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Porsche 911 Carrera (996), Technical Manual

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Summary of Contents for 911 Carrera (996)

Page 1: ...TechnicalManual 9ff 7 996 TechnicalInformation Contents Group 1 Engine Part 2 as of Repair Group 15 WKD 483 721 TlTEL CHP www WorkshopManuals co uk...

Page 2: ...ralsupplement WKD483721 20 Generalsupplement WKD483721 21 21 Generalsupplement WKD483721 22 22 23 Generalsupplement WKD483721 23 Generalsupplement WKD483721 25 25 26 Generalsupplement WKD483721 26 Gen...

Page 3: ...electronics 3 Transmission manualtransmission 3 Transmission automatictransmission 4 Runninggear 5 Body 6 Body equipment exterior 7 Body equipment interior 8 9 Air conditioning Electrics 9 Circuit dia...

Page 4: ...airs General technical data Instructionson repairs As can be seen from the breakdown the publishedTechnicalInformationis in the front part of each fol der numbered accordingto the Groups TheTable of C...

Page 5: ...d valvedrive Engine Lubrication Engine Cooling 2 20 21 24 25 26 27 28 Group 2 Fuel exhaust engine electronics Fuelsupply control Exhaust system turbocharging Fuelsystem electronic injection Fuelsystem...

Page 6: ...or equipment Interior equipment Passengerprotection 7 70 72 74 Group7 Body equipment interior Linings insulation Seatframes Seatupholsteries covers Group 8 8 80 85 87 88 Air conditioning Heating Venti...

Page 7: ...lve tappets of cylinder bank 4 6 Installing valve tappets cylinder bank 4 6 Completing camshafts Sealing cover for camshaft housing cylinder head cover Checking guide for valve tappets Removing and in...

Page 8: ...GT3 Removing bracket for oil cooler GT3 Installing bracket for oil cooler GT3 Removing and installing oil temperature sensor GT3 19 193817 195819 195019 191201 195021 195023 195819 195519 195521 19552...

Page 9: ...with screw Magnetic disassemblyhead Art No 6024650 Art No 6000102 F Art No 6006015 Assembly head1b for valvekeys Pressure piece6e 3ea G Padfor valve discs 3 ea H Art No 6025665 ItemsAto H refer to Wo...

Page 10: ...3365 VWspecialtool B 9605 c Cl 9605 1 9604 D E Pressure piece for fitting the oil protectiontubes Pressurepiece for fitting the oil protectiontubes engineinstalled Handpressure piece 1 set 2 ea Tensi...

Page 11: ...ssembling and assembling cylinder head Diagram shows cylinder head 4 6 69 97 15 4 15 7037 Disassembling and assembling cylinder head Inner parts 996151 Printed in Germany 10 1998 www WorkshopManuals c...

Page 12: ...over the valvestem Oil sealinglip of the valve stem seal and pushonto the assemblysleeve or valveguide by hand Carefullypressthe valve stem seal asfar as it will go into the valveguide usingthe press...

Page 13: ...iffer in the area of the chain tensionersand are therefore marked on the front with 1 3 or 4 6 to preventmix ups Cylinder bank 1 3 567_96 Cylinder bank 4 6 568_96 15 7037 Disassembling and assembling...

Page 14: ...m supports underno circumstanceson the sealingsurface 2 Mountshaftwith aluminiumsupportson the cylinderhead Fastencylinderhead to the workbench with screwclamps 3 Fastenmagnetic disassemblyheadto leve...

Page 15: ...s together withthe assemblyhead With slight pressure allowvalvecollets to engage Thevalve colletsare then automatically positionedin the right place 1 Fastenassemblyheadto lever arm Shift slidingsleev...

Page 16: ...allation Fitoriginalvalvespring support disc Slide plastic assemblysleeve 13 6 mm onto valve stem Oil sealinglip and seatingsurface of valve stem seal put on by hand and with assembly mandrel VWspecia...

Page 17: ...Torquewrench Explanation Referto WorkshopEquipment Manual Chapter2 4 No 88 B Socketwrench insert Torx T50 9633 Commerciallyavailable Socketwrench insert Torx T55 As of enginenumber M96 01 66XO3084 M9...

Page 18: ...dby Zyl 1 3 or Zyl 4 6 with OBEN TOP I plus the correspondingpart number Ensurecorrect seating of dowel sleeves in crankcase Puton gaskets 0 0 0 0 0 0 0 nOBEN TOPOwKz i J J 0 510 97 bi 0 0 0 0 0 0 0 O...

Page 19: ...atten 1st step 30 Nm 23 ftlb 2nd step Completely loosen cylinder head screws Final tightening 1st step 20 Nm 15 ftlb Application torque in prescribed tightening 2nd step 3rd step 1 x 600 t 20 1 x 600...

Page 20: ...teningthe cylinder headscrews additionallyfasten four pan headscrews M6 x 35 10 9 withcaptive washers in the area of the chainbox Tighteningtorque 13 Nm 10 ftlb 637 97 15 70 23 Installing cylinder hea...

Page 21: ...996 15 70 37 Disassembling and assembling cylinder head Camshaft drive Diagram shows cylinder head 1 3 46O_97 15 70 37 Disassembling and assembling cylinder head Camshaft drive Printed in Germanv 10...

Page 22: ...movetensioningscrew once both camshaft bearingsaddleshave beenfastened 4 Tensioningscrew tensioningscrew is already fitted as a transport lock on newchain tensioners Pan headscrew M6 x 35 4 Fitholding...

Page 23: ...kfor wear scoring observeidentification Checkfor wear scoring observeidentification 13 Valvetappet 12 Do not interchange store in suitableplace Checkfor wear scoring 14 Pan head screwwith captivewashe...

Page 24: ...inder heads are identified with 1 3 or 4 6 See Assembly instructions 22 Cylinder head gasket 1 Alwaysreplace The gasketsare identified by Zyl 1 3 or Zyl 4 6 andthe corresponding partnumber Whenthey ar...

Page 25: ...ogether and musttherefore alwaysbe installedtogether Observepairingnumbers c C Pairing number of the two bearingsaddles 401_96 Note The letters E or A before pairing numbersmean E Bearingsaddlefor inl...

Page 26: ...linder bank 1 3 Identificationon the camshaft Inletcamshaft Exhaustcamshaft 221 55 3 4 IN 13 222 55 3 4 EX13 Camshafts of cylinder bank 4 6 Identificationon the camshaft 464_97 Inletcamshaft Exhaust c...

Page 27: ...ry Illustration shows tensioning element of cylinder bank 1 3 623 97 1 Upperguide rail 2 O ring 3 Lower guide rail Note Parts 1 to 3 are availabletogether as a spare partrepair set via the PartsServic...

Page 28: ...5 05 19 Removingand installing camshafts Illustration shows camshafts with accessories 59 97 Illustration shows view from the belt pulley side 15 23 15 05 19 Removing and installing camshafts Printed...

Page 29: ...gelement 1 Relievetensioningelement withthe specialtool tensioningscrew9632 before removalof the camshafts Inspectguide rails for scoring and replace if necessary 9 1 Tighteningtorque 10 Nm 7 5 ftlb O...

Page 30: ...ce 20 a ring Tightening torque 14 Nm 10 5ftfb 21 Hexagon head bolt M6x 15 10 9 4 22 Drive plate Driving plate for oil extraction pump 23 Sprocketwheel 1 Thedeeper recesson the sprocketwheelmust face t...

Page 31: ...ified 29 Fasteningscrew 1 30 a ring 1 Replace grease lightly 31 Tensioningrail 1 Inspectfor scoring and replace if necessary 32 Fastening screw 2 33 O ring 2 Tighteningtorque 10 Nm 7 5 ftlb Replace gr...

Page 32: ...fixing pin 1 set 3 ea 9612 c D 9634 E 9611 1 set 4 ea F Designation Fixingpin for belt pulley Auxiliarychaintensioner for valvetiming adjustment Locking devicefor camshafts in timing position Ringwren...

Page 33: ...tcylinderheadgasket The gasket is identifiedbyZyl 1 3 and OBEN TOP plusthe correspondingpart number Ensurecorrect seating of dowel sleeves incrankcase 497_96 0 0 0 0 0 0 Q Q 0 0 OBEN TOP WKlyl I J 0 0...

Page 34: ...s Tighten pan head screws M6 x 35 from the inside to the outside Tightening torque 10 Nm 7 5 ftfb 567_96 5 1 Tighteningtorques andtighteningsequence refer to Page 15 8a 5 2 Fit shield Tightening torqu...

Page 35: ...e inlet camshaftor the lug on the camshaftposition sensorcover faces upward I II n 9 9 0 0 I 218_97 9 2 Fitholding down device 9624 on the cylinder headusinga M8 x 30 hexagon head bolt 246_97 9 Align...

Page 36: ...the sprocketwheel Fithexagon head bolts M6 x 15 10 9 Tightenhexagon head screws by hand so that the sprocketwheelcan still be rotated 401_1_96 E Bearingsaddle for inlet camshaft A Bearingsaddlefor exh...

Page 37: ...Preparecylinderheadcover for installation Cleansealingsurface of the cylinderhead and cylinderheadcover very carefully Apply a siliconebeadto the cylinderheadcover Referto Sealingcover for camshafthou...

Page 38: ...n Advance crankshaft 3600 clockwise until the bore 1 aT top dead centre in the belt pulley is aligned with the fixing bore on the crankcase Position or fix with fixing pin short of special tool 9595 1...

Page 39: ...3 Q Q 568_96 2 1 Fitcylinder headgasket The gasket is identified by Zyl 4 6 with OBEN TOP plus the correspondingpart number Ensurecorrect seating of dowel sleeves in crankcase Fitgasket 243 7 5 Align...

Page 40: ...rheadcover and bearingsaddles 5 1 Fastenholding downdevice9611 with auxiliaryscrews M6 x 45 218_97 5 2 Fitholding downdevice 9624 on the cylinder headusing a M8 x 30 hexagon head bolt 401_1_96 E Beari...

Page 41: ..._96 10 Positiondrive plate on the sprocketwheel Fithexagon head bolt M6 x 15 10 9 Tightenhexagon head bolts by hand only 11 Fitauxiliarychaintensioner of specialtool 9599 on cylinder head 4 6 Fitauxil...

Page 42: ...cylinderhead cover ServoNo 1591 51 430_1_96 Carefullyplacethe cylinder headcover in the correct position so that the sealingbead is not damaged Screwtwo studsor centringpins into the corners of the cy...

Page 43: ...d cover 1 Turn engineto installationposition on assemblysupport 2 Removefixingpin Advancecrankshaft3600 clockwiseuntil the bore 1 aT top dead centre in the belt pulley is alignedwith the fixing bore o...

Page 44: ...piece 8 and sword bolt C whentightening B Centring piece in groove of the exhaustcamshaft Pullsword bolt C back when tightening C Sword bolt D Centre section pivoting Viewfrom the belt pulleyside 474_...

Page 45: ...ly untilthe sword bolt C can be fixed in the bearingbore of the inletcamshaft 22O_97 10 Fastensprocketwheel Tighteningtorque 14 Nm 10 5 ftlb 11 Remove blocking device 15 41 15 05 15 Adjusting timing C...

Page 46: ...tool 9595 Viewfrom the belt pulleyside 624_97 4 Turn engine900 counterclockwiseon the assembly support Cylinder bank 4 6 facesupward 5 Ifthe allocationis correct the narrow segmentmustface the cylinde...

Page 47: ...ion of rotation or the marking I 3 mustface the crankcase Fitoil extractionpump Use newsealingring and newmicro encapsulated hexagonsocket headscrews Tighteningtorque 10 Nm 7 5 ftlb 9 Unscrewauxiliary...

Page 48: ...ntensioneron the crankcase 508_97 Chain tensioner I cylinder bank 4 6 Identification Without A B Chain tensioner on crankcase Identification I ring C Chain tensioner Jcylinder bank 1 3 Identification...

Page 49: ...camshaftbores Installation 1 Cleanreceiving bore remove anysilicone materialemerging Manually fit newcap dry and press in as far as it will go 685_97 15 05 15 Adjusting timing Cylinder bank 4 6 996154...

Page 50: ...tion 1 set 4 ea A 1 set 3 ea B 9599 9595 c Holding down device for camshafts Auxiliarychaintensioner for valvetiming adjustment Fixingpin for belt pulley 1 set 2 ea use short fixing pin Lockingdevicef...

Page 51: ...ion or fix with fixing pin short of specialtool 9595 _ I 2 Removecamshaftclosure caps above the cylinderheadoil extractionpumps Theclosurecap of cylinder bank 1 3 is locatedon the flywheelside andthe...

Page 52: ...shaft mustface inward toward the crankcase Viewfrom the belt pulleyside 625 97 Viewfrom the flywheelside 624_97 If the position of the camshaftsis incorrect removefixing pin at the pulleyand rotate th...

Page 53: ...er headcover 667_97 5 Unscrewhexagon head bolts M6 x 20 2 ea Removeclosure cap from tensioningelement VarioCam Viewfrom the flywheelside 625_97 2 Turn engineon assemblysupport until cylinderbank 1 3 f...

Page 54: ...urns Undofour hexagon head bolts M6x 15 on the chain sprocket Removeauxiliarychaintensioneragain 218_97 8 Relievecamshafttensioningelementwith specialtool tensioning screw9632 663_97 51 I II 9632 n n...

Page 55: ...r valvetappet Undothe pan headscrews 15 ea from the outside to the inside and removethe guide _ I 500_96 12 Detachtwo bearingsaddles Leverbearing saddles out of the guide sleeves 13 Removeholding down...

Page 56: ...ainjumped over reallocationis necessary Referto Completingcamshafts ServoNo 1505 33 218_97 6 Checkdowel sleeves 4 ea of the bearing saddlesto ensurethat they are properly seatedin the cylinderhead Oil...

Page 57: ...tension whenthe valvetiming is adjustedor checked The necessarypre tensionforce has beenachievedwhenthe measuring pin isflush with the face surface of the pressurescrew Turnthe screw if necessary 500...

Page 58: ...lemerging in the area of the camshaftclosurecap 15 Forthe subsequentadjustmentwork on the camshaft the pulleymustbe fixed at bore 1 aT TO C with the fixing pin specialtool 9595 44937 14 Fitcylinder he...

Page 59: ...sword bolt C back when tightening C Sword bolt 17 Allocatecamshafts to do this turn the pre tensioned centre piece accordingly untilthe sword bolt can be fixed in the bearingbore 503_96 22O_97 18 Fas...

Page 60: ...ionpump at cylinder head 1 3 flywheelside The arrowfor the direction of rotation or the marking I 3 mustface the crankcase Fitoil extractionpump Use newsealingring and newmicro encapsulated hexagonsoc...

Page 61: ...ltool 9595 Viewfrom the belt pulleyside 624_97 3 Turn engine by 900 on assembly support untilcylinderbank 4 6 faces upwards 4 Unscrewchaintensioner of cylinderbank 4 6 497_96 2 Check camshaftadjustmen...

Page 62: ...nsprocket Removeauxiliarychaintensioneragain l 12 Removedrive plate Connectsprocket wheeland chainwith a tie wrap installation position Witha secondtie wrap suspend the sprocketwheeland chainto the si...

Page 63: ...stface downward Ifthe allocationshouldbe uncertain e g chainjumped over reallocationis necessary Referto Completing camshafts ServoNo 15 05 33 hi rl o I Q 243_97 16 Lift out valve tappetswith a magnet...

Page 64: ...e tappet ServoNo 15 5902 2 Fitguide Tightenpan headscrews M6x 35 from the insideto the outside Tighteningtorque 10 Nm 7 5 ftlb 3 Lightlyoil the valve tappet and fit it in the guide 4 Lay the completeu...

Page 65: ...cylinderhead 4 6 401_1_96 E Bearingsaddle for inlet camshaft A Bearingsaddlefor exhaustcamshaft 7 Fittensioningelement VarioCam Tighten3 M6 x 95 pan headscrews Tighteningtorque 10 Nm 7 5 ftlb 8 Unscr...

Page 66: ...dthe auxiliarychain tensionerare fitted on the crankcasehalf 218 97 14 Preparecylinderheadcover for installation Cleansealingsurface of the cylinderhead and cylinderheadcover very carefully Apply a si...

Page 67: ...ensprocketwheel Tighteningtorque 14 Nm 10 5 ftlb 18 Remove blockingdevice 503_96 19 Fit camshaftclosure caps 3 ea dry Special tool fitting sequence A Fastening screwwith star knob on cylinderheadlug P...

Page 68: ...o encapsulated hexagonsocket head screws Tighteningtorque 10 Nm 7 5 ftlb 8 50 97 A Chain tensioner cylinder bank 4 6 Identification Without B Chain tensioneron crankcase Identification 1 ring 668_97 C...

Page 69: ...ginein installedposition Chaintensioneron the crankcase Chaintensioneron cylinderbank 4 6 508_97 507_97 Chain tensioner on cylinder bank 1 3 509_97 15 59 24 15 70 Installing valve tappets Printed in G...

Page 70: ...ocation Camshafts of cylinder bank 1 3 Identificationon the camshaft Inletcamshaft Exhaustcamshaft 221 55 3 4 IN 13 222 55 3 4 EX13 464_97 Camshafts of cylinder bank 4 6 Identificationon the camshaft...

Page 71: ...outer lugs of the chain mustface the dotting marks 1 Placethe inlet camshaftand exhaustcamshaft on a soft surface The lug of the camshaft positionsensor cover or the groove on the inlet camshaftand th...

Page 72: ...screw specialtool 9632 untilthe bearingsaddles andthe chaintensionerhavebeenfastened on the cylinderhead If allocationis correct the groove or lug of the camshaftposition sensorhousingface upward 491...

Page 73: ...ensor is no longer installed in vehicles without M660 08011 or M661 more demanding emission concept 1 The lug of the camshaftposition sensorcover or the groove on the inlet camshaftmustface downward T...

Page 74: ...itionsensorhousingfaces downward v Illustration shows tensioning element of cylinder bank 1 3 345_99 I i Relieveusing newspecialtool 9632 1 withleft handthread I 0 Q 243_97 Information Modifiedtension...

Page 75: ...n the cylinderheadcover Note After the sealanthas been applied the cylinderhead mustbe joinedwith the cylinderheadcover within 5 minutes Application of silicone bead At the processing nozzle cut off t...

Page 76: ...ressure duct If the hexagon head bolt arrow was loosened the micro encapsulated hexagon head bolt must alwaysbe replaced Partnumber900 378 163 09 M6x 16 5 _96 Applybead of sealantin the bearingsaddle...

Page 77: ...camshaft housing cylinder head cover Tighteningtorque 13 Nm 10 0 ftlb Tightening sequence 20 21 10 5 11 6 12 13 81 lIJ I 23 9 22 17 396_97 15 79 1591 51 Sealing cover for camshaft housing cylinder hea...

Page 78: ...ularitiesshownin the limit samplephoto are normaland must not be classified as damage influencingthe function of the part or requiring replacementof the part c A B I 1 I I D 644_97 Permissible irregul...

Page 79: ...anation Referto WorkshopEquipment Manual Chapter2 4 Nos 14 15 Commercially available Referto WorkshopEquipment Manual Chapter2 4 No 108 B Internalpuller 23 5 30 mm fJ 9604 c Handpressure piece for fit...

Page 80: ...era 996 Removing and installing oil protection tubes Engine installed 2 1 r j J L ri1U O J 0 I 4 632_97 Removing and installing oil protection tubes Engine installed 9861583 Printed in Germany 10 1998...

Page 81: ...ug Unscrewhexagonsocket headscrews wrenchsize 5 and pull off ignitioncoil with ignition coil plug 1 Remove ignition coil Unscrewspark plugs using commerciallyavailablesocket wrenchinsert refer to Work...

Page 82: ...d coatwith tyre mountingpaste Usingthe pressurepiece specialtool 96051 1 and hand pressurepiece specialtool 9604 manually press in the oil protectiontube asfar as it will go Fit spark plug Fit spark p...

Page 83: ...tube out 2 Manually press the oil protectiontube asfar as it will go into the fitted cylinderheadcover Installation 1 Coatsealingrings withtyre mountingpaste Pushtube onto pressure piece special tool...

Page 84: ...ustmentdevice 9612 9 Screwsfor holding down device 9634 5 Holding down devicefor 9634 camshafts Explanation 1 set 2 ea use shortfixing pin 1 set 3 ea c Onlyused with engineinstalled Onlyused with engi...

Page 85: ...the following additionalassemblyoperationsmust be performed 2 Removethe rear wheels 3 Drainengineoil SuckPentosinfluid out of the reservoir untilthe levelis just belowthejoint 4 Remove theair cleaner...

Page 86: ...eplug 30 mm f3 7 263 97 Bayonett lockopen 264_97 5 2 Removedrive belt Mark belttravel direction with a colouredpen Slackenbelt turning the tensioningpulley wrenchsize 24 mm clockwise hold still and si...

Page 87: ...ler 02 98 8 1 Undoupper hexagon head bolts usinga flexible headsocketwrench wrenchsize 13 Detachholder 217_98 9 Remove shieldofcylinderheadcover 15 59 20 Removing and installing valve tappets Engine i...

Page 88: ...ition Turn crankshaftclockwiseuntil the bore 1 aT top dead centre in the belt pulleyis alignedwith the fixing bore on the crankcase Positionor fix with fixing pin short of specialtool 9595 or 9595 1 1...

Page 89: ...in 9 Fitspecialtool holding down device9634 on the cylinderhead Fastenholding down device witha hexagon head bolt M8 x 3 Note In order to preventdamageto the camshafts or saddle bearings it is essenti...

Page 90: ...etachthe cylinderheadcover by knocking it gentlywith a plastic hammer and press off carefully Q i 153_98 15 To relievethe camshaftsfrom strain additionally fasten a holding down device of specialtool...

Page 91: ...nsioningelement bI 18 Undofour hexagon head bolts M6 x 15 on the chain sprocket a C J Lv I C U 221_98 I L 21 Take off drive plate of oil extractionpump Removesprocketwheeland chainand connectwith a ti...

Page 92: ...notjump over during this operation reallocate if necessary The groove or tab of the camshaftposition sensor cover mustface upward hi I 659_97 246_97 24 Pull out valvetappets by hand Note Donotuseamagn...

Page 93: ...camshaftswith chain and tensioningelement in the cylinderhead Thegroove or tab of the camshaftposition sensor cover mustface outward in installed position Ifthe allocationshouldbe uncertain e g chain...

Page 94: ...x 15 10 9 Tighten hexagon head bolt by hand only If 11 Fitauxiliarychaintensioner of specialtool 9599 on cylinder head1 3 Fitauxiliary chaintensioner withoutsealingring and fasten on the crankcase on...

Page 95: ...ltool cannotbe insertedin the bores allocatethe camshafts accordingly andturn the exhaustcamshaftswith an open ended wrench wrenchsize 24 until the adjustmentdevice can be insertedwith ease Fastenadju...

Page 96: ...Servo No 1591 51 7 Place oil extraction pump in the cylinder head Note For reasons of space the oil extractionpump must be fitted before the cylinderheadcover is installed 8 Lightlygrease the newseali...

Page 97: ...or centring pins into the corners of the cylinderhead as centring aids Tighteningtorque 13 Nm 10 0 ftlb Observetighteningsequence 11 Removeholding down device9634 12 Immediatelyremovesiliconematerial...

Page 98: ...c position Turn crankshaftclockwiseuntilthe bore 1 OT top dead centre in the belt pulleyis aligned with the fixing bore on the crankcase Positionor fix withfixing pin short of specialtool 9595 or 9595...

Page 99: ...specialtool holding down device 9634 onthecylinderhead 020_98 Note For reasons of space the position of the holding down device must be changed To do so remove originalbolts and replace by bolts from...

Page 100: ...ement out of the cylinderhead The chain must notjump over during this operation reallocate if necessary The groove or tab of the camshaftposition sensor cover mustface downward I Q Q 243_97 14 Pull ou...

Page 101: ...e valve tappet and fit it in the guide 4 Laythe complete unit camshaftswith chain andtensioningelement in the cylinderhead The groove or tab of the camshaftposition sensor cover mustface inward in ins...

Page 102: ...orce hasbeenachievedwhenthe measuringpin isflush withthe face surface of the pressure screw Turnthe screw if necessary hllr l 7 266_98 9 Removetie wrap and fit sprocketwheelwith chainon the flange of...

Page 103: ...ocket 4 Take specialtool adjustmentdevice9612 9 off the cylinderhead 157_98 2 Ifthe specialtool cannotbe insertedin the bores allocatethe camshafts accordingly andturn the exhaustcamshaftswith an open...

Page 104: ...er headcover has beenfitted 430_1_ 204_98 8 Carefullyplacethe cylinderheadcover in the correct positionso that the sealingbead is notdamaged Screwtwo studs or centring pins into the corners of the cyl...

Page 105: ...A Chain tensioner cylinder bank 4 6 Identification Without 223_98 B Chaintensioneron crankcase Identification 1 ring 12 Fitcamshaft closurecaps 6 ea dry c Chain tensioner cylinder bank 1 3 Identifica...

Page 106: ...pward toward the cylinderhead Tighteningtorque 25 Nm 18 ftlb 19 Fitdrivebelt 214_98 20 Fitair cleanerassembly 21 Mountrear wheels Tighteningtorque 130 Nm 96 ftlb 716 97 17 Fitair conditioning compress...

Page 107: ...stalling closure cap for camshaft bore Tools 206_98 Item Special tool Designation Extractor Explanation Shop madetool see note on Page 15 118 15 18 20 Removing and installing closure cap for camshaft...

Page 108: ...000 mm long iron rod e g 13 8 mm round steel bar see drawing I Installing and removing closure caps at cylinder head 1 3 pulley side 203_98 Diagramshowslower closure cap 2 Removethe upperclosure cap t...

Page 109: ...g point of closure cap and pull off the cap Removethe upper closure cap to do so first undothe tailpipefasteningclamp and twist the tailpipedownward Pull off the closurecap Installation 1 Clean the ca...

Page 110: ...el side Removal 1 Turn shop madeextractor into centre of piercing point of closure cap and pull off the cap 189_98 Diagramshows upper closure cap Diagramshowslower closure cap 20 98 Removing and insta...

Page 111: ...hop made tool iron rod or threaded rod approx 1000 mm long with weldedon sheetmetalscrew 6 3 x 14 with hexagonhead Use onlywith engineinstalled if engineis removed use blocking device9612 B Extractorf...

Page 112: ...ir cleaner assembly Note Thefollowingdescription enablesrapid trouble shootingof the camshaftdrive Theoriginalchaintensioner 3 ea does not haveto be removed Preliminary work 1 Disconnect battery 2 Rem...

Page 113: ...erhead nearcylinder6 4 Pull off caps of camshaftbores 6 ea using the shop made tool Referto ServoNo 15 182O Page 15 117 71O_97 201_97 188_98 Drawing shows closure cap on cylinder head 1 3 flywheel sid...

Page 114: ...fixing bore on the crankcase Positionor fix with fixing pin short of specialtool 9595 or 9595 1 215_98 Viewfrom the flywheelside 166_98 If the position of the camshaftsis incorrector the groove in the...

Page 115: ...ositioningthe special tool It shouldbe possibleto fit the specialtool and hexagon head boltwith ease 25 98 Viewfrom the belt pulleyside Rearmuffler removed for clearer illustration 5 Position special...

Page 116: ...er bank 4 6 to basicposition Turn crankshaft clockwiseuntilthe bore 1 aT top dead centre in the belt pulleyis alignedwith the fixing bore on the crankcase Positionor fix with fixing pin short of speci...

Page 117: ...wood between the cylinderheadandthe side member asa support Pressthe piece of wood forward and simultaneously insertthe specialtool Do not useforce whenpositioningthe specialtool It shouldbe possiblet...

Page 118: ...el side Tools c 13230005 Item Special tool 3176 9110 9538 1 Explanation A VWspecialtool B Designation Centringmandrel Socketwrench c D Toothed segmentwith hexagon headbolt M12 x 50 Retainingdevice 964...

Page 119: ...crankcase half cylinderbank 1 3 Detach thrust plate and removetogether with drive plate Detachand removethe flywheel 2 Drain engine oil Equip oil drain plug with new sealing ring and tighten Tightenin...

Page 120: ...10 Forthis purpose holdwith a slotted screwdriver 7 0 x 1 1 at the slotted threaded pin 11 Carefullypress off the intermediateflange Proceedcarefullyso as notto damagethe sealingsurfaces 442_97 10 Pos...

Page 121: ...iate shaftflange almost completelyinto the intermediateshaftbore by hand 5 Tightenthree micro encapsulated hexagon head bolts M6x 20 evenly tighteningtorque 10 Nm 7 5 ftlb Note Do not exert anypressur...

Page 122: ...dpin Tighteningtorque 11 Nm 22 ftlb I JJ I I I 442_97 7 Equip both chain tensionerswith newsealing rings screw in andtighten Tighteningtorque 80 Nm 59 ftlb 8 Fillin engineoil 9 Fitengine compartmentco...

Page 123: ...ulicvalveis installed horizontally installationposition of engine 2 Undoself tappingscrews TorxT 20 No 1 Note Mark a threaded screw andthreadedbore for reinstallation 3 Removesolenoidvalve Leavevalvep...

Page 124: ...5 mm Cylinderheadswith distorted sealing surface can be repaired by planingthem Permissibleunevenness after machining 0 03 mm Reworksealingsurface of the cylinderhead onlyuntil a flat surface hasbeena...

Page 125: ...Removing and installing camshaft housing GT3 Includes 15 03 21 Removing camshaft housing GT3 15 03 21 Installing camshaft housing GT3 15 139 15 03 19 Removing and installing camshaft housing GT3 Prin...

Page 126: ...rview 15050002 Item Special tool 9653 1 Explanation For stoppingthe exhaustcamshaft A B Designation Holdingwrench Holdingwrench 9653 For stopping the inlet camshaft 9330 c Torx socketwrench 15 141 150...

Page 127: ...www WorkshopManuals co uk...

Page 128: ...uality10 9 13 Nm 9 5 ftlb 6 Camshaftbearingsaddle 6 Location position and matching number Bolt quality 10 9 13 Nm 9 5 ftlb 7 Hexagon head bolt M6 x 35 4 1 8 Thrustbearingcover Variesbetweencylinder ba...

Page 129: ...oincide Removebracketfor the generator Removeintakedistributor Serv No 24 26 21 Removeoil container Serv No 17 52 21 Removeoil water bracket Serv No 17 62 21 Removecoolantguide housing Q Remove bracke...

Page 130: ...moved Remove boththe hexagonchead bolts of the chainten sioner Removethe chaintensionercover and the chaintensioner 76_99 4 Relieve camshaft For anyfurther work it is sensibleto turn the enginein such...

Page 131: ...the oil guide hous ing is stuck loosenthe thrust bearingcover 111_99 7 Removethe chain sprocketsof the camshafts Whenremovingthe chain sprocket of the inlet camshaft the former mustbe heldwith spe cia...

Page 132: ...fore it is sensibleto sort the bearing saddles Thebearing saddlespossessa matchingnumberto the respectivecylinder headand an identificationshowingthe installa tion position Lift the camshaftscarefull...

Page 133: ...using Removethe camshafthousingupwards moving it evenlyand withouttilting Make sure that the flat basedtappet guidesare not damaged 15 Removethe seals 208_99 Removethe seal betweenthe camshaft housing...

Page 134: ...nation Item For stoppingthe exhaustcamshaft A Holdingwrench For stoppingthe inlet camshaft 9653 9330 B Holding wrench Torx socketwrench c Fortorque angle controlled tightening of screwconnections 715...

Page 135: ...00013 Item A Special tool 9401 Designation Auxiliarychaintensioner 9661 9661 2 Explanation In order to remove playfrom the control chain In order to fix the camshaftsin the correct position B Camshaft...

Page 136: ...911 Carrera 996 Engine cylinder head valve drive Installing camshaft housing GT3 217_99 15 151 15 03 23 Installing camshaft housing GT3 Printed in Germany 39 2000 99615149 www WorkshopManuals co uk...

Page 137: ...bearingsaddle 6 7 Hexagon head bolts M6 x 30 4 Bolt quality 10 9 13 Nm 9 5 ftlb Location position and matching number Bolt quality 10 9 13 Nm 9 5 ftJb 8 Thrustbearingcover 9 Inlet camshaft 1 Variesbet...

Page 138: ...9 3 Insertguiderails Insertthe shorter curvedguide rail in the chaintensioner Insertthe longerguide rail in sucha waythat the slot pointstowardsthe crankcase Theguide rails of the left and right sides...

Page 139: ...llyin position Makesure that the flat basedtappet guides are notdamaged Beforeinsertingthe flat basedtappets smear them with a thin coat of cleanengineoil Make sure withoutfail that the flat basedtapp...

Page 140: ...1 3 insertthe camshafts in sucha waythat the cams of the first cylinder point inwardsand diagonallyinwards Designationposition 393_99 9 Setengineto top dead centre Usinga universalholder mounta dial g...

Page 141: ...n the camshaftbearinghousingmust point towards eachother Placethe thrust bearing cover on top It must be ensuredthat the camshaftsare properly positioned in the bearing surfaces Screwin fastening scre...

Page 142: ...three hexagon head boltsto 13 Nm 9 5 ftlb 412_99 14 Mountthe chain sprocket of the exhaust camshaft Cleanthe assemblysurfaces of the exhaust camshaftand of the chain sprocketand remove all oil and gre...

Page 143: ...kingtool can be pressed easilyinto the slot on the camshaft 392_99 17 Setthe camshafts timing Ivj roof Checkonce more with the dial gauge whetherthe engineis at top dead centre Thenflange specialtool...

Page 144: ...the first or fourth cylinder stands at top deadcentre Setthe timingwith the same procedureas on the other cylinder head 22 Stop the inlet camshaftwith the tool 9653 and tighten it with a 1300turn The...

Page 145: ...ustelapsebetweenstarting the application and replacingthe valve cover Applya bead of no more than 1 5 mm thickness Tighten screws to 9 7 Nm 7 0 ftlb from the inside outwards Removethe staking tool Tur...

Page 146: ...nstalling cylinder head GT3 1 o 0 L D O 0 0 0 10200001 Includes 15 70 21 Removing cylinder head GT3 15 20 23 Installing cylinder head GT3 15 161 15 70 19 Removing and installing cylinder head GT3 Prin...

Page 147: ...911 Carrera 996 Engine cylinder head 157021 Removing cylinder head GT3 10200001 15 163 15 70 21 Removing cylinder head GT3 Printed in Germany 32 1999 99615163 www WorkshopManuals co uk...

Page 148: ...Engine cylinder head 911 Carrera 996 Removing cylinder head GT3 14 h 413_99 Removing cylinder head GT3 Printed in Germany 32 1999 157021 15 164 99615163 www WorkshopManuals co uk...

Page 149: ...exhaustvalve 8 Valvestem seal 6 Replace 9 6 Lowervalveretainer exhaustvalve 6 10 Spacer exhaust valve 6 Valveguide exhaust valve 6 12 Exhaustvalve seatring 13 Exhaustvalve 6 14 Valvekeys inlet valve...

Page 150: ...inder head 911 Carrera 996 Removing cylinder head GT3 Note Qty Removal Installation No Designation 6 22 Inletvalve seatring Valveguide inlet valve 6 23 1 24 Cylinderhead 25 Dowelsleeve www WorkshopMan...

Page 151: ...www WorkshopManuals co uk...

Page 152: ...ce 2 8 Sealfor chaintensioner cover Hexagon head bolt M6 x 20 4 9 2 10 Coverfor chaintensioner Check 2 Tensioningrail 1 Check 1 Guiderail right Replace 2 3 Chainboxbase seal 4 Hexagonsocket head bolt...

Page 153: ...Removal Installation 22 Shaftbolt 2 Mustengagein the guide rail 23 12xl 5 sealing ring 1 Replace 24 Screwplug 1 25 Shaft bolt 4 26 Guiderail left 1 Check 27 Chainbox seal 1 Replace 15 70 21 Removing...

Page 154: ...the three hexagonsocket head boltsandtake the guide rails out of the chainbox 10200002 4 Unscrewcylinderhead Unscrewthe twelveinternalserration screws in 1 2 turn steps In order to avoiddistortion of...

Page 155: ...head Removing cylinder head GT3 6 Remove cylinder head Liftthe cylinderheadup and off Do not use the cylinderhead gasketagain 15 171 15 70 21 Removing cylinder head GT3 Printed in Germany 32 1999 996...

Page 156: ...911 Carrera 996 Engine cylinder head 15 70 23 Installing cylinder head GT3 10200001 15 173 15 70 23 Installing cylinder head GT3 Printed in Germany 32 1999 99615173 www WorkshopManuals co uk...

Page 157: ...Installing cylinder head GT3 113_99 Installing cylinder head GT3 Printed in Germany 32 1999 157023 15 174 99615173 www WorkshopManuals co uk...

Page 158: ...aust valve 6 8 Valvestem seal 6 Replace 9 Lowervalve retainer exhaustvalve 6 10 Spacer exhaust valve 6 6 1 Valve guide exhaust valve 12 6 Exhaustvalve seatring 13 Exhaust valve 6 14 12 Valvekeys inlet...

Page 159: ...der head GT3 Note Qty No Designation Removal Installation 22 Inletvalve seat ring 6 6 23 Valveguide inlet valve 24 Cylinder head 25 Dowelsleeve 1 18 Installing cylinder head GT3 Printed in Germany 32...

Page 160: ...www WorkshopManuals co uk...

Page 161: ...lace Sealfor chaintensioner cover 9 Hexagon head bolt M6 x 20 4 10 2 Coverfor chaintensioner 2 11 Tensioning rail Check 12 Guiderail right 1 Check 13 Chainboxbaseseal 2 Replace 14 Hexagonsockethead bo...

Page 162: ...ion 22 Shaft bolt 2 Mustengagein the guide rail 23 12xl 5 sealingring 1 Replace 24 Screwplug 1 25 Shaft bolt 4 26 Guiderail left 1 Check 27 Chainbox seal 1 Replace 15 179 15 70 23 Installing cylinder...

Page 163: ...x Tighteningtorque 23 Nm 17 ftlb 2 Placecylinderheadin position Placethe cylinder head back on the cylinders In doing so make sure that the inletducts in their correct position point upwards inlet duc...

Page 164: ...g cylinder head GT3 4 Replaceseals Replacethe upper seal on the chain boxand the seal betweenthe cylinderheadandthe camshafthousing 259_99 15 181 15 70 23 Installing cylinder head GT3 Printed in Germa...

Page 165: ...crankshaft pistons 15 20 37 Disassembling and assembling intermediate shaft GT3 3 4 248_99 15 183 15 20 37 Disassembling and assembling intermediate shaft GT3 Printed in Germany 32 1999 99615201 www...

Page 166: ...casehalf of cylinder bank4 6 7 Thrustbearingshell half 1 Replaceand insert into crankcasehalf of cylinder bank4 6 Snapring 36 x 1 75 1 8 9 Sprocketwheel Checktoothingfor wear press off if necessary Wa...

Page 167: ...in case of bearing damageandcleanthe oil bore 16 Intermediate shaft 1 pairedwith timing gear of the crankshaft only installtogether take note of the identificationon the crankcase 15 185 15 20 37 Dis...

Page 168: ...rera 996 Engine Lubrication 17 53 19 Removing and installing air oil separator Engine removed 17 1 17 53 19 Removing and installing air oil separator Printed in Germany 1997 996171 www WorkshopManuals...

Page 169: ...rera 996 Removingand installing air oil separator Engine in working position engine turned 180 6 5 1919 96 1753 19 996171 Removing and installing air oil separator Printed in Germany 1997 17 2 2 4 I 0...

Page 170: ...0 1 8 Hexagon head bolt M6 x 20 1 9 1 Air oilseparator 10 O ring12 x 2 Hexagon head bolt M6 x 20 11 1 12 Hexagon head bolt M6 x 20 1 13 Air oil separator 1 14 a ring12 x 2 1 Lightlyoiled 15 Hexagon he...

Page 171: ...silicone bead 1 At the processingnozzle cut off the first meteringstep 2 Applya uniformbead approximately1 5 mm wide to the cleanedsealingsurface of the oil pan I I 486_96 3 Placethe oil pan in the co...

Page 172: ...17 20 19 Removing and installing oil pump with coolant guide housing Engine removed 1 1 iL_i2 1 357 97 17 5 17 20 19 Removing and installing oil pump with coolant guide housing Printed in Germany 199...

Page 173: ...brication 911 Carrera 996 Removingand installing air oil separator Engine in working position engine turned 180 1 t 3 2 6 5 1919 1753 19 Removing and installing air oil separator 17 2 www WorkshopManu...

Page 174: ...agon head bolt M6 x 20 1 8 Hexagon head bolt M6 x 20 1 9 Air oil separator 1 10 a ring 12 x 2 Hexagon head bolt M6 x 20 1 12 Hexagon head bolt M6 x 20 1 13 Air oilseparator 1 14 a ring 12 x 2 1 Lightl...

Page 175: ...of silicone bead 1 At the processingnozzle cut off the first meteringstep 2 Apply a uniform bead approximately 1 5 mm wide to the cleaned sealing surface of the oil pan 486_96 3 Placethe oil pan in th...

Page 176: ...6 Engine Lubrication 17 20 19 Removing and installing oil pump with coolant guide housing Engine removed 0 y 357 97 17 5 Removing and installing oil pump with coolant guide housing 172019 www Workshop...

Page 177: ...Removing and installing oil pump with coolant guide housing 316 97 www WorkshopManuals co uk...

Page 178: ...e 10 Nm 7 5ftlb 8 5 6 Hexagon head bolt M6 x 20 Oil pump with coolantguide housing Gasket 1 7 1 Alwaysreplace insertor fit only if coolantguide housinghas been put onto the crankcase Alwaysreplace ins...

Page 179: ...e 25 t 5 Nm 19 t 3 5 ftlb 23 Temperaturesensorwith captive sealingring Sealingring 1 Replacement sealingring for item 22 fit if sealing ring of item 22 hasbeen damaged 2 Tightening torque 10 Nm 7 5 ft...

Page 180: ...911 Carrera 996 Engine Lubrication 17 19 19 Removing and installing oil extraction pumps Engine removed I 1 II 0 ti_ 358_97 www WorkshopManuals co uk...

Page 181: ...4 hexagon head bolts which fasten the oil extractionpumps Note After removing the oil extraction pumps do not lay them on the drivers Installation Note The oil extraction pumps on the cylinder heads a...

Page 182: ...d installing oil extraction pumps Engine installed Tools Q A 268_98 Special tool 9634 Explanation Item A Commercially available tool for fitting rear muffler holder B Designation Holding down devicefo...

Page 183: ...ad 1 3 flywheel side Note The oil extraction pump can onlybe removed after the cylinderhead cover has beentaken off 1 Removeleft rear wheel 2 Removeexhaustmanifold 218_98 3 1 Undo clamping sleeve and...

Page 184: ...agon head bolts usinga flexible headsocketwrench wrench size 13 Detachholder 7 Removeignition coils and spark plugs 8 Pull off oil protectiontubes Referto Servo No 1546 19 9 Fitspecialtool holding dow...

Page 185: ...721_97 10 Separate plugconnection ofthetensioning element VarioCam 11 Unscrewtwo hexagon head bolts M6x 20 and removeclosure cap from the tensioning element VarioCam 12 Undothe fasteningscrews of the...

Page 186: ...Observetighteningsequence Immediately remove silicone material emerging in the area of the camshaft closurecap 667_97 Engineremovedin drawing for clearer illustration 4 Tighten micro encapsulated hex...

Page 187: ...6 pulley side Removal 1 Unscrewfour fastening screwsand remove the oil extractionpump 9 Fit right rear wheel Tighteningtorque 130 Nm 96 ftlb Installation 1 Lightly grease the new sealing ring and lay...

Page 188: ...body protection covers on 2 Disconnect battery 3 Remove capon coolant expansion tank 4 Undodrain plug on the coolantguide housing and drainthe coolant r _ 5 Equipdrain plug with a newsealingring and...

Page 189: ...ervoiruntil the levelis just belowthejoint f iji I II 264_97 r Bayonett k open T 7 2 Disconnectbattery positive at B disconnectionpoint Undothe hexagon nutsand set the box aside 151_98 7 1 Turn bayone...

Page 190: ...andcrankcase 263 97 9 Loosenouter hose clamps at intakedistributor 10 Undo hexagon head bolts 6 ea on intake distributor and take off intake distributor 11 Removeoil waterheatexchanger Undo hexagonsoc...

Page 191: ...ngtorque 10 Nm 7 5 ftlb 3 Fasten support between the throttle body andcrankcase 4 Installair conditioning compressor Before installation check whetherthe spacer sleeve is fitted or present at the rear...

Page 192: ...Fill in coolant and bleed the system refer to Group 19 ServoNo 19 38 17 Page 19 13 0 10 Performtightnesstest 265 97 6 3 Fillin Pentosin Observethe specificationfor bleeding Referto ServoNo 480000 7 Ch...

Page 193: ...of the oil filler opening 3 1 Ifthe oil pan hasa leveragebar leverthe oil pan off usinga plastic coatedmountinglever 2 Lift the vehicle Drainengineoil e J 167_98 271_96 3 Undooil panfasteningscrews M6...

Page 194: ...ber flaps on the partition box before cleaning 6 589_97 2 Sealthe oil pan sealingsurface Whensealingthe sealingsurface on the oil pan use onlythe sealant Drei Bond Silikon type 1209 641_96 Note After...

Page 195: ...n engineoil Beforefillingwith engineoil affix the luggage compartmentprotective cover recommendedin the Workshop EquipmentManual 7 Bringthe engineto operatingtemperature and check the oil panfor leaks...

Page 196: ...x 34 I I Theplug is shownturned to show the button more clearly 186_98 3 Pull plug off the throttle body Undo 4 hexagon head bolts M6 x 40 and remove the throttle body 261_97 o 2 3 Pull plug off the m...

Page 197: ...remove intake distributor 447_98 8 Removegeneratorfrom bracket To do this relievedrive belt turn the tensioningroller wrenchsize 24 mm clockwiseand simultaneously removethe beltfrom the tensioningrol...

Page 198: ...prox 3 turns A gentle tap on the fastening screwloosensthe front fasteningbushingin the generator arm Unscrewfastening screw 2 11 A 445_98 8 3 Setdowngeneratorwith connectedlines J 441_98 8 2 Turn gen...

Page 199: ...orand supportfor hydraulicpump they mustbe at least5 mm apart 1 1 439_98 I Installation 1 Fit newsealingring 42 x 4 on oil filler neck Coat newsealingring e g with tyre mounting paste and fit oil fill...

Page 200: ...esentand properly seated in the transverselock panel Clipoil filler neck onto upper part of the air cleaner 9 Connectbattery 3 10 Carry out adaptation 10 1 Switchon ignition 10 2 Waitoneminute Do not...

Page 201: ...911 Carrera 996 Engine Lubrication 17 1921 Removing oil extraction pump GT3 JJ J 13o_99 171921 17 33 www WorkshopManuals co uk...

Page 202: ...Engine Lubrication 911 Carrera 996 A n v 201_99 www WorkshopManuals co uk...

Page 203: ...Removal overview of the oil extraction pump GT3 Undo return line 2 Undofastening screws 3 Remove oil extraction pump www WorkshopManuals co uk...

Page 204: ...iningoil wear protective equipment specified 1 Undo return line Undo return line on the oil extraction pump Make sure to counter with a wrench when doing this Collect draining oil 201_8_99 2 Undofaste...

Page 205: ...oveoil extractionpump Remove oil extraction pump at the camshaft housing If the oil extraction pump is stuck loosen the oil pump by gently tapping with a plastic hammer Remove the oil pump to the rear...

Page 206: ...911 Carrera 996 Engine Lubrication 17 19 37 Disassembling and assembling oil extraction pump GT3 1 1 1 O I JJ r 13o_99 www WorkshopManuals co uk...

Page 207: ...Disassembling oil extraction pump GT3 Overview 199_99 www WorkshopManuals co uk...

Page 208: ...Disassembling oil extraction pump GT3 Overview Undoassembly screws 2 Take off oil pump lid 3 Removeinput shaft 4 Removegear wheels www WorkshopManuals co uk...

Page 209: ...ise and remove 2 Take off oil pumplid Ifthe oil pumplid is stuck lever off carefullywith a plastic wedge The housingmust not be damagedduringthis procedure 199_b_99 3 Removeinputshaft Take feather key...

Page 210: ...xtractionpumpgear wheelsup andout The axle endsare differentlengths Avoidconfusingthe gear wheels in the oil extractionpumphousing Cleanoil pump thoroughly Cleanoil pumphousingand gear wheelsthoroughl...

Page 211: ...Engine Lubrication 911 Carrera 996 Assembling oil extraction pump GT3 Overview 2 I V ll II JJ D 3 4 200_99 www WorkshopManuals co uk...

Page 212: ...911 Carrera 996 Engine Lubrication Assembling oil extraction pump GT3 Overview 1 Insert gear wheels 2 Replaceseals 3 Fit input shaft 4 Fit lid 171937 17 45 www WorkshopManuals co uk...

Page 213: ...withthe axlesare located on the outer sides The short axle end 7 mm mustbe insertedface downwards in the oil pumphousing 2 Replaceseal The O ringmust alwaysbe replaced Insertsealingring carefullyinto...

Page 214: ...on pump lid with input shaft Insert feather key into the groove in the centre gear wheel Place lid on the oil extraction pump and position the four fastening screws Tighten the four screws crosswise t...

Page 215: ...911 Carrera 996 Engine Lubrication 17 19 23 Installing oil extraction pump GT3 1 co u j OI JJ 13o_99 Installing oil extraction pump GT3 17 49 171923 www WorkshopManuals co uk...

Page 216: ...Installation overview of the oil extraction pump GT3 n v 202_99 www WorkshopManuals co uk...

Page 217: ...911 Carrera 996 Engine Lubrication Installation overview of the oil extraction pump GT3 1 Replace seals 2 Put on oil extraction pump 3 Tightenreturnline www WorkshopManuals co uk...

Page 218: ...extractionpump 202_ _99 2 Puton oil extractionpump Puton oil extractionpump Whendoing this make sure that the driver andthe inputshaft of the oil extraction pumpare correctly aligned Tightenthe three...

Page 219: ...tion Installing oil extraction pump GT3 No Procedure Instructions Fillin drainedoil again Fillthe uncontaminated oil back into the enginethrough the oil filler opening Thencheck the engineoil level 17...

Page 220: ...911 Carrera 996 Engine Lubrication 17 52 19 Removing and installing oil container GT3 Preliminary work Removing and installing engine Service No 10 01 19 379_99 17 55 175219 www WorkshopManuals co uk...

Page 221: ...Engine Lubrication 911 Carrera 996 1 2 1 4 I 6 I 5 8 A 12 D 9 3 t 1 37 I 11 13 10 d 20 23 1 25 I 6 l 30 24 29 1 19 18 V 36 35 22 9 27 439_99 17 1 33 J I www WorkshopManuals co uk...

Page 222: ...necessary 7 1 8 Oil dipstick 1 9 Clamp 10 M6x16 hexagon head bolt 1 Fillertube 1 11 12 Guidetube for oil dipstick 1 Check replaceif necessary O ring 25x3 15 1 13 6 14 M 5 hexagonnut 15 5 3x9 5xl wash...

Page 223: ...28 M8x16 hexagon head bolt 1 29 Holder 1 30 M 12x40 hexagon head bolt 1 31 Upperspacer 1 32 M 12x40 hexagon head bolt 1 33 Lower spacer 1 34 M 8x30 pan headscrew 1 35 Suc on pipe fitting 36 21 89x2 62...

Page 224: ...911 Carrera 996 Engine Lubrication Removing and installing oil container GT3 Removal overview 2 PI c 1 1 I 1 fff 1 _ V 3 f J o l 5 445_99 175219 17 59 1b III www WorkshopManuals co uk...

Page 225: ...turnlineand ventline 2 Pulling plug off oil level sender and detaching oil line 3 Detachingpositivecrankcaseventilationandoil containerfastening 4 Detachinginletline 5 Unscrewingfasteningscrews Removi...

Page 226: ...Pullingplug off oil levelsenderand detachingoil line Pullplug off the oil levelsenderand set it aside Then detachthe returnlinefrom the cylinderhead Makesureto counterwitha wrenchwhendoing this in ord...

Page 227: ...edure Instructions 4 Detaching inlet line Detachinletlinebetweenthe oil containerandthe engine Unscrewthe two hexagonsockethead boltsfor this pur pose 445_d_99 Unscrewingfasteningscrews 5 Loosenthe tw...

Page 228: ...Removing and installing oil container GT3 Installation overview 4 JI i 5 I i v 111 I 0 3 l 1Y 1 I Illn f 7 4 0 t 2 1 C 0 I 1 447_99 17 63 www WorkshopManuals co uk...

Page 229: ...n overview 1 Tighteningfastening screws 2 Tighteninginlet line 3 Tighteningpositivecrankcaseventilationandoil containerfastening 4 Pushing on oil level sender and tightening the oil line Tightening oi...

Page 230: ...teninginletline Fita newa ring on the inletline betweenthe oil container andengineand insertthe line Tightenthe two hexagon socketheadbolts to 9 7 Nm 7 0 ftlb 445_d_99 3 Tighteningpositivecrankcaseven...

Page 231: ...urnlinefrom the cylinderhead Makesure to counterwith a wrench atthe oil containerwhendoing this 5 Tighteningoil returnlineand ventline Tighten oil return line on the oil container Make sure to counter...

Page 232: ...ing and installing bracket for oil cooler GT3 I 2 k 43o_99 Includes 17 67 21 Removing bracket for oil cooler GT3 17 67 23 Installing bracket for oil cooler GT3 Removing and installing bracket for oil...

Page 233: ...911 Carrera 996 Engine Lubrication 17 67 21 Removing bracket for oil cooler GT3 Preliminarywork Removingandinstallingengine ServiceNo 1001 19 J i f 43o_99 www WorkshopManuals co uk...

Page 234: ...Special tools 7O_99 Item Designation Spring band clamp pliers Special tool Commercially available refer to Workshop Equip ment Manual Chapter 2 4 No 72 or 73 Explanation Foropeningandclosingspring ba...

Page 235: ...911 Carrera 996 Engine Lubrication Removing bracket for oil cooler GT3 428_99 17 71 Removing bracket for oil cooler GT3 176721 www WorkshopManuals co uk...

Page 236: ...10 M 6x25 hexagon head bolt 11 Housingwith filter element 1 Replace 12 Seal Tighteningtorque 30 Nm 22 ftlb 13 Banjobolt 1 Sealing ring 2 Replace 14 Oilline 1 15 16 Temperaturesensor 1 1 Tighteningtor...

Page 237: ...e a ring 32 92 x 3 53 1 Replace 23 24 a ring 37 69 x 3 53 25 Connection fitting Replace 26 a ring 32 92 x 3 53 1 Replace 27 a ring 20 22 x 3 53 1 28 M 6x30 hexagon head bolt 29 A 6 4 washer 30 Oil ret...

Page 238: ...Removal overview of bracket for oil cooler GT3 6 d ffig_99 Removing bracket for oil cooler GT3 176721 17 74 www WorkshopManuals co uk...

Page 239: ...iner Unscrewoil containerfasteningscrewsand pressthe oil containerforward Detaching oil returnlineandventline 2 Pulling plug off oil level sender and detaching oil line 3 Detachingpositivecrankcaseven...

Page 240: ...Engine Lubrication 911 Carrera 996 Removal overview of bracket for oil cooler GT3 L 11 I 432_99 176721 Removing bracket for oil cooler GT3 1 www WorkshopManuals co uk...

Page 241: ...oil cooler GT3 8 Looseningbanjo bolt of the oil lineand looseninghosefastening 9 Looseninghosefasteningof the coolantline 10 Separating flange between bracket and oil filter 11 Unscrewingbracketfasten...

Page 242: ...off oil level sender and detaching oil line Pullplug off the oil levelsenderand set it aside Then detachthe returnlinefrom the cylinderhead Makesureto counterwitha wrenchwhendoingthis in order to prev...

Page 243: ...sen the eight hose clamps on the throttle body and tuning pipe Take out the throttle body and tuning pipe 099_d_99 Unscrewingfasteningscrewson the oil cooler 5 Unscrewthe four oil cooler fasteningscre...

Page 244: ...bracketand pull off the coolanthose 099 9_99 Looseningbanjobolt of the oil line and looseninghose fastening 8 Unscrew the banjo bolt and detach the hose fastening of the line Lay the oil line aside D...

Page 245: ...enthe bracket andthe oil filter and pullout the return line Unscrewingbracketfasteningscrews 11 Unscrewthe four bracketfasteningscrewsand lift the bracketoff Clean sealing surface 12 Cleanthe sealings...

Page 246: ...Engine Lubrication 911 Carrera 996 Installing bracket for oil cooler GT3 176723 J I I A 430_99 17 83 www WorkshopManuals co uk...

Page 247: ...T3 Special tool 446 99 Item Designation Spring band clamp pliers Special tool Commerciallyavailable refer to WorkshopEquip mentManual Chapter 2 4 No 72 or 73 Explanation For openingand closingspring b...

Page 248: ...911 Carrera 996 Engine Lubrication Installing bracket for oil cooler GT3 24 428_99 Installing bracket for oil cooler GT3 17 85 www WorkshopManuals co uk...

Page 249: ...rheadbolt 2 8 M 8x35 hexagon head bolt 2 9 Holder 1 10 M6x25 hexagon head bolt 3 11 Housing withfilter element 1 12 Seal Replace 13 Banjo bolt 1 Tightening torque 30 Nm 22 ftlb Replace 14 Sealingring...

Page 250: ...1 Replace 27 a ring 20 22 x 3 53 1 Replace 28 M 6x30 hexagon head bolt 29 A 6 4 washer 1 30 Oil return line 31 a ring 17 04 x 3 53 1 Replace 32 a ring 12 x 2 1 Replace Assemblynote Makesure the four f...

Page 251: ...bracket for oil cooler GT3 1 Applying sealant 2 Inserting oil return line 3 Fasteningbracketfor oil cooler 4 Screwingon hosefasteningof the coolant line 5 Screwingon banjobolt of the oil lineand scre...

Page 252: ...www WorkshopManuals co uk...

Page 253: ...eplacingseals 8 Tighteningoil cooler fasteningscrews 9 Tightening hoseclampsontheintakesystem 10 Fastening positive crankcase ventilation andoiltank 11 Pushingon oil levelsenderandtighteningthe oil li...

Page 254: ...oil or coolant circuit 2 Inserting oil return line Replacea ring on the oil return line and insertthe oil return line into the oil cooler bracket Positionthe bracketon the crankcaseat the sametime 3...

Page 255: ...lb 099_i_99 5 Screwingon banjobolt of the oil lineand screwingon hose fastening Put on the banjo bolt of the oil line with two new seal rings and tighten to 30 Nm 22 ftlb Put on the hose fastening aga...

Page 256: ...with grease Pushon the oil cooler again Tighteningoil coolerfasteningscrews 8 Screwin the four oil cooler fasteningscrewsandtightento 9 7 Nm 7 0 ftlb 099_e_W Tighteninghose clampson the intakesystem 9...

Page 257: ...7ftlb J Pushingon oil level senderandtighteningthe oil line 11 Pushon the connectingcable of the oil level sender Then tightenthe oil return line of the cylinderhead Makesureto counterwitha wrench at...

Page 258: ...or oil cooler GT3 Subsequent work Reinstallengineandtransmission Serv No 1001 19 fill in oil bleedthe coolantcircuit Checkoil level with the enginerunningand at an oil temperatureof at least80 C www W...

Page 259: ...connectthe electricalconnection on the compressor Lift the compressor out of the enginecompartmentand lay it asidewith the leads still connected Protectthe body from damagewith a cover 58_99 2 Removeh...

Page 260: ...teningscrewson the reservoirand tightento 23 Nm 17ftlb Tightenthe servo pump pulleyto 23 Nm 17ftlb Fitdrive belt I 406_99 Installing oil temperature sensor GT3 1 Install oil temperature sensor Fit oil...

Page 261: ...Insert air cleaner housing in its holder again Tighten the M6 x 34 hexagon head bolt to 9 7 Nm 7 0 ftlb Tighten the hose clamp on the throttle body and push the plug onto the hot film mass air flow se...

Page 262: ...Draining and filling in coolant includes bleeding the cooling system Draining coolant 1 Removecap from coolantexpansiontank 2 Undodrainplugonwaterguidehousing J rl 471 96 3 Disconnectventline 1 467 96...

Page 263: ...oolant 1 Remove cap 2 Liftbowonbleedervalve FuseB1 arrow 335 97 4 Checkif the coolant shutoffvalveis open 200 97 0 3 OnTiptronic vehicles the pneumaticallytrig gered coolant shutoffvalve flat seatvalv...

Page 264: ...ngine up to operating temperature at a speed of 2500 rpm until the thermostat opens after approx 10 minutes coolant temperature 90 C Check The radiator supply lines and return lines in the front wheel...

Page 265: ...th coolant if necessary Again intermittently rev the engine for 5 minutes 1 Deactivateauxiliaryfans again Replace jumpers by the standardrelays 12 Wait until coolant has cooled to 80 C coolingtime app...

Page 266: ...96 Engine Cooling 19 58 19 Removingand installing coolant regulator 302 97 Explanation No Designation Special tool 9627 Assemblyaid 19 5 Removing and installing coolant regulator 19 58 19 www Workshop...

Page 267: ...Engine Cooling 911 Carrera 996 Removingand installing coolant regulator 0 t z 1 J 5j e 0 3 aid 325 97 Removing and installing coolant regulator 19 58 19 www WorkshopManuals co uk...

Page 268: ...move housing with coolant regulator Replace seal for drain plug Tightening torque 10 5 Nm 7 5 3 5 ftlb 3 4 Remove or install coolant regulator Pushspecialtool 9627 assemblyaid downwardagainst the spri...

Page 269: ...www WorkshopManuals co uk...

Page 270: ...clamp Special tool Workshop Equipment Manual Chapter 2 2 No 3093 or 3094 Refer to Workshop Equipment Manual Chapter 2 4 No 72 or 73 B Spring bandclamp pliers Foropening andclosingspring band clamps c...

Page 271: ...911 Carrera 996 Engine Cooling Tools 397 97 Item Designation Special tool Explanation A Retainingdevice 9624 1 9614 B Socket wrenchinsert 19 11 www WorkshopManuals co uk...

Page 272: ...Removing coolant pump 326 97 www WorkshopManuals co uk...

Page 273: ...h a colouredpen Slacken belt turningthe tensioningpulley wrenchsize 24 mm clockwise hold still and simultaneously take the belt off the drive pulleys Visuallycheck state of belt and replace if necessa...

Page 274: ...r two hex agon nuts Unscrewcentring screw M6 Swivelenginecar rier to the rear 8 Loosen coolantpump Undohexagon head bolts The lower right hexagon head bolt is difficultto reach To undoit use flexible...

Page 275: ...Installing coolant pump 318 97 19 15 www WorkshopManuals co uk...

Page 276: ...usly andfasten Tighteningtorque 10 Nm 7 5 ftlb 2 Cutmetalsealandinstallcoolant pump Fitdrive belt see Page 13 2 3 Fitdrive belt and tension 4 Fitenginecarrier Screwin centring screw M6 by hand Tighten...

Page 277: ...ns of the coolant warning light 1 Enginecoolantleveltoo low light flashes slowly 0 5 Hz 2 Enginecompartmenttemperaturetoo high lightflashes slowly 0 5 Hz enginecompartmentblower mightbe faulty 3 Engin...

Page 278: ...esignation Spring band clamp pliers Explanation For openingand closing spring bandclamps Special tool Commerciallyavailable seeWorkshop EquipmentManual Chapter 2 4 No 72 or 73 Removing coolant pump en...

Page 279: ...ing 911 Carrera 996 Removal overview of the coolant pump engine installed GT3 3 C 2 I 11 1 1 JI L 1 t Y j 1J 7 jj I I a I y 4 0 edj7 _ 0 5 I 1 L 6 f 0 r I I 7 8 A 79_99 8 195021 I lQ I www WorkshopMan...

Page 280: ...ns rear end bottom centre heatshieldandbumpers 1 Drain coolant Removecoolanthose 2 Removeair cleaner assembly 3 Removedrive belt 4 Removecatalytic converter of cylinderbank1 3 5 Securecatalytic conver...

Page 281: ...he two necks 79_8_99 Remove coolant hose 2 Pull off the coolanthose betweenthe coolantexpansion tank and coolantpumpon the pump neck Undospring bandclampswith the commerciallyavailable pliers No 72 or...

Page 282: ...cylinder bank 1 3 Undothe catalytic converter of cylinderbank1 3 atthe exhaustmanifold Unplugoxygensensorcable andunclip Removethe holdingclamp betweenthe catalytic converter and support sheetand undo...

Page 283: ...T30 wrench Observe the different lengths of the screws Thetwo lighter screwsare longer 8 Remove coolant pump Lift off coolantpumpand pull out towards the rear through the openingin the supportplate Th...

Page 284: ...ne installed GT3 5r _J 5 1 J 0 129 99 Tools 7O_99 Item Designation Spring band clamp pliers Explanation For opening and closing spring band clamps A Special tool Commerciallyavailable seeWorkshop Equi...

Page 285: ...www WorkshopManuals co uk...

Page 286: ...he coolant pump engine installed GT3 1 Insert newmetal seal 2 Mount coolant pump 3 Install coolantpump 4 Pushon coolant hose 5 Installcatalytic converter Fit and tension the drive belt 6 7 Installair...

Page 287: ...nt pumpandwater guidehousing I I 2 Mount coolant pump Put on the coolant pump carefully through the support plate The impeller and the seal must not be damaged during this procedure 3 Install coolant...

Page 288: ...tic converter of cylinderbank1 3 with a new manifoldseal Screwholdingclamp and exhaustclampsinto horizontalposition if possible Use new nutson the exhaustmanifold Pushon and clip in oxygensensorcable...

Page 289: ...M6 x 34 Fix cable onto hot film mass air flow sensor I Q I 780 9_99 Fitrear spoiler Fit the accessories of the rear spoiler ServoNo 6355 contains rear end bottom centre heat shield and bumpers Fillin...

Page 290: ...ing 19 58 19 Removing and installing coolant regulator GT3 302_97 No Designation Assemblyaid Special tool Referto Workshop Equipment Manual Chapter 2 2 No 9627 Explanation To changethe coolantregulato...

Page 291: ...www WorkshopManuals co uk...

Page 292: ...96 Engine Cooling Removal overview of the coolant regulator GT3 Drain coolant 2 Remove closure cap 3 Removecoolanthose 4 Remove coolantregulator housing 5 Remove coolant regulator 8 19 33 www Workshop...

Page 293: ...on the drain plugs Tightening torque 10 Nm 7 5 ftlb to 15 Nm 11 ftlb Figure shows only one of the two necks 348_8_99 2 Removeclosure cap Removethe closurecap on the cylinderheadover the oi extractionp...

Page 294: ...ng Do not usethe sealagain 5 Remove coolant regulator Remove coolant regulator with special tool 9627 Insert assembly aid between the sheetmetal edges as shown Push the assembly aid against the spring...

Page 295: ...Engine Cooling 911 Carrera 996 V 0 0 r rn 1 1 J 11 5 _ 349_99 www WorkshopManuals co uk...

Page 296: ...Cooling Removal overview of the coolant regulator GT3 1 Installcoolantregulator 2 Install coolantregulator housing 3 Push on coolant hose 4 Installclosure cap 5 Bleed coolant circuit 19 58 19 19 37 ww...

Page 297: ...are touching the housing 348_9_99 Installcoolantregulatorhousing 2 Cleansealingsurface Positioncoolantregulator housing with a newseal Tightenthe three fastening screwsto 10 Nm 7 5ftlb 348_d_99 Pushon...

Page 298: ...on pump on the cylinder bank 1 to 3 Lightly grease the O ring to do this Press in the closure cap evenly by hand Tighten the three fastening screws to 10 Nm 7 5 ftlb 5 Bleedcoolantcircuit Bleedthe coo...

Page 299: ...Cooling 19 55 19 Removing and installing housing for coolant guide GT3 19550021 Includes 195521 Removing housing for coolant guide GT3 19 55 23 Installing housing for coolant guide GT3 195519 19 41 ww...

Page 300: ...911 Carrera 996 Engine Cooling 19 55 21 Removing housing for coolant guide GT3 19550021 19 43 www WorkshopManuals co uk...

Page 301: ...er plate Spacer Explanation 1 2 Special tool 9111 3 9111 1 3 9111 5 To compensate for the engine retainer plate in the necessary horizontal position 4 9111 4 5 Support plate Spring band clamp pliers C...

Page 302: ...Removing housing for coolant guide GT3 Removal overview 19550001 195521 19 45 www WorkshopManuals co uk...

Page 303: ...end bottom centre heat shieldandbumper 1 Drain coolant 2 Removeair cleaner assembly 3 Loosen belt pulley for hydraulic pump 4 Removedrive belt 5 Remove holder for oil filter 6 Removecatalytic converte...

Page 304: ...911 Carrera 996 Engine Cooling Removing housing for coolant guide GT3 Removal overview fit i i r I 11 t 10 9 19550002 19 47 195521 v 4 I www WorkshopManuals co uk...

Page 305: ...Remove air conditioning compressor 10 Undoconnectinghose 11 Remove bracket for generator 12 Undo hose connections on coolant pump 13 Undo oil return lines 14 Support engine and undo engine mount at re...

Page 306: ...two necks 19550005 2 Removethe air cleanerassembly Removethe completeair cleanerassembly To do this unscrewthe M6 x 34 fasteningscrews Pull off cablefrom hotfilm mass air flow sensorand set aside Undo...

Page 307: ...er two fastening screws Unscrew the third screw from the top and undo the fourth screw Lift the holder out 6 Remove catalytic converters and connecting sleeves Screwoff each of the catalyticconverters...

Page 308: ...the generator 8 Removehydraulicpump Undothe three fastening screwson the belt pulleyand removethe beltpulley Unscrewthe two fastening screws on the expansiontank andthe four fastening screwson the hy...

Page 309: ...19550014 11 Remove bracket for generator Remove bracket for generator To do this unscrew the four fastening screws and lift the bracket for the generator out of the engine compartment Serv No 27 27 2...

Page 310: ...Support the engine with special tool 9111 3 Undo the two engine mounts on the left and right and lower the engine a little Danger Danger of vehicle crash when changing the lifting platform position Pr...

Page 311: ...t on the left and right Undo the fastening points of the end mufflers but do not unscrew 16 Remove housing for coolant Swivelenginecarrier to the rear and pull out in a downwarddirection Pressthe end...

Page 312: ...19 55 23 Installing housing for coolant guide GT3 19550021 19 55 www WorkshopManuals co uk...

Page 313: ...e Adapterfor engineretainer plate Special tool 9111 3 9111 1 3 Spacer 9111 5 To compensatefor the engine retainerplate in the necessary horizontalposition 4 5 Support plate Spring band clamp pliers 91...

Page 314: ...gine Cooling 911 Carrera 996 Installing housing for coolant guide GT3 Installation overview 8 7 A p cO Ifjj 6 y 1 1 1 ijI I J 71 f 0 i C ICe 1 r Yo I 4 3 19550004 19 57 195523 www WorkshopManuals co u...

Page 315: ...usingfor coolant 2 Installenginecarrier 3 Tightenengine mount 4 Tighten oil return line 5 Push hose connections onto coolant pump 6 Install bracketfor generator 7 Pushon connectinghose 8 Install air c...

Page 316: ...911 Carrera 996 Engine Cooling Installing housing for coolant guide GT3 19550005 19 59 1955 23 www WorkshopManuals co uk...

Page 317: ...ulic pump 10 Installgenerator Installcatalytic convertersand connectingsleeves 12 Installholderfor oilfilter 13 Installdrive belt 14 Fasten belt pulley for hydraulic pump 15 Install air cleaner assemb...

Page 318: ...hoses on the coolant pump Then fit the engine carrier again To do this insert the engine carrier in the studs of the engine mounts and then swivel towards the engine Tightenenginecarrier 2 Screw on t...

Page 319: ...for the generator is not pressing on top of them Tighten the eight hose clamps Push the lower hose onto the coolant pump and fit the spring band clamp again using special tool No 72 or 73 6 Installbra...

Page 320: ...lair conditioning compressor Placethe air conditioning compressor onto the bracketfor the generatoragain Connectelectrical connectionsagain Screwin the three fastening screwsandtightento 23 Nm 17 ftJb...

Page 321: ...Installcatalytic converters Pushon the connectingsleevesagain Alignthe connecting sleevesso that the slot in the sleevedirectly coversthe arrowon the connectortube of the endmuffler First fit the cata...

Page 322: ...rv No 13 78 19 14 Tightenbeltpulley onthehydraulic pump Tighten the three fastening screws on the belt pulley of the hydraulic pump to 23 Nm 17 ftlb r 19550007 15 Installair cleanerassembly Place the...

Page 323: ...sing for coolant guide GT3 No Procedure Instructions 16 Bleed coolantcircuit Lift bow on bleeder valve Allow engine to warm up and carry out brief accelerations Top up missing coolant Set antifreeze p...

Page 324: ...and set to one side Unscrewtemperaturesensor aft 22 Collectemerging coolantit necessary _J 58_99 2 Removegenerator Serv No 27 22 19 UnscrewB wire of battery Relievedrive belt and removefrom the idler...

Page 325: ...g in its holder again Tighten the M6 x 34 hexagon head bolt to 9 7 Nm 7 0 ftlb Tighten the hose clamp on the throttle body and push the plug onto the hot film mass air flow sensor l 405_99 4 Checkcool...

Page 326: ...ingoil cooler all guideand tensioningrails must be checked Damagedand well worn rails must be replaced 13490001 3 Inspectthe bearingshells of the crankshaft for scoring and replace if necessary 4 Chec...

Page 327: ...Special tool Item Explanation ItemsAto D see GeneralWorkshop EquipmentManual Chapter2 5 Commercially available A B Designation Tester for cooling system tightness test Hose with plug in coupling c Ada...

Page 328: ...ain andthe valve closesat 1 0 bar Ifthe pressure decreases further replacethe cap 2 Pumpthe cooling systemup to an excess pressureof 1 3 bar Ifthe pressure decreases locatethe leak and remedythe fault...

Page 329: ...911 Carrera 996 Engine Cooling 2 3 4 1 0 5 0 p 1 1 1 I 1 1 I 7 6 19 73 page1 www WorkshopManuals co uk...

Page 330: ...cking points Raise the vehicle at the engine by means of a workshop jack so that the swivel arms of the hoist passes under neath the kick plates 4 Raisethe vehicleto working heightwith the lifting pla...

Page 331: ...ninglever of the tensioningroller clockwisewith a socketwrench SW15 and hold removethe beltfrom the drive pulleysofthe air condition ingcompressor hydraulicpumpandthe generator 0 Relieving and removin...

Page 332: ...ller SW15 8 underthe generator Unscrewthe right generatorfastening screw C SW15 approx 10mm andsubsequently drivein the felt platewith a hammerandaluminiummandreluntil it is flush This loosensthe fron...

Page 333: ...d loosen the four screws lower arrows three M8 screws and one M6 screw on the hydraulic pump I 3 Removetemperaturesensorsfor engine compartment fan 14 Loosen three hexagon head bolts on the air condit...

Page 334: ...t Inorder to reducethe excesspressureinthe cooling system carefullyopenthe closurecaps of the coolant expansiontank Undocoolantdrainplugson the left and right and collect coolantin a suitablecontainer...

Page 335: ...onto the coolantnecks 20 Remove coolant flangeontherightcylinder head cylinder 4 6 Remove theholding clamponthecoolant pipe Loosen two hexagon head bolts Remove holderandcoolant flange 1 21 Loosen ho...

Page 336: ...tand remove 23 Undohoseclamps onthecoolant hoses Todothis openthe hoseclamps arrow pI Warning Danger of injury Wear protective gloves 24 e g Disconnectcoolanthoseswith a knifein the positions shown ar...

Page 337: ...off the temperature sensor and open the spring band clamp L 26 Loosen two hexagon head bolts M6 and remove flange from link cylinder head K r I J E 27 Undocoolanthosefrom the oil cooler bracketandpull...

Page 338: ...ulloff Removeanddispose of seal C 29 Remove coolant hosebetween coolant expansion tankand coolant pump o c 30 Remove coolant hose from the coolant pump 31 Remove coolant residue from the housing ribbi...

Page 339: ...ket 2 Mountthe coolantlinein the area ofthe cylinderbank4 6 _ t 0 3 Fastencoolanthose A and coolanthose 8 to the cylinder bankbetweenthe oil cooler bracketandcoolantguidehousing Insert newsealingring...

Page 340: ...l connection plugto the coolant temperature sensor 1 y I 6 Checkwhetherlocking clipsare properlyseated 7 Fit coolanthosesonthe left andright Coatthe sealingrings and sealarea liberallywithwater I L i...

Page 341: ...fitted properly by tilt ing it on both sides and by pulling on it 9 Coatthe coolanthosewith water andfastento the flangefor the coolanthose Engagecoolanthoseto the upperholder 1 i I 7 10 Coatthe cool...

Page 342: ...mbersmustbe legiblefrom theright 12 Fasten hoseclamps Observe the correctposition Fasten the hoseclampstwistedslightly downwards IJ Note If incorrectly positioned thegeneratorbracket canmake contact T...

Page 343: ...ket Tightening torque 65 Nm 34 ftlb 15 Mountright coolantflangeto the cylinderbank4 6 To dothis equipthe connectionfitting with newsealingrings 2 ea and insert newsealingring to the cylinderhead y 19...

Page 344: ...96 Engine Cooling 16 Fastentwo hexagon head screwsandholderto the coolant flange G 17 Fixthe coolant pipewithholding clamp 18 Inserthydraulic pumpintothe bracketbutdo notfastenyet J I Sl www WorkshopM...

Page 345: ...boltwith grease 20 Fastenthe spacersleeverswith grease 21 Join the electrical connections before the final installation posi tion Insert the air condtioning compressor and fasten I Tightening torque...

Page 346: ...ankfasteningscrew F 24 Install generator Fasten B wire to the generator Make sure that the mounting position is correct in the upper cable guide Push plug connection on the generator and press in The...

Page 347: ...eltpulley ofthehydraulic pumpwiththefitteddrive beltofthehydraulic pump Screw inthreehexagon head bolts byhand 27 Fitdrivebelt To do this turn the tensioninglever of the ten sioningrollerclockwiseandh...

Page 348: ...19 911 Carrera 996 Engine Cooling 28 Place thedrivebeltontotheidlerpulley I I Complete view of fitted drive belt IZ 1 J 2 tf o o 1 1 www WorkshopManuals co uk...

Page 349: ...ectric torch 30 Fitaircleaner assembly 31 Bleed thecoolingsystem Rep Gr 19 38 17 Draining andfillingin coolant includes bleeding thecoolingsystem 32 Enterradio code 33 Performa test drive Tightening t...

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