2 1 3 0 I k1 4 Q 6 5 383A 97 Removing and installing belt tensioner 13 10 13 73 19 www WorkshopManuals co uk...

Page 149: ...air cleaner assembly 2 Removing air cleaner assembly 3 Loosening belt pulley of the hydraulic pump 4 Relieving and removing drive belt 5 Loosening three phase generator 6 Loosening air conditioning co...

Page 150: ...Engine Crankshaft pistons 911 Carrera 996 Removing belt tensioner 137319 13 12 www WorkshopManuals co uk...

Page 151: ...r 8 Removing throttle body 9 Removing supply tank of the power steering system 10 Removing supply tank of the power steering system Detaching steering return line 11 Detaching steering return line fro...

Page 152: ...p after removalof the drive belt Mark belttravel direction witha colouredpen Slacken belt turningthe tensioningpulley wrenchsize 24 mm clockwise hold still and simultaneously take the belt off the dri...

Page 153: ...vacuumcheck valve 9 Removingsupplytank of the power steering system Suckfluid out of the upper supplytank untilthe levelis be lowthejoint Turn bayonetlock ring counter clockwise 10 Removingsupplytank...

Page 154: ...tdirt and scratcheswith a cap Detachinghydraulicpump and steering supplyline 13 Undosteering supplyline wrenchsize 17 simultaneously counter at the body wrenchsize 27 Undothree hexagon head bolts M8x...

Page 155: ...13 911 Carrera 996 Engine Crankshaft pistons Installing belt tensioner 2 1 1 3 0 4 6 Q 5 384 97 13 17 13 73 19 www WorkshopManuals co uk...

Page 156: ...position 3 Removeplug Positiontank observemarkings Lock bayo netlock Fitting supplytank for power steering system 4 Fittingdrive belt 5 Fit belt pulleyof the hydraulicpump and screwin hexagor headbolt...

Page 157: ...911 Carrera 996 Engine Crankshaft pistons 13 73 37 Disassembling and assembling belt tensioner 10 7 2 t 9 385 97 13 19 www WorkshopManuals co uk...

Page 158: ...Hexagon head bolt micro encapsulated 1 Greaseplastic bushings of the lever bearingwith OlistaLongtime3 EP Applya thin coat of screwlocking lacquerto the thread of the hexagon headbolt Observenote Theh...

Page 159: ...in the two bores of the bracket on right side in direction of travel Note Either the screw locking lacquer Loctite 242 Mittelfesf medium strength or screw locking lacquer Loctite 270 Hochfesf high str...

Page 160: ...37 Disassembling and assembling bearing housing with crankshaft Tools 482_96 Special tool 9607 Item Explanation Fastenbearinghousingwithtwo MIO x 30 hexagon head bolts Designation Assemblyfixture for...

Page 161: ...Disassembling and assembling bearing housing with crankshaft 183_96 www WorkshopManuals co uk...

Page 162: ...on Removal Installation Qty Connecting rod bolt 6 Lightlyoil thread and bearingsurface 2 1 3 Connecting rodbearing cap cyl 4 Connectingrod cyl 4 1 Immediately join with the connecting rodbearing cap a...

Page 163: ...l groove facesthe beltpulley oil groove of opposite thrust plate facesthe flywheel insert thrust plateswith grease Insert in correct position locating stud or anti turn lock towards dowel sleeve side...

Page 164: ...g housing with crankshaft Important Bearing housings without connecting rod bearing twist locks should not be installed See twist lock page 13 28 sequence figure no 4 arrow 1 5 0 Q Q J I J I e e i 213...

Page 165: ...Disassembling and assembling bearing housing with crankshaft 13 28 www WorkshopManuals co uk...

Page 166: ...911 Carrera 996 Engine Crankshaft pistons Disassembling and assembling bearing housing with crankshaft 8 65_98 13 29 www WorkshopManuals co uk...

Page 167: ...thrustbearings Fitthe locatingstud or the locatingstud of the twist lock on the dowel sleeve side Lightlyoil slidingsurfaces Insertthe thrust platesin the recess of main thrust bearing4 of the bearing...

Page 168: ...od Lubricate sliding surface liberally with grease e g Optimol Optipit 00004320417 Note Greaseto facilitate assemblyduring subsequentpiston pin installationof cylinderbank 4 6 10 Completing connecting...

Page 169: ...kshaft pistons 911 Carrera 996 Assembly instructions Tighteningsequencefor thrust bearingscrews 185_ Screws bearing housing Initialtightening 25 Nm 19 ftlb Finaltightening 1 x 900 turn www WorkshopMan...

Page 170: ...nder bank 4 6 3 Additionally fasten the assemblyfixture on the workbenchusingC clamps I II I 213_98 Special tool 9607 4 Placeandfastenthe bearinghousinghalf of cylinderbank 4 6 on the specialtool for...

Page 171: ...earings in the bearinghousing 00 0 q 00 0 0 o 1 0 0 0 0 p 9 0 0 0 0 0 0 0 i 67_98 68_98 Mainthrust bearing1 on the belt pulley side Connecting rod bearingof cylinder1 on the belt pulley side Mainthrus...

Page 172: ...Carrera 996 Engine Crankshaft pistons Disassembling and assembling bearing housing with intermediate shaft 10 9 6 I 7 I 11 12 i 14 1 13 15 rr1 l f 2 it 5 Sa 1 4 0 3 187_96 13 32c www WorkshopManuals c...

Page 173: ...gfor tensioningrail 1 Unclip Checkfor wear marks and replace if necessary Intermediateshaft 1 6 7 Chainfor intermediate shaftdrive 1 Chainfor camshaftdrive of cylinder bank1 3 1 8 1 9 1 Alwaysreplace...

Page 174: ...a 996 Engine Crankshaft pistons Disassembling and assembling bearing housing with intermediate shaft 188_96 13 49 37 Disassembling and assembling bearing housing with crankshaft 13 32e www WorkshopMan...

Page 175: ...egrooveofthe intermediate shaft flange Donotfit twisted Grease lightly 4 Fitting chainfor intermediate shaft Puton chainbetweencrankshaftdrive sprocketand intermediateshaftdrive sprocket Fitguide rail...

Page 176: ...4 19 Removingand installing crankshaft sealing ring Engine installed pulley side Tools e e c 711 7 Item Special tool 9593 9594 Explanation A B Designation Retainingdevice Socketwrench insert c Inserti...

Page 177: ...of the belt with a colouredpen Relievethe belttension To do this turn the tensioningroller wrench size 24 mm clockwiseand simultaneously removethe beltfrom the drive pulleys 261_97 1 2 Detachoil fille...

Page 178: ...sheetmetal screw place support betweenthe mounting leverandcrankcase 25 97 Lever crankshaftsealingring out of the crankcase 4 Remove crankshaft sealing ring The following tools and parts are required...

Page 179: ...iningdevice9593 b Thoroughlylubricatethe crankshaftjournal assemblysleeveand sealinglip Tightening sequence Initial tightening Final tightening 50 Nm 37 ftlb 1 x 900 turn Note Do not lubricate outer d...

Page 180: ...heckwhetherthe belt is correctly positionedon all drive pulleys 1 Coolantpump drive pulley 1 2 Alternator drive pulley 2 3 Deflectionroller 1 3 4 Powersteering pumpdrive pulley 4 5 Air conditioningcom...

Page 181: ...rvice No 34 35 19 or Group 3 Tiptronic transmission Service No 37 01 19 Tools 13590001 Explanation Designation Special tool Item 9609 9609 1 A Insertion tool B 3237 9538 1 c Mounting bell Extractor D...

Page 182: ...prox 5 mm into the bore 8 Pull out sealingring with extractor 3237 r 607_97 3 Detachthrust plate Note In order to avoid deformation of the thrust plate housing always loosen screws in several stages a...

Page 183: ...llustrationshowssurroundingedge of 13590004 centring piece Thesurroundingedge must not be damaged 2 Fastenassemblysleeveof specialtool 9609 3 Lubricatecrankshaftjournaland assembly sleeve Note The mic...

Page 184: ...5 Fit crankshaftsealingring Insert sealingring as far as it will go usingthe insertiontool which consists of the special tools 9609 and9609 1 240_97 www WorkshopManuals co uk...

Page 185: ...13 911 Carrera 996 Engine Crankshaft pistons 13 10 19 Removing and installing pistons 514_98 13 41 131019 www WorkshopManuals co uk...

Page 186: ...Explanation Item Designation Retaining device for pistons and connecting rods for pre fitting the piston pins of cylinder bank 1 3 Spacer ring A Al 9597 1 B Assembly sleeves for pre fitting 9603 1 the...

Page 187: ...rsunk screws Fasten on crankcase with two M6 x 20 crosshead countersunk screws Reason Piston pin circlips installed in different position Assembly tool for fitting the piston pins and piston pin circl...

Page 188: ...ine Crankshaft pistons 911 Carrera 996 Fitting pistons and connecting rods Preparepistonsand connectingrods for installationin the crankcasehalf of cylinders 1 3 f 0 1 a 515_98 www WorkshopManuals co...

Page 189: ...Engine Crankshaft pistons 911 Carrera 996 Fitting pistons and connecting rods 2 M 3 8 I II r J ll 6 7 51 98 8 131019 13 46 www WorkshopManuals co uk...

Page 190: ...Manuallyinsertthe newcirclip into the conicalpart of the assemblysleeve specialtool 9603 1 4 5 Presspiston pin circlip into the assemblytube Placethe cylindricalpart of the assemblysleeve9603 1 on th...

Page 191: ...inghousing in the crankcasehalf cylinders1 3 As the bearinghousingis heavy it should be installedusinga workshopcrane Carefullyand in stages lower bearinghousing withfitted holder 9607 andworkshopcran...

Page 192: ...vel exists Lift the bearinghousingand check the chaininstallationif necessary 467_97 3 2 Just before reachingthe final installation position pull the loosenedintermediate shaft flange out of the housi...

Page 193: ...teningtorque 30 Nm 23 ftlb UseTorx screwdriverinsert T50 or T55 U4 0 604_97 8 Removepreas sembledconnectingrod with piston of cylinder 1 from the assemblyfixture Iil 5 Turn crankcaseby 1800on the asse...

Page 194: ...while firmly pressing on the edge of the restrainingstrap Use protectivegloves 258_97 11 Tighten piston ring clamp and fit piston with connecting rod Note Thepiston mustbe fitted in the cylinder caref...

Page 195: ...d with larger diameter and insertiondepth II S 1 I 1 r 256_97 I 1 o o 0 Q 251_97 14 Turn crankcase by 180 Makesure the bearingshell is correctly seated in the connectingrod Thefixing lugs pointto the...

Page 196: ...ith fixing pin short of specialtool 9595 2 Final tightening 1 x 900 turn Use 10 mm socketwrench insert double hexagon 17 Fitting piston and connecting rod in cylinder 2 Turncrankcaseby 180 Turn cranks...

Page 197: ...oil guide andthe two seals left and right of the coolant duct are seated correctly 561_98 3 Placecentring mandrel specialtool 9645 on the receivingbore of the oil pumpandturn the star knob clockwiseun...

Page 198: ...refullyset the crankcasehalfin place so that the sealingbead is notdamaged 7 Fastencrankcasehalf Tighteningtorque 13 Nm 10 ftlb Tighteningsequence see Group10 Page 10 37 Immediatelyremove siliconemate...

Page 199: ...491_96 I 11 Fit belt pulley Screw in fastening screw by hand Cylinder bank 4 6 faces upward Bore U6 on the belt pulley must be aligned with the fixing bore on the crankcase Position or fix with fixin...

Page 200: ...screws with crosshead M6 x 20 on the crankcase Q co 0 0 J View Specialtool 9602 3 5 _98 506_98 Note Centring aid special tool 9602 2 is used as from engine numbers 66X07679 and 68X03514 0 CD 0 Q III...

Page 201: ...9_98 v 16 Movepistonto installationposition position the pistonring restrainingstrap and insert the piston 5 _98 15 2 Beforeinstallation check whetherthe assemblytube 2 can be moved easilyin the pisto...

Page 202: ...gently into the cylinder while firmly pressing on the edge of the restraining strap Use protective gloves Note The piston must be fitted in the cylinder carefully and with feeling If the resistance in...

Page 203: ...are piston pin circlip for fitting on the piston It is important to pre fit the circlip on a firm surface The circlip must be pre fitted only immediately prior to fitting on the piston pin eye 22 1 Ma...

Page 204: ...ury if circlip springs out Check position of the circlip only by visual inspection of the assembly tube from the side f or IJ J 523_98 528_98 23 Pushassemblytube throughthe centring pieceinto the cran...

Page 205: ...seating of the piston pin circlip e g with a shop made electric torch with mirror 504_98 244_97 25 Move the piston pin circlip to its installation position by briefly and forcefully striking the palm...

Page 206: ...the crankcase Positionor fix with fixingpin rn R 524_98 0 us l A I 046_98 28 Performthe following assemblysteps for piston installationin cylinder 5 as described from Step 14 to Step26 V A spacer slee...

Page 207: ...e crankcase Position or fix with fixing pin 7 ill 525_98 0 U4 I 044_98 I 30 Perform the following assembly steps for piston installation in cylinder 4 as described from Step 14 to Step 26 31 Two space...

Page 208: ...ct correct seating of the piston circlip on the piston of cylinder 4 34 After fitting the pistons fit a screwplug and newsealingring in the assemblybore Use a 12 mm hexagonsocketwrenchinsert Tightenin...

Page 209: ...ide fit guide rails in correct position 36 Fitguide rails andtensioningrails of cylinder bank 4 6 flywheelside fit guide rails in correctposition Viewfrom the belt pulleyside Viewfrom the belt pulleys...

Page 210: ...ange Greasereceiverbore in area of the crankcase Carefullypressin the intermediateflange Screwin newmicro encapsulated hexagon head bolts M6 x 20 3 ea Tighteningtorque 10 Nm 7 5ftlb Tighten locknutwit...

Page 211: ...ote Checkwhetherthere are foreign objects in the drive belt grooves of the pulleyand removethem if necessary Tighten hexagon head bolt using the socket wrench insert 9594 simultaneously hold with reta...

Page 212: ...911 Carrera 996 Engine Crankshaft pistons 13 78 19 Removing and installing drive belt engine installed GT3 k I 11 J JJ 129_99 13 69 www WorkshopManuals co uk...

Page 213: ...www WorkshopManuals co uk...

Page 214: ...rview of the drive belt GT3 Removeair cleaner assembly 2 Loosen servo pump wheel 3 Relievedrive belt 4 Remove servopumpwheel 5 Remove drivebelt Removing and installing drive belt engine installed GT3...

Page 215: ...air flow sensorand removeair cleanerassembly ii E ii f 188_8_99 Loosenservo pumpwheel 2 Mark belttravel directionwith a colouredpen Undothe three hexagon head bolts on the servo pump by approx one ha...

Page 216: ...tructions 4 Removeservopumpwheel Removeservopumpwheelwith drive beltto the rear Important Only remove the servo pump wheel when the drive belt is completely relieved Removethe beltfrom all drive wheel...

Page 217: ...911 Carrera 996 Engine Crankshaft pistons Installation overview of the drive belt engine installed GT3 2 1 J C 1 t_ jjT I J t J c 7 5 189_99 1 1 www WorkshopManuals co uk...

Page 218: ...stons Installation overview of the drive belt engine installed GT3 Fitdrivebelt 2 Positionservo pumpwheel 3 Tensiondrive belt 4 Tighten fastening screws on servo pump 5 Installair cleaner assembly 13...

Page 219: ...tly tighten the three fastening screws on the servo pump wheel 189_b_ 3 Tension drivebelt To tensionthe drivebelt turn the tensioningroller 7 in clockwisedirectionand simultaneously fit the drive belt...

Page 220: ...nthe fasteningscrews of the servo pumpdrive wheel Thethree screwsare tightenedto 23 Nm 17 ftlb J 189_d_99 5 Installair cleaner assembly Installair cleaner assemblycompletely Attach connector onto mass...

Page 221: ...13 911 Carrera 996 Engine crankshaft pistons 13 73 37 Disassembling and assembling belt tensioner GT3 www WorkshopManuals co uk...

Page 222: ...for smooth running or roughness before undoing 6 7 Spacer Check replace if necessary 8 a ring 1 Tightening torque 23 Nm 17 ftlb 9 Hexagon head bolt M8 x 55 1 1 10 Coverplate 1 Check for smooth runnin...

Page 223: ...ve out of the tensioning element with a drift 5 Threadon to tensioning lever No 21 See Assemblynote Tighteningtorque 9 7 Nm 7 0 ftlb Fitin correct position grease in area of bearing 22 Dustcap 23 Pan...

Page 224: ...rrera 996 Assembly note 1 Threadtransmissionleveron to tensioning lever if 137 2 2 Insert the front right hexagon head bolt on the bracket with Loctite 574 Tightening torque 65 Nm 48 ftlb 0 c t A f 1...

Page 225: ...c 10100003 Item Designation Retainerplate Special tool 209a Explanation A Al Pan head screws Part No 928 102 151 01 3 pieces B C SpecialgreaseVolta EF 90 Snapring pliers PartNo 000 043 300 12 Commerc...

Page 226: ...Engine crankshaft pistons 911 Carrera 996 13 48 37 Disassembling and assembling crankshaft 335_99 www WorkshopManuals co uk...

Page 227: ...ft only install together warm on heat ing plate push on up to stop The collar of the timing gear must point to bearing 7 8 Woodruffkey 1 9 Connectingrod nut M9 x 1 25 12 Tightening torque Initial tigh...

Page 228: ...ce 15 Con rod bolts 12 Greasethread of the con rodbolts use only specialgrease Part No 000 043 300 12 16 12 Replace 17 Main bearing shells of bearings 2 7 Main thrust bearing shells 1 2 Replace 18 Cra...

Page 229: ...lampspecialtool retainingplate P 209a in the vice Fastenthe crankshaftto the retainingplatewith 3 pan headscrewsLa No 928 102 151 01 277_99 5 Remove Woodruff key 6 Removecrankshaftfrom retainingplate...

Page 230: ...an oil bath or on a heating plate and push it on to the crankshaft journal up to the stop The collar of the timing gear must point to bearing 7 Note 401_99 As an assemblyaid removethe timing gear from...

Page 231: ...e con rodbolts must be greased without fail Usespecialgrease PartNo 000 043 300 12 The matchingnumbersof the con rodsand the con rodbearingcaps mustall pointto the same side ill I 278_99 7 Tighten con...

Page 232: ...l tool 9657 Explanation For positioning the restraining strap over the piston rings 9659 B Restrainingstrap c Pistonring restrainingstrap Forthe pistonassemblyof pistons from cylinders2 and 5 Referto...

Page 233: ...yaid For pre assembly of snaprings in 9500 5 H Plunger Assemblytool 9500 4 9500 5 9500 3 J Assemblyaid for snapring For assemblyof piston pin snapring For pre assembly of snapring in 9500 5 K Greasefo...

Page 234: ...911 Carrera 996 Engine crankshaft pistons Removing and installing pistons 346_99 13 211 www WorkshopManuals co uk...

Page 235: ...ase do not mounttwisted 4 a ring 110 00 x 2 50 6 Replace on principle wet with grease do not mount twisted 5 6 Piston pin circlip Lever out Replaceon principle ensurecorrect seating 6 Pistonpin 3 Assi...

Page 236: ...911 Carrera 996 Engine crankshaft pistons 132023 Installing pistons GT3 Includes removing and installing cylinders 10200004 13 213 132023 Installing pistons GT3 www WorkshopManuals co uk...

Page 237: ...untone piston pin snapring for each piston Ensurethat the outer snapring is alwaysmountedon the pistonwhenthe piston is in the correct installationposition the large valve notchesin the pistonpointing...

Page 238: ...Mountthe central piston 6 1 Offset the gaps of the piston rings by 1200 and mount the restraining strap 6 2 Mountrestrainingstrap Positionthe restrainingstrap specialtool 9659 on top of the piston En...

Page 239: ...neforwards in runningdirection until the two outer connectingrods stand equally far from the crankcase 600 crk in front of top dead centre Puton the spacers specialtool 9651 228_99 6 4 Mountingthe pis...

Page 240: ...bushing is guided by the studs Ensure that the flattened areas on the bushing point towards the neighbouring bushings 15700005 9 Mountthe piston pincirclip Mountthe piston pin circlips of both piston...

Page 241: ...place on the piston by turning the handwheel Then loosen the special tool again and turn the motor in running direction until the central piston can no longer be seen in the gap between the cylinder a...

Page 242: ...ial tool 9500 5 9500 4 9500 3 A Assembly tool Explanation For fitting piston pin circlip B C Plunger Assemblyaid for circlip D Assemblyaid 9500 6 For pre assemblyof the circlip in 9500 5 For pre assem...

Page 243: ...911 Carrera 996 Engine crankshaft pistons Installing piston pin circlip GT3 24460014 Installing piston pin with piston pin circlip GT3 www WorkshopManuals co uk...

Page 244: ...pincirclip in assemblyaid 9500 6 2 Positionthe piston pincirclip 9500 5 3 Presspiston pincirclip into assemblytool 9500 5 4 Check position of the circlip 5 Positionthe assemblytool 6 Pressin the pisto...

Page 245: ...ted in the piston from the left or from the right I 24460016 2 Position the assembly tool I Positionthe assemblytool 9500 5 under assemblyaid 9500 6 It mustbe ensuredthat the groove in the mountingaid...

Page 246: ...nfitted in the correct cutout dependingon whether it is fitted from the left or from the right Note Differentinsertion seefigure below into the assemblyaids and in the assemblytool is necessary I beca...

Page 247: ...Engine crankshaft pistons 911 Carrera 996 Installing piston pin circlip GT3 i J 13260001 www WorkshopManuals co uk...

Page 248: ...Pressthe assemblytool againstthe piston and insertthe plunger9500 4 into the assemblytool Pressthe plunger firmly againstthe piston The circlip must audiblyengage 24460021 7 Checkfor correctfitting T...

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